A Checklist for Selecting a Training Supplierd284f45nftegze.cloudfront.net/ARandD/WhitePaper...

March 2013

A Checklist for

Selecting a Training Supplier

Automotive Research and Design, LLC

White Paper

By: Dr. Mark Quarto - Chief Technology Officer

Email: [email protected]

March 2013 Automotive Research & Design, LLC

Contents

Introduction ................................................................................................................................... 3

CHECKLIST:

How long has the training company been in business and is it documented? ................ 4

Does the Company offer more than HEV training ................................................................ 5

Does the Training Supplier Company partner with other technology or educational

organizations? ............................................................................................................................... 6

Can you purchase the training supplier mateirals, tools, equipment, etc. PRIOR to

purchasing their Training? ......................................................................................................... 7

Instructor Popularity vs. Instructor Competence ................................................................... 8

Is the Instructor a Product Specialist or a Technologist? ...................................................... 9

Do the Instructors have Professional Education, Training, and Experience (OR) are

they Self-Taught (Enthusiast or Hobbyist) ............................................................................ 10

How the HEV Self-Taught Instructors and Enthusiasts go “OFF THE RAILS” and

Take you with Them .................................................................................................................. 11

Summary ...................................................................................................................................... 14


1

Introduction

As manufacturers continue to offer more hybrid electric vehicles (HEV) in the automotive market (57 production models available as of years 2012-2013), both OEM and aftermarket service organizations are beginning to ask the question “is there a good HEV training company that I can hire to properly train my technicians?” If you have had experiences with several HEV training companies the answer may be very clear. However, if this is the first time that you’ve been thinking about partnering with an HEV training supplier the answer may not be nearly as clear. Therefore, a checklist may help you decide how to select a reputable qualified supplier as well as how to “weed out” HEV training companies that may have great marketing or contacts in the aftermarket industry however they lack the technical depth, professional training, and experience within the advanced vehicle systems market. You may find out through some inquiries that there are companies and independent instructors making claims about their expertise which is well outside of their capabilities or, maybe some of these claims include fraudulent credentials, experience, or both. The HEV technologies are a completely new area for automotive technicians. Therefore, there is virtually no knowledge from a traditional vehicle that can be used to learn hybrid high voltage technology (legacy knowledge), and the same is true for transferring any technology knowledge (technology transfer) from traditional vehicles to HEV. As examples, traditional vehicles do not use high voltage battery packs, (one or two) 3-phase high power electric machines that provide propulsion and power generation, power inverters, dc-dc converters, interlock circuits, isolation fault circuits, electric A/C compressors, etc. Therefore, if there is no legacy knowledge or technology transfer that a technician can utilize in learning HEV technology, it is vitally important that the training supplier selected is highly qualified to instruct the topics to the technician(s) that will result in “real” learning of the technology. When teaching traditional automotive systems, the typical instructor is not required to possess any “special” knowledge or skills because, the topic content is mature, they have significant legacy knowledge, and there is no technology transfer concern. Therefore, there are a high percentage of automotive training suppliers that should be able to provide adequate training on traditional systems to your technician staff.

In the 26 years that Automotive Research & Design (AR&D) has been in the technology development and technical training business, we have read hundreds of articles by many, many different trainers and/or companies on HEV technology. The following checklist has been developed with the help of a few decades dedicated to supporting the HEV Technology Aftermarket.


2

How long has the training company been in

business and is it documented?

This is an especially important question because it directly points to experience. This is a question that AR&D has researched on a significant number of the more popular training companies, and we have found some interesting information on many of them. As an example, one company claims to have been instructing in advanced technology area for more than 20 years but, their company was formed in 2007. A company should have a demonstrated minimum of 10 years’ experience in instructing the technology. The training supplier should have a Better-Business-Bureau rating, etc. There are many HEV training suppliers, and if you are planning to spend significant budget to train your technician staff on HEV technology, it may be prudent to complete some cursory background checks on them.

