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Evidence Guide: AURETH4003 - Test and repair high voltage battery systems in battery electric vehicles

Student: __________________________________________________

Signature: _________________________________________________

Tips for gathering evidence to demonstrate your skills

The important thing to remember when gathering evidence is that the more evidence the better - that is, the more evidence you gather to demonstrate your skills, the more confident an assessor can be that you have learned the skills not just at one point in time, but are continuing to apply and develop those skills (as opposed to just learning for the test!). Furthermore, one piece of evidence that you collect will not usualy demonstrate all the required criteria for a unit of competency, whereas multiple overlapping pieces of evidence will usually do the trick!

From the Wiki University

 

AURETH4003 - Test and repair high voltage battery systems in battery electric vehicles

What evidence can you provide to prove your understanding of each of the following citeria?

Prepare for repair operations

  1. HV batteryrepair information is accessed
  2. Workplace health and safety (WHS) requirements and appropriate precautions are identified and applied
  3. Repair method most appropriate for the specific circumstances is selected and prepared for
  4. Tools andtesting equipment necessary to conduct the work are assembled
  5. Technical and/or calibration requirements for repair of the HV battery system are established
HV batteryrepair information is accessed

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Workplace health and safety (WHS) requirements and appropriate precautions are identified and applied

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Repair method most appropriate for the specific circumstances is selected and prepared for

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Tools andtesting equipment necessary to conduct the work are assembled

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Technical and/or calibration requirements for repair of the HV battery system are established

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Test battery system

  1. HV battery systems is tested for electrical efficiency using manufacturer specifications and test procedures
  2. Diagnostic equipment is used to retrieve system parameters and information
  3. Faults with the battery system are identified
  4. Test results are recorded
HV battery systems is tested for electrical efficiency using manufacturer specifications and test procedures

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Diagnostic equipment is used to retrieve system parameters and information

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Faults with the battery system are identified

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Test results are recorded

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Repair battery system

  1. Test results are compared with equipment specifications to decide on appropriate corrective action
  2. HV battery system components are replaced, repaired or adjusted as required
  3. Repaired HV battery systems are re-tested for correct operation
  4. Replacement, repair or adjustment procedures are recorded
Test results are compared with equipment specifications to decide on appropriate corrective action

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

HV battery system components are replaced, repaired or adjusted as required

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Repaired HV battery systems are re-tested for correct operation

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Replacement, repair or adjustment procedures are recorded

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Complete repair operations

  1. Work area is tidied, and tools and equipment are replaced according toworkplace requirements
  2. Job card or repair order is completed according to workplace requirements
  3. Client report is prepared on the outcomes of the repair of the HV battery system, according to workplace requirements
  4. Vehicle is prepared for return to the client
Work area is tidied, and tools and equipment are replaced according toworkplace requirements

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Job card or repair order is completed according to workplace requirements

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Client report is prepared on the outcomes of the repair of the HV battery system, according to workplace requirements

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Vehicle is prepared for return to the client

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Assessed

Teacher: ___________________________________ Date: _________

Signature: ________________________________________________

Comments:

 

 

 

 

 

 

 

 

Instructions to Assessors

Evidence Guide

The evidence guide provides advice on assessment and must be read in conjunction with the performance criteria, required skills and knowledge, range statement and the Assessment Guidelines for the Training Package.

Overview of assessment

Critical aspects for assessment and evidence required to demonstrate competency in this unit

The evidence required to demonstrate competency in this unit must be relevant to workplace operations and satisfy all of the requirements of the performance criteria and required skills and knowledge.

A person who demonstrates competency in this unit must be able to:

comply with WHS requirements and safe work practices

ensure electrical and mechanical integrity of any component or system is maintained when performing tests

check HV battery system performance against manufacturer’s specifications

replace, repair and adjust HV battery system components as required to correct deficiencies

complete relevant documentation for the repair of the HV battery system.

Context of, and specific resources for assessment

Competency is to be assessed in the workplace or a simulated workplace environment that accurately reflects performance in a real workplace setting.

Assessment is to occur:

using standard workplace practices and procedures

following safety requirements

applying environmental constraints.

Assessment is to comply with relevant:

regulatory requirements

Australian standards

industry codes of practice.

Competency is to be assessed using a BEV that uses HV and LV AC/DC electrical systems. Where simulation is used, an operational BEV must be included in the simulation.

