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
Program Outcomes
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
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)
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 Dashboards
| Introduction to Electric Vehicle Architecture and Safety Measures (10 Hours) | ||
|---|---|---|
| EV Architecture Fundamentals (4 Hours) | ||
| Theory (2 Hours): | ||
| Mechanical systems comparison: ICE vs EV powertrain | Electric/Electronic architecture of drivetrain systems | Component overview: Motor, battery, inverter, charging system |
| Simulation Activity (2 Hours): | ||
| MATLAB/Simulink: Basic EV powertrain modelling | Creating simple vehicle dynamics model | Power flow analysis simulation |
| High Voltage Safety Protocols (2 Hours) | ||
| 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 (4 Hours) | ||
| Theory (1 Hour) | ||
| ESP32 architecture and capabilities for EV applications | Free RTOS basics for real-time EV control | |
| Hands-on Programming (3 Hours) | ||
| 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 (6 Hours) | ||
| Theory (3 Hours) | ||
| 12V auxiliary systems in EVs | Battery-alternator-starter circuits | Component analysis: relays, contactors, fuses |
| Circuit Simulation (3 Hours): | ||
| MATLAB/Simulink circuit modeling | LT Spice for detailed circuit analysis | Power distribution system simulation |
| Sensors and Actuators (6 Hours) | ||
| Theory (2 Hours) | ||
| EV-specific sensors: current, voltage, temperature, position | Actuator types and control mechanisms | |
| ESP32 Implementation (4 Hours): | ||
| Multi-sensor interfacing with ESP32 | ADC configuration and calibration | PWM control for actuator driving |
| Free RTOS task management for sensor polling | ||
| Communication Protocols (4 Hours) | ||
| Theory (2 Hours) | ||
| CAN bus architecture and implementation | LIN protocol for low-speed devices | Ethernet in automotive applications |
| Practical Implementation (2 Hours) | ||
| ESP32 CAN controller programming | Message frame design and parsing | Network topology simulation |
| Diagnostics and Troubleshooting (4 Hours) | ||
| Theory (1 Hours) | ||
|---|---|---|
| OBD-II protocols and diagnostic procedures | Fault detection and isolation techniques | |
| Simulation and Programming (3 Hours): | ||
| 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 – 20 Hours | ||
|---|---|---|
| Battery Fundamentals (6 Hours) | ||
| Theory (3 Hours): | ||
| Li-ion chemistry: NMC vs LFP comparison | Cell types: cylindrical, prismatic, pouch, blade | Cell selection criteria and pack configuration |
| Modeling and Simulation (3 Hours): | ||
| MATLAB battery modeling using Simscape | Equivalent circuit models (RC, Thevenin) | State-of-Charge (SOC) and State-of-Health (SOH) estimation |
| Battery Management Systems (8 Hours) | ||
| Theory (3 Hours): | ||
| BMS architecture and functions | Cell balancing: active vs passive methods | Safety monitoring and protection |
| ESP32 BMS Development (5 Hours): | ||
| 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 (4 Hours) | ||
| Theory (2 Hours): | ||
| Heat generation mechanisms in batteries | Cooling strategies: air, liquid, phase-change materials | Thermal interface materials and pack construction |
| Simulation (2 Hours): | ||
| Thermal modeling in MATLAB/Simulink | Cooling system optimization | Temperature control algorithm design |
| Testing and Standards (2 Hours) | ||
| 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 |
| Mini-Project: | ||
| Complete BMS Simulator: MATLAB/Simulink model with ESP32 hardware interface | Battery Pack Analyzer: Real-time monitoring and analysis system | Thermal Management Controller: ESP32-based cooling system with predictive control |
| EV Charging Technology and Infrastructure– 20 Hours | ||
| Charging Fundamentals (6 Hours) | ||
| Theory (3 Hours): | ||
| Charging levels: Level 1, 2, 3 (DC fast charging) | Charging connectors and standards | CC/CV charging methods and variations |
| Simulation (3 Hours): | ||
| MATLAB/Simulink charger modelling | Power electronics converter design | Charging characteristic analysis |
| Charging Control Systems (6 Hours) | ||
| Theory (2 Hours): | ||
| Control pilot and proximity pilot circuits | On-board charger architecture | Communication protocols (ISO 15118) |
| ESP32 Implementation (4 Hours): | ||
| PWM-based charging control | Safety interlocks and monitoring | User interface for charging status |
| Wireless charging monitoring system | ||
| Power Electronics for Charging (4 Hours) | ||
|---|---|---|
| Theory (2 Hours): | ||
| AC-DC converter topologies | Power factor correction | Isolation and safety considerations |
| Simulation (2 Hours): | ||
| PLECS/Simulink power converter modelling | Control loop design and stability analysis | Efficiency optimization |
| Smart Charging and Grid Integration (4 Hours) | ||
