Training and Further Education in Automotive Engineering Know-how – Skills – Passion Training in the Automotive Diagnostics Workshop Lab 7th Edition Contents More Than a Laboratory Complete Solution – Diagnostics Workshop Lab for Automotive Engineering .................................................................................. 6 Teaching Skills and Know-how ................................................................................................................................................. 10 Multimedia Learning Environment LabSoft as a System-based Training/Administration Software ......................................................................................................... 12 Classroom Manager 4.0 ............................................................................................................................................................. 14 Contents Electricity/Electronics ............................................................................................................................................................ 16-25 DC and AC Technology, Electronics and Digital Technology, Pulse-width Modulated Signals, Fundamentals of Electronics, Plug-in System General Electrical Systems in Vehicles ................................................................................................................................. 26-41 Battery Diagnostic Training System, Three-phase Alternator/Generator, Three-phase Generator with Hybrid Controller, Three-phase Generator with Multifunction Controller, Main Lighting, Auxiliary Lighting, Trailer Lighting, Static Cornering Light, CAN bus Extension, Onboard Power Supply Expansion, Xenon, LED and daylight driving lights, Dashboard Training Model Incorporating CAN and LIN Buses Networked Systems .............................................................................................................................................................. 42-53 CAN Bus, CAN Lighting Technology, Programming and Diagnostics, CAN Comfort Technology Programming and Diagnostics, LIN Bus, Fibre Optic Waveguides, FlexRay, Dashboard Training Model Incorporating CAN and LIN Buses, Auto Shop Communications with RFID, Comfort Systems and Keyless Entry Safety and Comfort .............................................................................................................................................................. 54-63 Electromechanical Power Steering, Airbag, Belt Tensioner and Crash Response, ABS/ASR/ESP, Electromechanical Parking Brake, Alarm Systems and Immobilizers, Wheel speed sensor technology Petrol Engines ....................................................................................................................................................................... 64-75 Sensors in the Motor Vehicle, Ignition Systems, Onboard Diagnosis II, CarTrain Motronic 2.8, CarTrain Direct Fuel Injection, Exploded Model, Functional Engine, Cut-away Models Diesel Engines ....................................................................................................................................................................... 76-87 Common Rail Diesel Injection System, CarTrain Common Rail, CarTrain Common Rail with Variable Geometry Turbocharger, Changing Timing Belts, High-speed Glos Heating Systems, Working Engines Alternative Drives ............................................................................................................................................................... 88-105 DC/AC Conversion, DC-DC step-up and step-down converters, Hybrid Drive in Motor Vehicles, Fuel Cells, Photovoltaics, Pilot line, High-voltage battery disconnection unit, Safe handling of high-voltage systems, Training system for high-voltage and air-conditioning systems, CarTrain Electromobility, Charging Station for Electric Vehicles Diagnostics and Instrumentation .................................................................................................................................... 106-119 Student / Teacher Measuring Stations, SUN PDL 3000, SUN PDL 5500, Mega Macs 66, Mega Macs PC, Multiscan, CAN / LIN Monitor, High-voltage Instrumentation, Common Rail Diagnostics Set – High-pressure Injector Testing Using Circulation Method, Common Rail Diagnostics Set – Testing of Low-pressure Circuits, Vehicle Diagnostics Case The mastery of modern methods and techniques, including ful- In addition to our classical experiments and training systems our filling internationally required standards not to mention quality new generation of PC-based systems provide the answer to in- requirements, poses a challenge to our current and future crafts- creasing global demand for “blended learning” solutions in the men, technicians, engineers and scientists in terms of their tech- area of automotive technology training and instruction. nological skills and competence. Lucas-Nülle has devoted itself to taking up this challenge. For To spark interest and enthusiasm, to provide insight into com- that reason, we develop and manufacture training equipment plex relationships and permit practical applications, these are the and systems targeting key technologies within the context and training and educational objectives that are paramount for us in background of traditionally premium German vocational training designing and developing Lucas-Nülle training systems. and engineering education. These technical systems are supplement- A high percentage of hands-on, prac- ed by high-end literature and experiment tical training qualifications provide the guarantee to industry that trainees will Guarantee for manuals, which ensure not only that the have the practical skills they need. necessary technical know-how is under- successful training stood but that the experiments are also These are the prerequisites for ma- stery of sophisticated technologies. carried out safely and successfully. After all, such technologies require Thanks in part to its technical competence and social commit- theoretical knowledge and practical abilities. Experimentation ment, a willingness to cooperate and work on a personal level, with our educationally optimised systems combines theoretical information with hands-on know-how, and teases practical ex- success is as good as guaranteed for our company. The company pertise out of theoretical knowledge thus guaranteeing bona fide fosters a living, breathing team-spirit which is anchored in the occupational skills. lean organisational structure of the firm. 4 Introduction Production features the highest standards Lucas-Nülle training systems are manufactured in the company’s own factory at its headquarters in Kerpen, Germany. The com- plexity and depth of our product range can only be managed by a highly-motivated team of competent, self-reliant and ex- perienced professionals and engineers. Siegfried Schulz Product Manager Automotive Technology Efficient manufacturing processes Efficient manufacturing management is controlled using a modern PPS system. This is how we ensure that the delivery schedule agreed upon with the client is fulfilled. Quality guaranteed – setting standards In LN’s company philosophy, quality has a very special significance and plays a central role in the company’s strategy. Besides con- Bernd Bongartz tinuously guaranteeing that our agreed quality targets are met Product Manager in accordance with the requirements set forth by ISO 9001, a Automotive Technology l arge number of additional certificates gives testimony to our high quality standards. The work flows, process standards and tests described therein, and guaranteed to our clients, are proof that they can rely on the promised quality and reliability of our products and services. Comprehensive function tests Every piece of equipment undergoes operational tests of func- tionality prior to leaving our premises. During testing we apply the Christian Klingler highest standards and by far exceed the boundaries of prescribed Product Manager norms. Automotive Technology “As in the past, automotive engineering continues to be a driver of innovation. With our systems, professionals as well as people involved in actual training can get help in finding ways to get young people closer to these complex topics of technology and engineering.” 5 Lucid presentations of complex concepts with modern training and educational media Complete solutions for modern engine management, brake, climate control and airbag systems Training Panel Systems Individual experiment set-ups for competent system understanding CarTrain Training on real components – interactive course software is used to facilitate overall system comprehension More than a Laboratory Student Measurement Stations Multisignal-capable environment provided for each student as a guarantee for optimum learning success Training Vehicle Diagnostics performed directly on the motor vehicle – testing and maintaining networked systems UniTrain Deepening the student’s understanding using the hardware and software provided with the experiments Interactive 360° Laboratory Experience the Lucas-Nülle automotive laboratory in 360° view! Teaching Skills and Know-how Using LN Training Systems To enhance the individual learning curves of every trainee, Lucas-Nülle offers a variety of training systems. This is how the individual topics of vocational and advanced training in automotive technology can be opti- mally and efficiently taught. At the focal point of our system is the link between experiment hardware and training software.