Vehicle Conversions for technical training
Production vehicles can be individually converted into practical training vehicles. Depending on the training objective, we integrate measurement access points, breakout systems, fault simulations and additional diagnostic options directly into the existing vehicle.
Gasoline, diesel, hybrid, plug-in hybrid and electric vehicles can be individually equipped according to the vehicle technology, available installation space and desired scope of training.
TRAINING
Different vehicles possible
The conversion is not limited to a specific manufacturer or vehicle model. Suitable production vehicles can be selected according to the desired training content.
Customized installation concepts
Breakout boxes, measurement connections, fault-simulation systems and additional diagnostic units can be integrated in different positions depending on the vehicle and available space.
From a single measurement point to a complete conversion
Options range from individual additional measurement points to fully equipped training vehicles with measurement technology, fault simulation and comprehensive documentation.
Different installation and configuration options
Every vehicle has different space constraints and technical conditions. The didactic conversion therefore does not follow a rigid template. Systems are integrated so that the vehicle remains practical to use while providing optimum access to the relevant electrical and electronic systems.
Directly on the system
Measurement connections can be brought out directly at sensors, actuators and control-unit connections.
Breakout systems
Larger measurement panels can be integrated, for example, in the interior, in the rear of the vehicle or at other suitable installation positions.
Fault simulation
Defined faults can be introduced deliberately using lockable switch boxes, bridging plugs or electronic systems.
Diagnostics & evaluation
Additional diagnostic, CAN-bus, measurement and evaluation units can be integrated directly into the training vehicle.
Training vehicles for gasoline, diesel, hybrid and electric powertrains
The didactic conversion can be adapted to different powertrain concepts. This allows the diagnostic, measurement and system knowledge relevant to each vehicle type to be taught specifically.
Gasoline
Engine management, mixture formation, ignition, sensors, actuators, exhaust aftertreatment and electronic engine control.
Diesel
Common-rail systems and modern exhaust aftertreatment with DPF, NOx and SCR systems as well as engine management.
Hybrid / Plug-in Hybrid
Combustion engine, high-voltage system, electric machine, power electronics, charging equipment and low-voltage electrical system.
Electric
High-voltage battery, electric machine, power electronics, charging equipment, thermal management and vehicle electrical system.
Diesel training vehicle with extensive exhaust and measurement technology
This completed vehicle shows one possible configuration of a modern diesel training vehicle. Engine management, exhaust aftertreatment, breakout measurement technology and electrical fault simulation can be examined together on the complete vehicle.
Examine modern diesel technology directly on a production vehicle
The reference setup is based on a modern common-rail diesel vehicle. Comparable training vehicles can also be implemented using other suitable vehicle models.
In addition to engine management, complex exhaust aftertreatment and electrical diagnostics can be examined together under realistic operating and fault conditions.
The number and type of measurement points, breakout systems and fault options are defined according to the vehicle and training objective.
Gasoline training vehicle with integrated breakout systems
This example shows another method of mechanical integration. Extensive measurement technology has been installed in a protected location inside the vehicle and is available for diagnostic and measurement tasks directly on the complete vehicle.
Integrate measurement technology securely into the vehicle
In this configuration, extensive breakout systems were integrated into the rear vehicle interior. This keeps the measurement panels readily accessible without filling the engine compartment with additional large control elements.
Open circuits as well as ground, positive and resistance faults can be introduced deliberately. The configuration and number of fault options can be defined for each project.
VW Golf GTE as an extensively prepared plug-in hybrid training vehicle
In a plug-in hybrid, the combustion engine, high-voltage system, electric machine, power electronics, charging function and conventional vehicle electronics come together in one vehicle. The VW Golf GTE therefore enables particularly comprehensive system, measurement and diagnostic training.
VW Golf GTE plug-in hybrid training vehicle
Like-new, fully functional VW Golf GTE with extensive didactic preparation for training and diagnostic purposes.
The vehicle includes its registration document, two keys, diagnostic-capable control units and vehicle-specific circuit diagrams on digital media.
In addition to the standard equipment, ACC and lane-keeping assist are fitted. This allows modern driver-assistance and communication systems to be included in training alongside the drivetrain and high-voltage technology.
The combination of high-voltage measurement technology, an engine-management breakout system, extensive fault simulation and CAN-bus evaluation enables diagnostic exercises across multiple interconnected vehicle systems.
Combine measurement, diagnostic and fault systems individually
Not every training vehicle requires the same level of conversion. The individual systems can be combined on a project-specific basis, making both compact conversions and very extensively equipped training vehicles possible.
Measure directly at control-unit pins
Breakout boxes enable voltage, current and resistance measurements directly in the real vehicle system.
Measurement sockets on sensors and actuators
Externally accessible 4 mm measurement sockets provide permanently available measurement points at selected sensors and actuators.
Introduce electrical faults reproducibly
Open-circuit, ground, positive and resistance faults can be introduced deliberately for defined diagnostic tasks.
Control faults via the web
Electronic fault-simulation systems can be controlled via PC, tablet or smartphone and used for flexible training and examination scenarios.
Prepare different hybrid concepts for training
Other hybrid vehicles can also be equipped with measurement, diagnostic and fault systems according to their technical design.
Examine combustion and high-voltage systems together
Depending on the hybrid concept, the combustion engine, electric machine, high-voltage components, power electronics, energy storage and low-voltage electrical system can all be included in training.
The scope and position of additional measurement and diagnostic systems are individually adapted to the respective vehicle.
Didactic preparation of modern electric vehicles
The same basic concept can be applied to battery-electric vehicles. Here, the focus shifts from engine management and combustion technology to the high-voltage battery, electric machine, power electronics, charging equipment and thermal management.
Depending on the vehicle and training objective, suitable low-voltage measurement points, diagnostic access, breakout systems and fault simulations can be integrated. Interactions between the high-voltage system, 12-volt electrical system, control-unit communication and charging electronics can also form part of the customized training setup.
Customized training vehicles instead of rigid standard solutions
Vehicle, powertrain technology and didactic equipment can be combined according to the respective training objectives. The setups shown are examples of different technical and mechanical solutions.
Your vehicle – individually prepared for training
Vehicle manufacturer, model, powertrain concept, installation positions and scope of measurement technology can all be individually adapted to the respective requirements.
From a single measurement access point to a fully equipped training vehicle, BBH Technische Anlagen GmbH develops a technical solution tailored to the vehicle, training objective and desired diagnostic scope.