Remember, length of time in business is only one of many metrics to use when reviewing prospective HEV training suppliers. The number of years in business should correlate with other information such as training staff experience and credentials (OEM or OEM supplier experience in hybrid technology) along with demonstrating other hybrid product offerings (equipment, books, CDs, etc.).

Any reputable high quality training supplier should be able to provide you information relating to their direct experience supporting HEV technologies and their project related partnerships including specifics related to projects with these partners.


3

Does the company offer more than HEV

training?

One important method of measuring the level of technical knowledge or competence of a training supplier is to inquire if the company offers supplementary “related” products in addition to their training. This provides some validation that the company has technical depth and experience in the technology when they are directly involved in multiple HEV technology discipline areas. As an example, if the company has product lines and experience in these areas:

e-Learning

mobile-learning

live streaming training events

high quality technical training videos

they may have designed and developed specialty HEV tools & equipment

rebuild or remanufacture high quality HEV parts

solid work experience in HEV development

other direct experience working with this technology either with OEM’s or suppliers to major OEM’s

Answers to these questions would indicate if the company has depth in its understanding of HEV technology and the overall technical experience or expertise to provide technical training to the automotive aftermarket industries, technicians, and professional educators.


4

Does the training supplier company have

partnerships with other technology or

educational organizations?

This is one metric that will help you determine if a training company is viewed by others as legitimate and that other organizations are willing to make an investment in your prospective training supplier. An easy method of acquiring this information is to visit the training supplier website and there should one or more logo’s, listing or links to partner websites, or possibly a dedicated web page that has their partners listed. Partnering is defined as a partnership that is bound legally. If a training supplier is partnered with another company to provide training books/curriculum, instruction, etc. as part of a for-service contract (i.e., training supplier has an ongoing contract to provide services to another company) this is a sign that there is some legitimacy. No business partners listed on the website usually means that the prospective training supplier’s quality of materials or instructions could be less than desirable, not peer reviewed, technically accurate, validated, etc. Additionally, they may not be a worthy supplier if there is no website or the company cannot site and provide evidence of legitimate partnerships. This should be a red flag. Note: If the company lists or provides names of their partners, it may be prudent to request that the training supplier provide you the contact information to these partners……and then call the partners to request more information. As we all have experienced at some point, just because it’s on the internet does not make it true.


5

Can you purchase or review the training

supplier materials, tools/equipment, etc.

prior to purchasing their Training?

A quality training supplier should have one or more ways for you to preview their training information and/or program prior to purchase: 1) Provide a courtesy copy or representative example of their training

materials or,

2) Provide a method for you to purchase training materials at a reduced cost or,

3) If your interest is in the area of parts or tools/equipment, does the

training/equipment supplier provide on-site, video, or streaming video with equipment demonstrations

By acquiring training materials from multiple training suppliers this can provide you one metric to compare the quality of products from each company. If they do not have training materials for sale to the public this should be a warning sign to you that the information could be low quality or there is possible copyright violation. In the internet age, if they don’t have a website with some level of technical content, on-line store, sample material downloads, etc. - This should be another red flag.


6

Instructor Popularity vs. Instructor

Competence

There are many instructors that are “likeable” and/or convey themselves as “an authority” or “expert” on the topic of HEV or electric drive systems. Likeability is a wonderful quality but, this doesn’t mean that the training supplier or instructor is competent. Competency is difficult to measure when you don’t have a metric for comparison. If you want a more credible measurement of competence, ensure that your instructor has had at least 10 years HEV experience with OEM product development, an OEM supplier, or has at least been an OEM training instructor. Product development or supplier experiences are the best indicators. Without this type of experience there is a high probability that the instructor is “self-taught” in the technology. Without a solid working knowledge and experience in this new and complex technology this should raise a significant red-flag during the selection process of a training supplier.


7

Is the Instructor a Product Specialist or a

Technologist?

