The FutureTech Auto Solutions Blog

Hybrid, Plug-In, and Electric vehicle technologies have implemented a multitude of battery technologies into a significant number of vehicle platforms.  From 2000 – 2010 Nickel Metal Hydride (NiMH) dominated hybrid vehicles and it continues to dominate the hybrid market today.  However, in 2009 Lithium technology began to make its mark in the hybrid market and this technology has continued to move steadily into the hybrid market with each passing model year.  Plug-In and full electric hybrids have been predominantly Lithium technology from the very beginning and these vehicles have been strictly Lithium for many model years. 

Every technology has iterations during its life cycle.  The frequency of these iterations becomes less frequent as the technology matures.  Battery technology is not maturing, but, it is iterating quickly due to the rapid cell technology changes.  When applying these changes to the repair industry where vehicles must be - it has a profound effect on the technicians that must perform the data analysis, diagnostics, and repair.  Unlike traditional vehicles that are far more mature and can be repaired by using pattern failure (pattern failure symptom recognition) analysis for a given vehicle manufacturer and model, advanced technology vehicles with electric drives and battery packs cannot be diagnosed using pattern failure recognition.  With changes in battery cell chemistry, sometimes by model year, pattern failure recognition is impossible.  Furthermore, when cell chemistries change, this means that the data and how it will react with various driving conditions is very different from year to year – even for the same vehicle model.
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To solve this dilemma, service technicians and their managers need to recognize that the necessary analysis and diagnostic treatment for the advanced technology vehicles is significantly different than a traditional vehicle.  Technicians will need to accept that they will need to learn the operation of the different battery technologies so they can determine how to interpret scan tool data and how to manipulate the vehicle system to force the diagnostic process into something less gray and more binary.  So, it’s time for technicians to go back to school; the train has already left the station.   

​Many times during a FutureTech hybrid training class, we’re asked by students if there is any easy method of determining whether a driveability problem is engine related or electric propulsion related.  Depending on which manufacturer and systems design this can be more or less difficult to determine.  However, there is one generic method of at least isolating whether the problem is engine or electric propulsion related and that is to use the Regenerative (Regen) Braking mode. As a short review, Regen converts the kinetic energy stored by the vehicle (in motion) into electricity by the 3-phase electric drive motor.  This converted energy is then transferred to the 3-phase power inverter and rectified using software controls from alternating current to direct current.  This direct current is transferred to the battery pack to store the energy.
 
To determine whether a hesitation, chuggle, fish bite, or other low power condition is engine or electric propulsion related, merely accelerate the vehicle at wide-open throttle for about 5-10 seconds.  You will likely feel the problem during this acceleration.  After the 5-10 second acceleration, immediately perform an aggressive braking event.  If you can still feel the problem during Regen braking, it’s a problem related to the electric propulsion system (drive motor or power inverter).  If the problem is no longer there during Regen, the problem resides in the traditional engine system.  I want to stress here that, this is a simple generic test to help narrow where the problem may be stemming, it is not meant to be an “all encompassing” test.  Notice that I didn’t mention the battery pack.  There is a separate test that can be performed on the battery pack (stress test), and this can be performed during the same test drive for the engine and electric propulsion system by using a scan tool.  The battery pack can also cause hesitations, chuggles, fish bites, etc.
 
In total, this is about a 20 minute test drive for the engine, electric propulsion, and battery pack.  It’s simple, effective, and will save a technician significant diagnostic time.   

​In the late 1990’s and early 2000’s, hybrid bus systems were being developed at a feverish pace, based on low emission and higher fuel efficiency requirements from many major cities in the U.S. Market. However, as transportation technologies march forward, it appears that hybrid bus systems may experience serious competition from pure electric bus systems.  Many countries external of the U.S. are venturing into the zero emission vehicle (ZEV) market to improve air quality (i.e., China, Singapore, etc.) this is driving the need for bus fleets with ZEV systems.  Companies such as BYD and Proterra have quickly caught the eye of several U.S. cities that are shifting from traditional diesel powered buses directly to ZEV bus systems, eliminating the “in between step” of using hybrid technology.

