Electric Vehicle Design and Development Boot Camp – 120 hrs.
Level-1: Duration – 60 Hrs
Level-2: Duration – 60 Hrs
Modules
- 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
Program Objectives
- Build strong foundational knowledge in Python, focusing on data manipulation, control structures, object-oriented programming, and file handling.
- Enable learners to develop robust problem-solving skills by applying computational techniques using Python programming.
- Prepare learners for employability in software engineering roles by mastering essential tools and frameworks
Program Outcomes
- Integrated Problem-Solving Approach
- Hands-on experience solving challenges from platforms like CodeChef, HackerRank, and GeeksforGeeks.
- Practical exposure to real-time issues and debugging strategies.
- Industry-Ready Skills
- Preparedness for assessments via platforms like Mettl.
Project Stream:
- Mini projects: Student Management System,
- Competitive coding problems (arrays, strings, patterns)
Experiential Project Based Learning
Upon completion, students will have:
- 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 EV sector
Tools / Platform:
- MATLAB/Simulink, Sim’s cape, LT Spice,
- ESP32, Arduino IDE / ESP-IDF, Free RTOS
- C/C++, Python
- CAN, LIN, Ethernet Protocols
- IoT Platforms, Cloud Dashboardsv
| Electric Vehicle Design and Development Boot Camp – 120 Hours | |||
|---|---|---|---|
| Module | Topic | Description | Hours |
| Introduction to EV Architecture and Safety Measures | |||
| EV Architecture Fundamentals | Mechanical vs EV systems | ICE vs EV powertrain, E/E architecture, components overview (motor, inverter, charger) | 4 |
| Simulation Activity | MATLAB/Simulink | EV powertrain modelling, vehicle dynamics, power flow analysis | 2 |
| High Voltage Safety Protocols | HV Awareness | Arc flash protection, HV boundaries, safety procedures, virtual training | 2 |
| Virtual Safety Training | ESP32 Integration | Safety simulation, PPE identification, safety scenario training | 2 |
| ESP32 Introduction and EV System Integration | |||
| Theory | ESP32 & FreeRTOS | Architecture, setup, and control for EV systems | 1 |
| Hands-on Programming | ESP32 Programming | Sensor interfacing, voltage/current monitoring, data logging system | 3 |
| Assignments: Design EV architecture, ESP32 code for battery monitoring, Virtual EV Dashboard | |||
| Low Voltage System Architecture | |||
| LV Circuit Fundamentals | 12V System | Auxiliary systems, relays, contactors, fuses, MATLAB/Simulink + LTSpice simulation | 6 |
| Sensors and Actuators | EV Sensors | Sensor interfacing, ADC configuration, PWM actuator control via ESP32 | 6 |
| Communication Protocols | CAN / LIN / Ethernet | Bus architecture, ESP32 CAN programming, message frame design | 4 |
| Diagnostics & Troubleshooting | OBD-II, MATLAB | Fault detection, diagnostic algorithms, oscilloscope simulation | 4 |
| Assignments: 12V circuit simulation, CAN communication, diagnostic tool, EV Auxiliary Controller | |||
| Battery Technology | |||
| Battery Fundamentals | Cell Chemistry | Li-ion (NMC/LFP), pack configuration, MATLAB modeling, SOC/SOH estimation | 6 |
| Battery Management Systems | BMS Architecture | Balancing methods, ESP32 BMS development (voltage/current/temp) | 8 |
| Thermal Management | Cooling Strategies | Heat generation, air/liquid cooling, MATLAB simulation | 4 |
| Testing and Standards | ECE/AIS Standards | ECE R100, AIS 038, AIS 156, sustainability & validation | 2 |
| Assignments: Battery pack design, SOC estimation, thermal model, BMS Simulator | |||
| EV Charging Technology and Infrastructure | |||
| Charging Fundamentals | Charging Levels | L1/L2/L3 charging, connectors, CC/CV, MATLAB charger simulation | 6 |
| Charging Control Systems | Control Logic | Pilot circuits, ISO 15118, ESP32 PWM charging control | 6 |
| Power Electronics | Converter Topologies | AC-DC converters, PFC, isolation & safety, PLECS/Simulink modeling | 4 |
| Smart Charging | V2G Integration | Grid load management, renewable integration, ESP32-based controller | 4 |
| Assignments: AC-DC charger design, protocol state machine, Smart Charging Station | |||
| EV Drivetrain and Power Converters | |||
| Motor Fundamentals | Motor Types | PMDC, BLDC, PMSM, Induction motors, Simulink motor modeling | 6 |
| Motor Control Systems | FOC & PWM | Vector control, sensorless methods, ESP32 3-phase PWM & torque control | 8 |
| Powertrain Integration | Efficiency | Performance optimization, drivetrain modeling, regen simulation | 4 |
| Assignments: FOC design, sensorless control, drivetrain modeling, Motor Control Unit | |||
| HV Safety, Protections, and Compliance | |||
| HV Safety Systems | Safety Protocols | HVIL design, de-energization, ESP32 safety monitoring | 4 |
| Protection Circuits | Pre-Charge / Discharge | Pre-charge, discharge circuits, insulation monitoring, safety checks | 2 |
| Advanced Safety Systems | Galvanic Isolation | Fault detection, emergency protocols, ESP32 monitoring | 4 |
| Assignments: HVIL system, pre-charge algorithm, HV Safety Controller | |||
| Thermal Management System and Future Trends | |||
| Thermal Design | Cooling & Simulation | Battery/motor/inverter thermal modeling, ESP32 thermal controller | 4 |
| IoT and Connectivity | EV IoT | Cloud dashboards, predictive maintenance, OTA updates | 4 |
| Assignments: Thermal system design, IoT-enabled monitoring, Smart EV Management System | |||
| Electric Vehicle Standards and Testing | |||
| Standards & Regulations | ISO/IEC/SAE | Regional standards, compliance, certification processes | 4 |
| EMI/EMC Considerations | Design Guidelines | EMI mitigation, PCB layout, shielding techniques | 2 |
| ESP32 Testing Framework | Testing Automation | Unit testing, continuous integration for EV controllers | 1 |
| Capstone Project: Complete EV System Integration using MATLAB/Simulink and ESP32 controllers | |||