This area is typically unknown or not questioned by most automotive aftermarket service businesses, educational institutions or, those seeking to partner or retain the services of a training supplier. In our 26 year experience with HEV and electric drive systems, most automotive technicians believe that if an instructor has product knowledge (i.e., knows how to remove a component, can locate a component on the vehicle, knows a specific wire color of a circuit, memorized diagnostic DTCs, etc.) this means that they have equal knowledge and competency in the technology. This is an enormous mistake. Most HEV instructors in the aftermarket are product specialists, not technologists. A technologist has been professionally trained in the automotive, electrical, and/or mechanical sciences with special emphasis in the HEV areas. Technologists fully understand the relationships of the components, component design, systems analysis, diagnostic systems structure, use of diagnostic equipment, and have significant hands-on experience with HEV and electric drive systems. Many (product) instructors became aware of this technology by reading about it or taking an HEV apart and putting it back together. However, there is no substitute for actual work/project experience and professional training in HEV technology development. Therefore, if an instructor has not been employed for a significant number of years by an OEM or a component/systems supplier in HEV product development, they severely lack the credentials to promote themselves as a technologist. To become competent on a totally new technology like HEV or electric drive systems our recommendation is to secure it from an HEV technologist in addition to having solid product knowledge. Product knowledge can be learned significantly easier compared to the extensive knowledge and experience level that is required of a qualified technologist. For example, there are several well-known and popular instructors that are sincerely passionate about HEVs, have varied levels of product knowledge and, may have one or more cars they use to instruct courses. However, based on the technical articles they have authored and reviewing some of the training materials and webinars available, it’s evident that there is a minimal understanding of HEV technologies and no objective evidence of professional qualifications validating these trainer(s) as experts or technologists. It may be more accurate to categorize trainers such as these as an HEV enthusiast. Be very careful not to confuse product knowledge with a technologist. Scrutinize and ask any prospective HEV training supplier to provide information on their instructor staff to determine if they have product specialists or technologists on their staff –or at a minimum Professionally Trained Instructor(s) in HEV Technologies. Request instructor bio(s) to review their HEV professional training, experience, etc. A reputable trainer/company will be more than willing to provide you the professional training, experience, and credentials of their staff.


8

Do the Instructors have Professional

Education & Training and Experience (OR)

are they “Self Taught” (Enthusiast or

Hobbyist)?

Without question the area of instructor credentials is one of the most sensitive topics in the arena of technical education. Why? Because, it identifies the background, depth of professional knowledge, breadth of knowledge, expertise, etc., of the company and its instructors. Experience in HEV development with an OEM or OEM supplier is critical as a first step for determining the quality of a training supplier. When combining HEV OEM or supplier experiences with technical education the result is a perfect combination. However, technical credentials in the HEV technical education arena are essential and critical if technicians at your service business or, instructor staff at an educational institution are to be successful. Quality training suppliers have a staff with professional training background in electrical & mechanical engineering and technology, automotive technology, electronics engineering/technology typically coupled with at least 10 years of HEV experience at an OEM or supplier. This level of professional training and experience will ensure that the training supplier is deeply grounded in HEV technology and they are able to provide well designed programs. As stated earlier, high quality or legitimate training suppliers will provide you complete biographies and will answer all questions relating to credentials. Self-taught individuals are typically very passionate about HEV technology. Moreover, they are usually HEV owners and are knowledgeable about the particular product that they own. All of these are admirable traits because passion can drive anyone to a higher state of knowledge and learning. However, for as much as passion can drive some of these wonderful traits, it is not a substitute for professional training and experience on HEV or electric drive system products. Many technicians and college instructors will attend a training event held by a company that utilizes self-taught instructors that are more accurately categorized as impassioned enthusiasts. The instructor will infuse passion into the students on the topics within the class. The technicians or instructors will leave the course feeling energized and inspired. However, some or most of the information, skills, and materials may be incorrect or, just opinion. Many self-taught HEV instructors are knowledgeable about a specific product but, some of them may venture into the area that only a technologist should be treading. However, the technicians and instructors that are students in the class does not know if the information, skills, etc. are based in opinion sprinkled with some “reverse engineering” information and most important that is not founded in solid science coupled with the requisite experiences and validation.


