Elements and Performance Criteria

The objective of the failure analysis and evaluation process may be to determine fault rectification measures, to effect variation in system characteristics and parameters or to enhance system performance
Electric and hybrid vehicle systems are to include petrol/electric hybrid vehicles, series and parallel drive vehicles, industrial floor cleaners, forklifts and golf buggies
Coverage is to include battery technology, motor drive systems, motor controllers, air conditioning systems, electronic protection systems and multi-class bus systems
Electric and hybrid vehicle systems electrical and electronic failures covered by this unit are to include direct faults in input sensors, output actuators, including inverters, high-voltage AC and DC motors, high-voltage generators, wiring harness, computer systems, calibration/adjustment specifications, component specifications, component assembly, component damage and system modifications
Electric and hybrid vehicle systems failures covered by this unit are to include indirect faults caused by the influence of external systems (electrical and electronic) which may or may not be faulty in their primary operations

OH&S requirements include legislation, vehicle industry regulations, safety management systems, hazardous substances and dangerous goods code and safe operating procedures
Work is carried out in accordance with legislative obligations, Australian Design Rules, environmental legislation, health regulations, manual handling procedures and organisation insurance requirements
Work requires individuals to demonstrate research, analytical, judgement and problem-solving skills in the diagnosis of faults

Evaluative criteria, sometimes referred to as success factors, detail the criteria against which the achievement of the objectives of the analysis are to be judged. They are to include statistically based criteria and may include other measures

Equipment isolation procedures are to be to industry and enterprise standards and are to include the disarming of supplementary restraint systems (SRS) by manufacturer/ component supplier specifications

Testing equipment is to include multimeters, lab oscilloscopes, data scanners, test lights, battery testers and test LEDs, and may include manufacturer/component supplier testing equipment

Tests to be conducted are to include batteries, drive motor, generator, inverter, chargers, motor controller, emissions, wiring and connector integrity, operation and specification of input and output devices, controlling electronic components and computers, data interpretation and readings related to direct, indirect and intermittent causes

Personal protective equipment is to include that prescribed under legislation, regulations and enterprise policies and practices

Workplace procedures relating to the use of tooling and equipment
Workplace procedures relating to reporting and communication
Manufacturer/component supplier specifications and application procedures for testing equipment and materials
Manufacturer/component supplier specifications, schematics and operational procedures related to electric and hybrid vehicle systems
Australian Design Rules
Vehicle industry regulations
Vehicle industry publications related to electric and hybrid vehicle system technology and technology changes

Critical aspects of evidence
Interpret work order and locate and apply information
Apply safety requirements, including the isolation of equipment and use of personal protective equipment

Follow work instructions, operating procedures and inspection processes to:

minimise the risk of injury to self and others
prevent damage and wastage of goods, equipment and products
maintain required production output and product quality
Complete failure analyses on a minimum of three different hybrid vehicle systems with real or simulated multi-system and intermittent faults and identify, evaluate, select and document the most appropriate rectification measure
Analyse and validate or recommend variations to a minimum of two available repair/modification procedures for different hybrid vehicle systems
Work effectively with others
Modify activities to cater for variations in workplace context and environment

Underpinning knowledge
Mechanical theory covering the concepts and principles of mechanical, hydraulic and pneumatic systems
General knowledge of the concepts, principles and processes involved in planning and implementing systems analysis and evaluation
General knowledge of the types, functions and operations of systems
General knowledge of the theory of diagnosis, including concept, design and planning
General knowledge of the concepts, types, functions, operations and limitations of electric and hybrid vehicle systems
Detailed knowledge of electrical theory and operation covering automotive digital computers, networked vehicles, voltage, current, resistance, power, capacitance, electrostatics, magnetics, inductance, high-voltage safety requirements, high-voltage battery technology, high-voltage inverter, high-voltage permanent magnet DC motors, high-voltage wire wound field magnet motors, high-voltage single and three phase AC motors, high-voltage permanent magnet three-phase AC motors, DC stepper motors, series hybrid drive, parallel hybrid drive, discrete electronic components, logic families and radio frequency
Detailed knowledge of the types, functions, operations and limitations of diagnostic testing equipment
General knowledge of the methods and processes for documenting and reporting diagnostic findings and recommendations
General knowledge of personal computer operation

Specific key competencies, underpinning and employability skills required to achieve the performance criteria
These include a number of processes that are learned throughout work and life, which are required in most jobs. Some of these are covered by the national key competencies, although others may be added. The details below highlight how these competencies are to be applied in the attainment of this unit.

Application of the key competencies in this unit are to satisfy the nominated level in which:

Level 1 - relates to working effectively within set conditions and processes;
Level 2 - relates to management or facilitation of conditions or processes; and
Level 3 - relates to design, development and evaluation of conditions or process.
How will the candidate apply the following key competency in this unit? The candidate will need to:

Collect, analyse and organise information
Research, organise and understand technical information related to contemporary hybrid vehicle systems, monitoring and testing processes, diagnostic methods and options and safety procedures
(Level 3)

Communicate ideas and information
Communicate ideas and information to enable confirmation of work requirements and specifications, coordination of work with site supervisor, other workers and customers, reporting of work outcomes and completion of regulatory, commercial and vehicle information systems inputs
(Level 2)

Plan and organise activities
Plan and organise activities, including the planning of analytical processes, establishment of evaluative (success) criteria, preparation and layout of the worksite and the obtaining of testing equipment and materials to avoid backtracking, workflow interruptions or wastage
(Level 2)

Work with others and in a team
Work with others and in a team by recognising dependencies and using cooperative approaches to optimise workflow and productivity
(Level 2)

Use mathematical ideas and techniques
Use mathematical ideas and techniques to complete measurements, calculate analytical requirements, calibrate and establish testing equipment and present analytical results
(Level 2)

Solve problems
Establish analytical processes, including diagnostic processes, which anticipate and allow for risks, cater for both direct and indirect evidence, avoid or minimise reworking and avoid wastage
(Level 3)

Use technology
Use the workplace technology related to systems analysis and diagnosis, information research and management systems, testing equipment, maintenance equipment, tooling, calculators and measuring devices
(Level 2)

Context of assessment
Assessment may occur on the job or in a workplace simulated facility with process equipment, materials, work instructions and deadlines

Method of assessment
Assessment of this unit of competence is most likely to be project related under real or simulated conditions and require portfolios or other forms of indirect evidence of process. Direct evidence may include certification of compliance of the final outcome/product or authorisation for use by a competent authority
Assessment must confirm the inference that competence is able not only to be satisfied under the particular circumstances, but is able to be transferred to other circumstances

Specific resource requirements for this unit
Access to a requirement and objective(s) for analysis and evaluation, operational hybrid vehicle systems with real or simulated faults, monitoring processes and testing equipment appropriate to the objective(s), research facilities and technical information and a work environment