Real Hybrid Vehicle with Educational Cutaway
The platform uses a 2026 BYD Qin MAX DM-i 230 km plug-in hybrid vehicle, modified for educational purposes. The vehicle body is partially cut away, particularly on the right-hand side, including sections of the front bumper, hood, roof, trunk lid, and rear bumper. The cutaway sections are color-coded and protected against corrosion, providing clear visibility of the body structure, internal components, and electrical modules.
Components remain in their original positions, enabling trainees to identify equipment, study component locations, and understand the structural relationships between the various vehicle systems.
Hybrid Propulsion System Architecture
The vehicle retains its original hybrid propulsion system, integrating a thermal engine and a high-voltage electric propulsion system. This configuration enables the study of connections, control relationships, and operating principles between the main powertrain components.
High-voltage components, including the integrated power assembly, electric motor, transmission, battery management system, and electronic control units, remain installed in their original positions. Trainees can therefore understand the organization of the propulsion system, the operating principles of its components, and the essential safety precautions associated with high-voltage system maintenance.
Mechanical Structure and Onboard Equipment
The platform retains the essential structural characteristics of the original vehicle, including the chassis, track width, and front suspension parameters. The main equipment remains installed in its original positions, including:
- High-voltage integrated power system comprising DC-DC converter, PDU, OBC, VCU, and motor controller.
- Electric traction motor and transmission assembly.
- Traction battery and battery management system (BMS).
- Body control system and low-voltage electrical equipment.
- Air conditioning, door locking, and smart key systems.
- Integrated power braking system (IPB) and electric power steering (EPS).
- Gear selector and instrument cluster.
- Radiator, cooling circuit, and brake master cylinder.
- Charging port and other original electrical equipment.
The front wheels remain connected to the transmission through the original drive shafts and can be driven when a driving gear is selected.
Connection, Measurement, and Diagnostic Platform
The vehicle is equipped with a dedicated educational connection, detection, and fault simulation platform, enabling analysis of vehicle data and signals without damaging the original wiring harness.
The platform supports the acquisition, analysis, and diagnosis of dynamic and static parameters from the following control units and systems:
- Thermal engine control unit.
- Integrated electric propulsion system control unit.
- Electric motor controller.
- DC-DC converter.
- Vehicle control unit (VCU).
- On-board charger (OBC).
- Power distribution unit (PDU).
- Battery management system (BMS).
- Body control unit and associated systems, including door locking, smart key, lighting, air conditioning, and electronic gateway.
Fault Simulation Systems
The platform integrates mechanical and electrical fault simulation systems, enabling instructors to create various diagnostic scenarios for practical training exercises.
The mechanical fault simulation system uses gold-plated U-shaped connectors and provides at least 300 fault simulation points. The platform also incorporates a wireless fault simulation system operated through FXB software installed on a tablet, providing at least 30 additional fault simulation points.
The mechanical fault simulation area is located at the front left of the training panel. It features an upward-opening access compartment, facilitating access to the controls and fault simulation points. Dedicated 2 mm jumper wires are supplied for short-circuit fault simulation.
Mobile and Ergonomic Structure
The mobile support frame is manufactured from alloy steel and is designed to withstand oil exposure, corrosion, and intensive use in educational environments. It is equipped with four casters, including two swivel casters and two fixed casters. The swivel casters feature locking mechanisms to secure the platform during practical training. Their outer diameter is at least 4 inches, ensuring convenient mobility and quiet operation.
Vehicle Technical Specifications
Reference Vehicle
2026 BYD Qin MAX DM-i 230 km Leading Edition – Front-wheel-drive plug-in hybrid sedan.
Traction Battery
- Technology: Second-generation fast-charging lithium iron phosphate (LFP) Blade battery.
- Battery capacity: ≥ 25.25 kWh.
Thermal Engine
- Engine type: Atkinson-cycle engine.
- Maximum power: ≥ 70 kW at 6,000 rpm.
- Maximum torque: ≥ 126 N·m at 4,500 rpm.
- Power output: ≥ 101 hp.
- Displacement: ≥ 1.5 L.
- Intake: Naturally aspirated.
- Valve train: DOHC (double overhead camshaft).
Electric Propulsion System
- Front motor type: Permanent magnet synchronous motor.
- Peak power: ≥ 175 kW.
- Peak torque: ≥ 270 N·m.
- Cooling: Liquid-cooled.
- Electric transmission: Single-speed transmission.
General Vehicle Specifications
- Length: Approximately 4'866 mm.
- Width: Approximately 1'880 mm.
- Height: Approximately 1'495 mm.
- Fast charging time: Approximately 20 minutes.
- Number of doors: 4.
- Seating capacity: 5.
- Body type: Three-box sedan.
- Steering: Electric power steering.
- Front brakes: Ventilated disc brakes.
- Rear brakes: Disc brakes.
- Parking brake: Electronic parking brake.
- Drive configuration: Front-wheel drive.
- Front suspension: MacPherson independent suspension.
- Rear suspension: Multi-link independent suspension.
Standard Configuration
- 1 modified BYD Qin MAX DM-i plug-in hybrid vehicle with educational cutaway.
- 1 complete set of dedicated connection harnesses.
- 1 vehicle fault simulation and diagnostic training panel, minimum dimensions: 1'500 × 650 × 1'740 mm.
- 1 mechanical fault simulation system.
- 1 tablet with wireless fault simulation system.
Practical Training Exercises
- Identification of the overall architecture and layout of hybrid vehicle systems.
- Study of hybrid vehicle chassis structure, body construction, and body panels.
- Identification and study of the electric propulsion system and its components.
- Study, identification, and diagnosis of the hybrid air conditioning system.
- Study, identification, and diagnosis of the thermal engine system.
- Study, identification, and diagnosis of the high-voltage system.
- Study, identification, and diagnosis of the steering system.
- Study, identification, and diagnosis of onboard electrical and electronic systems.
- Study and analysis of the battery management system (BMS).
- Study of hybrid vehicle maintenance procedures and essential inspection points.
- Diagnostic and troubleshooting exercises using simulated fault scenarios.