9

How the HEV Self-Taught Instructors and

Enthusiasts go “OFF THE RAILS” and Take

You with Them

A couple of examples may help to explain how an enthusiast sprinkled with some product knowledge can tread into deep water and drown – this eventually leaves the students with information that will lead them directly into the weeds.

One example relating to Technical Training HEV Batteries: Let’s explore how unqualified or self-taught instructors can lead their students or aftermarket businesses into treacherous waters in the area of HEV battery testing and analysis. There are several instructors that teach students to load test batteries with light bulbs (or by using other load methods) and recharge the batteries with a traditional 12 volt charger or, with Radio Controlled (RC) car chargers. Unfortunately, when using these methods there is a high probability that battery pack modules will be damaged (without the knowledge of the person performing the testing), exhibit an unbalanced condition or, cause poor performance/fuel economy.

In the interest of science, our company purchased the equipment utilized by these instructors (12 volt light bulbs and RC car chargers). We also acquired their conditioning/balancing process for the purposes of performing an experiment (duplicating the process) to determine how effective this method was in servicing an HEV battery pack. To ensure accuracy, the battery pack was conditioned with the proper commercial battery discharging and charging equipment that can condition and balance a battery pack. The battery pack was then discharged using 12 volt light bulbs and charged with RC car chargers. After completion it was found that the battery modules were unbalanced and in worse capacity condition when compared to its pristine condition when the testing had started. There are many reasons of why this method is inferior but, in the interest of detail, some of the rationale will be conveyed.

First, when using a 12 volt bulb to discharge a battery module (or module group) there is no control on when the discharging will be terminated or the discharge rate. Therefore, the batteries may be discharged well below the low threshold limit which will damage the cells. Or, the battery modules may not be discharged to the cut-off voltage level that will leave them in a capacity state that is higher than other modules.

Second, since there is no method to control the battery module discharge voltage cut-off point the batteries terminal voltages (and capacities) could be significantly different. This would introduce variation in each of the battery module capacities and cause battery module imbalances. Imbalances are one of the worst conditions in which to


place a battery system because it can significantly reduce battery module life. It not only can cause Malfunction Indicator Lights (MIL) to be triggered (only if the condition becomes severe) and reduce its service life and overall performance. Light bulbs, RC car chargers, or any variation of “back yard” battery testing will only lead to poor performing vehicles and unhappy customers.

The last point on battery testing is that the non-professionals are not Power Testing the battery modules because they are unaware that it needs to be performed, they don’t know how to perform the test, and/or they are not equipped to perform the test based on testing standards. Typically, non-professionals only test battery energy without the rigor of standards or professional training. Power testing is high current testing to determine the resistance of the battery module or module group. This is extremely critical to determine how well the battery module can deliver electrical power to the electric traction system for short periods. Therefore, when selecting a training supplier to learn how to perform HEV battery tests and analysis, you may want to inquire as to how they are performing the tests. If they are not performing both Power and Energy testing with commercial equipment that is software controlled (to control the testing and provide test data results) then, you should consider contacting a supplier that has the requisite experience to train your staff and also has the proper equipment. The equipment should be able to perform Energy tests at the module level and have independent discharge control of each module group. There are HEV battery dischargers on the market being sold by well-known battery testing companies that perform Energy tests at the battery pack level instead of using independent channel control, and it will not perform Power testing.

Additionally, a training company should have the proper equipment available for you purchase or, be partnered with a company in which you can purchase equipment that tests battery Power and Energy at the battery pack module level. It is vitally important that that the battery pack be tested at the module level to permit proper testing, conditioning, balancing, rebuilding, or remanufacturing. Before contracting with a training supplier to instruct your staff in HEV battery pack service ask them where they acquired their training on how to perform battery pack testing, their years of HEV battery testing experience, how long they have been commercially testing battery packs, and what equipment they use to perform the testing. This should provide enough information to you on their capabilities.