The reason that ZEV buses can be utilized is that Lithium battery technology has superior specific energy and energy density that reduces the size and mass (weight) of the battery pack system.  Therefore, enormous battery systems are not necessary for a bus system due to the advantages of Lithium technology.  This alters the need for large battery packs which may no longer be necessary for bus systems.  If high power wireless charging technology is placed on bus routes and in depot sub-stations to permit fast charging of the battery pack, large battery packs will no longer be necessary.  Also, logistics would be significantly easier because, requiring the bus to return to the main depot for charging would not be necessary.   While this is occurring on a global scale, keep in mind there are and will continue to be other technologies that will be considered for charging batteries along a bus route.  Overhead wire systems located only at bus stops or sub-depot locations can also be used to rapidly charge the batteries.  This would eliminate the need for modifying streets or roads when installing wireless charging pads.    

Traditional vehicle purchasing may experience some significant changes during the next several years and throughout this next decade.  In fact, major automotive OEMs are betting on it.  As companies like Uber and Zip Car (ride sharing and vehicle sharing) services continually resonate with younger generations and environmentally conscience consumers, the landscape of vehicle ownership will also change.  In lieu of an individual investing in the purchasing of a vehicle that may only be utilized a small percentage of the time, many prospective buyers are now turning toward ride and vehicle sharing and only pay for “when” the vehicle is used.  Automotive OEMs have heard this message loud and clear.  Obviously, if this type of trend continues, the OEM sales numbers could decrease and shift from primarily private ownership to a significant volume of corporate ownership.  This is one reason why the OEMs are partnering with Autonomous vehicle systems suppliers to “hedge their bet” in the event that the ride and vehicle sharing trend growth continues to grow and expand at rates that increase the relevance to the transportation market. 
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GM has recently announced a partnership with Lyft to begin navigating the waters of Uber and Zip.  The $500M GM investment in Lyft indicates that the automotive OEM is serious about expanding into the rental vehicle market but, more importantly, it indicates GM’s interest in moving deeply into the Autonomous vehicle space.  Most companies that have considered or that are currently in the Autonomous vehicle space have targeted the use of battery electric vehicles as the primary platform, such as the GM Bolt.  Lyft and GM believe that the Express Drive program will assist both companies implement technology infrastructure for fleets of self-driving in the future.  However, the immediate focus of the Lyft Express Drive program is place more Lyft vehicles into service.

Las Vegas, NV (October 11, 2016) - FutureTech is expanding its Electric Drive Training division Access, with 27 online instructor-led training courses for Hybrid, Battery Electric, EREV, Plug-In, and Fuel Cell Vehicle diagnostics and repair. The expansion, dubbed Access Online, has begun taking registrations for its first-quarter 2017 training courses, with additional courses being added quarterly thereafter. The courses are conveniently timed for evening sessions and are run in 1-hour increments.
 
Early-bird registrants can enjoy 25% off of all Access Online training courses until November 30th, 2016 with no promo code required. Courses start at just $52 (including discount), and range from 1-5 one-hour sessions per course. Additional discounts and special pricing are available for bulk registrations of 10 or more by contacting Access Online.
 
Unlike Access’ free 30-minute webinars that focus primarily on technical theory and basic systems overviews, Access Online’s technical training courses will emphasize practical application of diagnostic and repair techniques and tools, including scan tool data and PIDs. At the conclusion of each training course, participants will be able to take their new skills back to their businesses and apply it to existing needs. In fact, each participant will receive a Certificate of Completion after successfully concluding each complete training course, which can be applied toward NATEF credits and other automotive professional development requirements.
 
Technical training topics include but are not limited to:

• Nickel Metal Hydride (NiMH) Battery Systems
• Lithium Ion Battery Family Systems
• Hybrid Electric Vehicle “Tune-Up” Maintenance
• How to Analyze, Test & Diagnose 3-Phase Hybrid & Electric Vehicle Transmissions & Drive Units
• Service Advisor & Manager Training for Hybrid Electric Vehicles
• Plus model-specific diagnostic and repair training on the Toyota Prius, Chevrolet Volt, Hyundai Sonata Hybrid, Honda Civic Hybrid, and the GMC/Chevrolet Yukon/Tahoe 2-Mode system.