The following resources must be made available for the assessment of this unit:

appropriate PPE

a BEV

manufacturer specifications for the BEV

testing equipment

full range of essential tools and equipment

workplace documentation.

Method of assessment

Assessment must satisfy the endorsed Assessment Guidelines of this Training Package.

Assessment methods must confirm consistency and accuracy of performance (over time and in a range of workplace relevant contexts) together with the application of required skills and knowledge.

Assessment methods must be by direct observation of tasks and include questioning on required skills and knowledge to ensure correct interpretation and application.

Competence in this unit may be assessed in conjunction with other units which together form part of an holistic work role.

Where applicable, reasonable adjustment must be made to work environments and training situations to accommodate the needs of diverse clients.

Assessment processes and techniques must be culturally sensitive and appropriate to the language, literacy and numeracy capacity of the candidate and the work being performed.

Required Skills and Knowledge

Required skills

technical skills to:

use workplace technology relating to testing and repairing BEV HV battery systems and components

use specialist tools and equipment

use computerised measuring equipment

report and record actions

communication skills to:

confirm work requirements and specifications

communicate effectively regarding work requirements with supervisor, other workers and customers

report work outcomes and problems

literacy skills to interpret technical information and specifications

numeracy skills to complete tests and measurements to determine correct operation

problem-solving skills to:

interpret test results

identify repair options

self-management skills to:

manage risks and hazards associated with HV BEV battery systems and components

optimise workflow and productivity

Required knowledge

components of HV battery systems and their functions

battery management system (BMS) theory

battery theory, including:

battery internal resistance

battery types

terminal corrosion

terminal resistance

battery pack theory, including:

cell failure theory

charging characteristics

open circuit cells

reverse polarisation

series cell configuration

strapping and layout

HV battery charger and DC to DC converter characteristics

WHS requirements relating to:

safe work practices

electrical safety

power distribution unit (PDU) theory

principles of electricity, including AC and DC

principles of operation of HV battery systems

applicable commonwealth, state or territory legislation, regulations, standards, codes of practice and environmental regulations relating to the repair of HV battery systems

vehicle-specific electrical requirements

workplace policies and procedures, including quality, recording and reporting procedures relating to the repair of HV BEV battery systems

Range Statement

The range statement relates to the unit of competency as a whole. It allows for different work environments and situations that may affect performance. Bold italicised wording, if used in the performance criteria, is detailed below. Essential operating conditions that may be present with training and assessment (depending on the work situation, needs of the candidate, accessibility of the item, and local industry and regional contexts) may also be included.

Repair information may include:

Australian standards

diagrams and sketches

engineer or manufacturer design specifications and instructions

industry codes of practice

parts catalogues

verbal, written and graphical instructions issued by authorised internal and external persons

workplace specifications and requirements.

WHS requirements may include:

elimination of hazardous materials and substances

first aid equipment

following emergency procedures

hazard and risk control

material safety data sheets (MSDS)

personal protective equipment (PPE) and clothing

safety equipment

techniques for manual handling, including shifting, lifting and carrying.

Appropriate precautions may include:

analysing task to define risk

applying electrical safety precautions, such as:

“one hand rule”

live system warning tags and signs

isolating the HV battery supply

depowering the vehicle

using PPE, such as:

electrical safety gloves 1000V

HV insulating mats (Australian standards rated).

Testing equipment may include:

AC/DC current clamp

BMS diagnostic equipment

diagnostic scanner

insulation or mega ohm tester

multimeter CAT 3 1000V

oscilloscope

thermal imaging equipment or non-contact thermometer.

Electrical efficiency relates to:

charging

discharge rate

holding capacity

temperature

voltage.

Test procedures may include:

battery charging interlock

battery cooling system

BMS

HV contactors

HV current leakage to vehicle chassis

HV fuse

inertia safety cut-out switch

isolation/cut-off emergency device

leakage of electrolyte

loose cable connections

mounting of batteries

on-board battery charging system

PDU.

Appropriate corrective action may include:

balancing state of charge

replacing cable connection

replacing system component

replacing the battery

tightening connection.

Workplace requirements may include:

industry codes of practice

manufacturer specifications

quality policies and procedures

safe work procedures

sustainability, environment, equal opportunity and anti-discrimination policies and procedures

workplace recording and reporting procedures.