One example relating to Technical Training on Diagnosing Electric Motors: Let’s consider for a moment that a popular and relatively well known HEV training company that teaches HEV technology to organizations throughout varied venues in the U.S. is in a position to mislead individuals looking for training supporting this technology if their credentials and experience are uncertain. An instructor can claim to have a Master’s of Science Degree in Engineering and decades of advanced technology experience. They begin teaching electric motor diagnostic/testing and develop their own diagnostic methods/processes. Moreover, they have it published and further enforce these processes during hands-on training sessions pushing this (less expensive) method can match and/or exceed some of the commercial motor test instruments specifically designed by OEM’s for field testing HEV motor-generators. Moreover, the trainer has moved into the area of evaluating professional electric motor test equipment and compares it their own method, posts “test results” on internet forums, and


incorporates their “research” (??) results into the HEV courses that is taught to technicians in the aftermarket and college instructors.

Now this story becomes more interesting…….An OEM specializing in Motor testers, after reading some of this popular instructor’s blog posts about their instrument, they hired attorneys to legally acquire the instructor’s credentials to ascertain the level of professional technical education in this field and this individuals professional qualifications to evaluate electrical test equipment. It was concluded that the instructor had not earned a Master’s of Science in engineering degree. However, the instructor did earn an overseas Master’s Degree in a non-technical program from an educational institution that was not accredited in the U.S. without an Undergraduate degree in engineering as a pre-requisite (only a Fine Arts degree). The message here is that an individual that does not properly vet their training supplier would not know that this trainer is not professional trained or experienced in the Technology that is being taught. Furthermore this trainer currently continues publishing fraudulent credentials and is teaching electric motor diagnostic/testing using diagnostic methods/processes/procedures personally developed without partners, peer review, validation, or any other standard applied by the industry. Unfortunately, the most important aspect of this story is that those methods have been proven (by real engineers working for OEMs and suppliers) to provide deficient test results (false positives, inaccurate test results, etc.). Regrettably, this trainer continues to acquire new clients and teach these incomplete processes using equipment and procedures that have been proven by professionals to be sub-standard. In year 2012, a major OEM completed a two-year comparative study on five (5) different motor-generator diagnostic methods and equipment that, included the processes and equipment promoted by this instructor. The results of this study indicated the processes (and some of the equipment) utilized by this instructor tied in ranking for (4th and 5th ) place out of the five (5) test methods. On a scale of 1 - 10 (1= low ranking and 10 = high ranking), this instructors processes and equipment rated a one (1). Using a 12 volt light-bulb for motor-generator diagnostics could be considered as a worse rating even though it received the same rating of one (1) on the 1-10 scale. You can acquire the results of this comparative study by contacting our company and making the request (see our company contact information at the end of this article).


10

Summary

We sincerely hope that you use the content of this checklist the next time you are contemplating contracting with an HEV training supplier. In our 26 years of HEV and electric drive development and training experience, we have directly experienced the information and examples contained in this document. While preparing this information it was our desire that all or some portion will serve to assist the readers in becoming a more discriminating customer when they are searching for a training supplier. Please keep in mind that you and/or your staff will only be able to perform HEV diagnostics at the level at which the training company has delivered, however your customer’s expectation is that the technician servicing their vehicle is properly trained, experienced, knowledgeable, and competent.

This White Paper is for informational purposes only. AR&D MAKES NO WARRANTIES, EXPRESS OR

IMPLIED, IN THIS WHITE PAPER. AR&D is not responsible for errors in typography.

© 2012 Automotive Research and Design, LLC. All rights reserved.

Reproduction in any method whatsoever without the express written permission of Automotive Research

and Design, LLC is strictly forbidden. For more information, contact:

Automotive Research and Design, LLC

2010 E. Lindberg Road

Port Angeles, WA 98362

Ph: 586.718.9469 Fax: 360.504.2790

www.go2hev.com

Information in this document is subject to change without notice.

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