 
Access has recruited three additional instructors to lead the online training courses: Yves Racette, Paul Pelly, and Alan Nagel will facilitate the courses alongside FutureTech’s Chief Technical Officer, Dr. Mark Quarto. Participants can expect the same high-quality training courses in Access’ online sessions as have been experienced in hands-on training.
 
Access Online’s training courses are perfect for automotive technicians, shop owners, service advisors, educators, new and pre-owned car dealers, fleets, and other automotive service professionals who find themselves tight on time and budgetary flexibility. Although hands-on instruction is the automotive industry’s gold-standard for training, Access is prepared to deliver quality solutions to those who are unable to travel to a classroom.

Individuals who are interested in a preview of Access' hands-on training are invited to two free hands-on training sessions in Las Vegas: Service Advisor and manager Training for Hybrid Electric Vehicles (October 31, 2016), and Battery Testing and Installation (November 4, 2016). 
 

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FutureTech has a combined 70 years’ experience in developing and delivering Advanced Vehicle Technology solutions. By understanding that the industry is composed of many equally important pieces, FutureTech can deliver multi-faceted solutions to automotive service shops, fleets, distributors, manufacturers, educators, and more. FutureTech meets the demands of today's automotive service professionals while developing tomorrow's advanced technology solutions. 

​As with most of the technologies associated with Plug-In and Electric Vehicles, the battery pack charging technologies are changing with blazing speed.  Currently, the conductive (cable plug-in) systems are marching toward ever-higher charging rates.  With most SAE and CHAdeMO conductive Direct Current Fast Charging (DCFC) systems capable of 50kW – 100kW power, Wireless Charging is now beginning to gain traction in the vehicle battery charging market.  Wireless Charging systems have obvious advantages by not requiring a vehicle operator to make a direct connection between the charging station and the vehicle.  Electric vehicles can have a vehicle pad mounted under the vehicle so it can receive power after the vehicle is driven over the base pad to initialize Wireless Charging.  The vehicle or your smart phone will assist in positioning the vehicle pad with the base pad. However, currently Wireless systems are not capable of delivering the level of kW power when compared to conductive systems.  For example, the Qualcomm HALO system can currently provide 3.7kW, 7.4kW, 11kW, and 22kW Wireless Charging. 

​The Wireless Charging system has one significant advantage when compared to conductive charging systems – it can be located within a road or street to permit quick charging when a vehicle is within range.  As an example, Wireless Charging is perfect for electric buses.  When the bus has stopped to pick-up passengers at a bus stop location, the bus can charge while it is taking on passengers.  Also, the bus can charge when the driver is on a rest break.  Having Wireless Charging locations along a bus route, it eliminates the necessity of returning the bus to the depot to be charged at a conductive charging station which, is a significant advantage and convenience.

To ensure that there will be trained automotive technicians to service HEV, PHEV, EREV, and BEV (e.g., Advanced Technology vehicles) Automotive Instructors play the pivotal role in developing these technicians.  Prior to instructing any automotive topic, instructors should receive professional training and develop experiences that can be transferred to their students.  With degrees already brimming with traditional automotive courses, instructors are finding it extremely difficult to determine how Advanced Technology vehicle information will be inserted into a structure that cannot accommodate additional courses.  Additionally, college level administrators may not see a need to include the necessary courses to automotive degrees and certificates that properly prepare the students to analyze, diagnose, and repair vehicles with high voltage electric drive systems, battery packs, electric air conditioning compressors, etc.  There are college administrators that have tried to solve this problem by offering adjunct 1-year certificate programs that permit students to continue with their automotive studies for a 3rd year.  However, students quickly realize that, because the extra year of training in the Advanced Technologies is not a component of their 2-year degree program, they cannot acquire financial aid to help defray the educational costs until after graduation.  Therefore, there are multiple issues in offering Advanced Technology vehicle training to the students, even if they desire it. 

