Electric Vehicle Design and Development Boot Camp
Durations -15 days.
Program Structure
- Introduction to Electric Vehicle Architecture and Safety Measures
- Low Voltage System Architecture
- Battery Technology
- EV Charging Technology and Infrastructure
- EV Drivetrain and Power Converters
- HV Safety, Protections, and Compliance
- Thermal Management System and Future Trends
- Electric Vehicle Standards and Testing
Experiential Project Based Learning
- Virtual EV Dashboard (MATLAB + ESP32)
- EV Auxiliary Controller (ESP32 – Lights, Wipers, HVAC)
- Battery Management System Simulator (MATLAB + ESP32)
- Intelligent Charging Station & V2G Integration (ESP32)
- Motor Control Unit & Regenerative Braking (ESP32 + Simulink)
- HV Safety Controller (ESP32)
- Smart EV IoT Monitoring System (ESP32 + Cloud)
- Capstone Project: Complete EV System Integration (MATLAB/Simulink + ESP32)
Program Outcomes
- Comprehensive understanding of EV systems and components
- Hands-on experience with motor control and power electronics
- Practical skills in embedded system development for automotive applications
- Portfolio of projects demonstrating EV system design capabilities
- Industry-relevant skills for immediate employment in the EV sector
AI Tools / Platform:
- MATLAB/Simulink, Simscape, LTspice
- ESP32, Arduino IDE / ESP-IDF, FreeRTOS
- C/C++, Python
- CAN, LIN, Ethernet Protocols
- IoT Platforms, Cloud Dashboards
| Introduction to Electric Vehicle Architecture and Safety Measures | ||
|---|---|---|
| EV Architecture Fundamentals | ||
| Theory | ||
| Mechanical systems comparison: ICE vs EV powertrain | Electric/Electronic architecture of drivetrain systems | Component overview: Motor, battery, inverter, charging system |
| Simulation Activity | ||
| MATLAB/Simulink: Basic EV powertrain modelling | Creating simple vehicle dynamics model | Power flow analysis simulation |
| High Voltage Safety Protocols | ||
| Theory | ||
| HV hazard awareness levels (0-5) | Arc flash protection and HV boundaries | Warning labels and safety procedures |
| Virtual Safety Training | ||
| Interactive safety protocol simulation | HV PPE identification and usage scenarios | |
| ESP32 Introduction and EV System Integration | ||
|---|---|---|
| Theory | ||
| ESP32 architecture and capabilities for EV applications | Free RTOS basics for real-time EV control | |
| Hands-on Programming | ||
| ESP32 setup and development environment | Basic sensor interfacing (voltage, current, temperature) | Simple data logging system for EV parameters |
| Assignments: | ||
| Assignment 1: Design a basic EV architecture diagram using Simulink blocks | Assignment 2: Create ESP32 code for battery voltage monitoring with safety alerts | |
| Mini-Project: | ||
| Virtual EV Dashboard Development | ||
| Create a MATLAB GUI displaying real-time EV parameters | Interface with ESP32 for sensor data acquisition | Implement safety warnings for HV conditions |
| Low Voltage System Architecture | ||
|---|---|---|
| LV Circuit Fundamentals | ||
| Theory | ||
| 12V auxiliary systems in EVs | Battery-alternator-starter circuits | Component analysis: relays, contactors, fuses |
| Circuit Simulation | ||
| MATLAB/Simulink circuit modeling | LT Spice for detailed circuit analysis | Power distribution system simulation |
| Sensors and Actuators | ||
| Theory | ||
| EV-specific sensors: current, voltage, temperature, position | Actuator types and control mechanisms | |
| ESP32 Implementation | ||
| Multi-sensor interfacing with ESP32 | ADC configuration and calibration | PWM control for actuator driving |
| Free RTOS task management for sensor polling | ||
| Communication Protocols | ||
| Theory | ||
| CAN bus architecture and implementation | LIN protocol for low-speed devices | Ethernet in automotive applications |
| Practical Implementation | ||
| ESP32 CAN controller programming | Message frame design and parsing | Network topology simulation |
| Diagnostics and Troubleshooting | ||
| Theory | ||
| OBD-II protocols and diagnostic procedures | Fault detection and isolation techniques | |
| Simulation and Programming | ||
| Virtual oscilloscope using MATLAB | ESP32-based diagnostic tool development | Fault injection and detection algorithms |
| Assignments: | ||
| Assignment 1: Design and simulate a complete 12V power distribution system | Assignment 2: Implement CAN communication between two ESP32 modules | Assignment 3: Create a diagnostic system for LV circuit fault detection |
| Mini-Project: | ||
| EV Auxiliary System Controller: ESP32-based system managing lights, wipers, HVAC | Wireless Sensor Network: Multiple ESP32 nodes communicating vehicle status | |
| Battery Technology | ||
|---|---|---|
| Battery Fundamentals | ||
| Theory | ||
| Li-ion chemistry: NMC vs LFP comparison | Cell types: cylindrical, prismatic, pouch, blade | Cell selection criteria and pack configuration |
| Modeling and Simulation | ||
| MATLAB battery modeling using Simscape | Equivalent circuit models (RC, Thevenin) | State-of-Charge (SOC) and State-of-Health (SOH) estimation |
| Battery Management Systems | ||
| Theory | ||
| BMS architecture and functions | Cell balancing: active vs passive methods | Safety monitoring and protection |
| ESP32 BMS Development | ||
| multi-cell voltage monitoring system | Current measurement and integration for SOC | Temperature monitoring and thermal runaway detection |
| Cell balancing algorithm implementation | CAN communication for BMS data | |
| Thermal Management | ||
| Theory | ||
| Heat generation mechanisms in batteries | Cooling strategies: air, liquid, phase-change materials | Thermal interface materials and pack construction |
| Simulation | ||
| Thermal modeling in MATLAB/Simulink | Cooling system optimization | Temperature control algorithm design |
| Testing and Standards | ||
| Theory and Virtual Testing: | ||
| Testing standards: ECE R100, AIS 038, AIS 156 | Virtual validation procedures | Recycling and sustainability considerations |
| Assignments: | ||
| Assignment 1: Design optimal battery pack configuration for different EV types | Assignment 2: Implement Kalman filter for SOC estimation on ESP32 | Assignment 3: Create thermal model and control strategy for battery cooling |
