The High Voltage Battery Training System is a compact, interactive training unit designed for teaching high-voltage battery management and diagnostics, using components from the Toyota Prius II OEM model. It enables students to connect and disconnect service plugs, measure battery voltage, and understand power transfer from the battery to the inverter. Equipped with a detailed wiring diagram and the ability to measure each battery cell separately, this trainer replicates real-world electric car conditions. The system includes LED indicators for monitoring relay and inverter status and offers a slowed start-up mode to facilitate step-by-step analysis of the activation sequence. All high-voltage components are safely enclosed under plexiglass for enhanced safety during hands-on training.
Features
OEM-based Toyota Prius II high voltage battery system with all components.
Service plug management with interlock connection and disconnection procedures.
Real and safe direct current 201.6V voltage at battery contacts.
Safe contacts for convenient battery voltage measurement on the left side and for inverter voltage measurement on the right side.
High voltage battery cells measurements within safe measuring points.
Power transfer analysis from battery to inverter.
Sequential activation of high-voltage relays, including soft-start relay.
Demonstration of the correct method of removing the service key according to manufacturer recommendations.
Checking the service key fuse and interlock functions.
Inverter cover lifting interlock for enhanced safety and functionality.
High voltage battery (divided into two parts by removing the service key) voltage measurement of 1/2 and 2/2 sections.
Measurement of high-voltage relay control signals and polarity.
All system components are clearly visible: service plug with interlock, high-voltage relays with soft-start relay, high-voltage cells, and other necessary components.
4 real high-voltage battery cells with individual measurement points.
Detailed wiring diagram accurately reflecting the OEM electric vehicle configuration, including markings for high-voltage battery rows using electrical symbols.
All measurements replicate real-world scenarios.
System startup sequence slow-motion feature (10x slower than normal) for detailed learning.
LED indicators on relays and inverter for system status visualization.
Safely enclosed under plexiglass, ensuring safety while maintaining visibility.
Lightweight, portable design, making it easy to transport and integrate into classroom settings.
Educational training tool powered by 220V (110V US), a 12V battery, or a DC 12V power source.
Value for Students
Hands-on experience to understand and manage high-voltage battery operations, including the service plug and interlock connection procedures, system launching sequence, and safety protocols.
Analyze and measure high-voltage battery voltage with or without the service plug connected.
Measure and understand voltage distribution in battery sections (1/2 and 2/2) as well as individual cells.
Examine the steps to transfer power from the battery to the inverter, including service plug connection, ignition, and inverter switch activation.
Learn the turning-on sequence of high-voltage relays and soft-start relay, including slowed-down analysis at 10x slower speed.
Observe the operation of the inverter cover lifting interlock.
Measure high-voltage relay control signals and polarity.
Understand electrical mass disable procedures, including system shutdown, power source disconnection, and service plug removal.
Value for Instructors
OEM-based high voltage system from a Toyota Prius II for realistic and effective training in electric vehicle battery management.
Designed for classroom and workshop integration, making complex concepts approachable with its compact and mobile structure.
Engaging and interactive trainer for easy understanding of high-voltage battery system operation and management.
LED indicators on relays and inverter enable clear visual aid, assisting in explaining complex processes to students.
Demonstrate all steps involved in transferring power from batteries to the inverter, offering opportunities for practical observation and guided practice.
Provides controlled scenarios with slowed-down starting sequences for instructional purposes.
Plexiglass protective panels ensure safe handling during demonstrations while allowing visibility for learning purposes.
Lightweight and portable design enables flexible lesson planning and transport.
Specifications
Dimensions: 560 x 715 x 60 mm (22 in x 28.14 in x 2.36 in)
Power supply: 230 V/110 V (US version), 12V battery, DC 12V power source