A more pressing issue involves automotive instructor training.  If colleges aren’t supporting the addition of Advanced Technology education as a part of their automotive programs then, it may be difficult for automotive instructors to acquire support from their administration to attend qualified professional training.  At FutureTech, our staff recognized this problem many years ago.  The concern is real – with the production of Advanced Technology vehicles accelerating at exponential speed and instructors not receiving qualified training then, how will the next generation of technicians be trained to fundamentally learn the knowledge and skills necessary to diagnose and repair Advanced Technology products? 
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The answer is simple.  FutureTech supports colleges and their automotive instructor staff that currently or plan to provide this training as part of a certificate or degree program.  For those colleges that do not include or offer this training, private sector companies, such as FutureTech have already developed the training products, tools, and equipment for field technicians and can easily begin to integrate college level students into these Advanced Technology vehicle courses.   

An MIT Study by Professor Jessika Trancik cites that Battery Electric Vehicles (BEV) can meet needs of most drivers.  The study indicates that “current EVs could meet the needs of about 90 percent of drivers, at a total cost no greater than that of legacy ICE vehicles. EVs could also play a significant role in meeting emissions reduction goals. Furthermore, assuming battery technology improves at the expected rate, by 2020 up to 98 percent of vehicles could be replaced…..by a low-cost electric vehicle available on the market today, even if the cars can only charge overnight,…..which would more than meet near-term US climate targets for personal vehicle travel.” The study contends that overall, when accounting for emissions from today’s power plants, this would lead to a 30 percent reduction in emissions from transportation.  
 
Although this study may seem aggressive in application, its findings may be closer to how BEVs could be deployed into the market at a faster rate than previously thought.  With the advent of more Level 2 and Level 3 (Fast) Charging Station accessibility, Level 3 Charging Stations are capable of providing 80% battery charging in 20-30 minutes, that will provide significant vehicle range increases at (200 - 250 miles/charge +), making BEV acceptance a much simpler reality than in years past.  And for those that need more range than 200 miles there are always the BEVs that have a range extender option or there are extended range electric vehicles (EREV), like the Chevrolet Volt, that offer no range limitations with on-board electrical generation. 
 
As the electric drive vehicle technologies and their derivatives continue to evolve at an exceptionally fast pace, these vehicles have now become part of the main stream market.  FutureTech expects to see a rapid adoption of BEV and other Plug-In vehicle technologies to move to the market forefront, very soon.

Automotive service businesses may be missing out on how the can market their services to a new generation of vehicle owners.  The new generation of Plug-In Hybrid, Extended Range Electric, and Battery Electric (Advanced Technology) vehicle owners are very “tech savvy” and are constantly scanning their local area for businesses that can maintain, analyze, diagnose, and repair their Advanced Technology vehicle.  Acquiring their business may be very simple and does not require more than a few minutes of your time with them.  By adding a plug-in Charging Station, you can easily begin to market your business as “friendly” to these Advanced Technology vehicle owners.  The marketing is very simple:  Most plug-in vehicle owners want to know where they can plug-in to charge their vehicle.  In fact, many owners use smart phone apps such as Charge Point to determine where the nearest charging station is located to receive a quick charge.  And, it would be very simple to add your business to the many smart phone apps that are available to vehicle owners.  If your business is already diagnosing and repairing Advanced Technology products then, this would be a simple and inexpensive strategy to market your business as a location for not only vehicle charging but, also vehicle repair.  Level 2 charging stations can be purchased for less than $750.00 and only need a dedicated 220V electrical circuit with 20 – 40 Amp capability. 
 
You may want to think about adding a charging station to your business.  It’s an inexpensive method for exposing your service business to Advanced Technology vehicle owners globally.  It’s also a method to acquire traditional service business from a customer.  Remember, most customers believe that, if a business can maintain and repair their Advanced Technology vehicle, certainly they can repair a traditional vehicle with “old” technology.

​How many customers could your charge station attract in your business' service area? FutureTech can develop a report that is unique to your business, showing how many Hybrid, EREV, Plug-In Hybrid, and Electric Vehicles are close to you.