| Theory (2 Hours): | ||
| V2G technology and bidirectional charging | Grid stability and load management | Renewable energy integration |
| Project Development (2 Hours): | ||
| Smart charging algorithm implementation | Load balancing and demand response | ESP32-based smart charging station controller |
| Assignments: | ||
| Assignment 1: Design and simulate complete AC-DC charging system | Assignment 2: Implement charging protocol state machine on ESP32 | Assignment 3: Create smart charging algorithm for multiple vehicles |
| Mini-Project: | ||
|---|---|---|
| Intelligent Charging Station: ESP32-based system with load management | Wireless Charging Controller: Inductive charging system with alignment detection | V2G Integration System: Bidirectional power flow controller |
| EV Drivetrain and Power Converters – 20 Hours | ||
| Electric Motor Fundamentals (6 Hours) | ||
| Theory (3 Hours): | ||
| Electromagnetic principles and permanent magnets | Motor types: PMDC, BLDC, PMSM, Induction | Electronic commutation vs mechanical commutation |
| Simulation (3 Hours): | ||
| MATLAB/Simulink motor modelling | Torque-speed characteristics analysis | Motor parameter identification |
| Motor Control Systems (8 Hours) | ||
| Theory (3 Hours): | ||
| Vector control (Field Oriented Control) | Space vector PWM techniques | Sensor and sensor less control methods |
| ESP32 Implementation (5 Hours): | ||
| 3-phase PWM generation using ESP32 | Encoder interfacing and position feedback | Speed and torque control algorithms |
| FOC implementation with FreeRTOS | Motor protection and fault detection | |
| Powertrain Integration (4 Hours) | ||
|---|---|---|
| Theory (2 Hours): | ||
| Powertrain sizing methodology | Efficiency mapping and loss analysis | Thermal management for motors and inverters |
| System Design (2 Hours): | ||
| Complete drivetrain modelling in Simulink | Performance optimization | Range and efficiency calculations |
| Regenerative Braking (2 Hours) | ||
| Theory and Implementation: | ||
| Regenerative braking principles | Blended braking strategies | ESP32-based regen control implementation |
| Assignments: | ||
| Assignment 1: Design motor control algorithm for BLDC motor | Assignment 2: Implement sensor less control using back-EMF detection | Assignment 3: Create complete powertrain model with efficiency analysis |
| Mini-Projects: | ||
| Motor Control Unit: ESP32-based FOC controller with real-time monitoring | Regenerative Braking System: Energy recovery optimization algorithm | Drivetrain Simulator: Complete virtual test bench for motor-inverter system |
| HV Safety, Protections, and Compliance– 10 Hours | ||
|---|---|---|
| HV Safety Systems (4 Hours) | ||
| Theory (2 Hours): | ||
| HV Safety Rules implementation | De-energization procedures and verification | HVIL (High Voltage Interlock Loop) design |
| ESP32 Implementation (2 Hours): | ||
| Safety interlock monitoring system | Emergency shutdown sequences | Status indication and logging |
| Protection Circuits (2 Hours) | ||
| Theory and Design: | ||
| Pre-charge circuit design and control | Active and passive discharge systems | HVIL (High Voltage Interlock Loop) design |
| ESP32 Implementation (2 Hours): | ||
| Safety interlock monitoring system | Emergency shutdown sequences | Insulation monitoring techniques |
| Advanced Safety Systems (4 Hours) | ||
| Theory (2 Hours): | ||
| Equipotential bonding and galvanic isolation | Fault detection and diagnosis | Emergency response protocols |
| Implementation (2 Hours): | ||
| ESP32-based insulation monitoring | Fault logging and analysis system | Automated safety response algorithms |
| Assignments: | ||
| Assignment 1: Design complete HVIL system with ESP32 monitoring | Assignment 2: Implement pre-charge control algorithm with safety checks | |
| Mini-Projects: | ||
| Comprehensive HV Safety Controller: Integrated system managing all HV safety aspects with real-time monitoring and automated responses | ||
| Thermal Management System and Future Trends | ||
|---|---|---|
| Thermal Management Design (4 Hours) | ||
| Theory (2 Hours): | ||
| Thermal management for battery, motor, inverter, charger | Heat exchanger design and cooling strategies | Thermal modeling and simulation |
| Simulation and Control (2 Hours): | ||
| MATLAB thermal system modeling | ESP32-based thermal controller design | Predictive thermal management algorithms |
| Future Technologies (2 Hours) | ||
|---|---|---|
| Emerging Trends: | ||
| Fuel cell vehicles and hybrid systems | Integration with autonomous vehicles | Solid-state batteries and advanced materials |
| IoT and Connectivity (4 Hours) | ||
| Theory (1 Hour): | ||
| IoT applications in EVs | Cloud connectivity and data analytics | Over-the-air updates and remote diagnostics |
| Implementation (3 Hours): | ||
| ESP32 IoT platform development | Cloud dashboard for EV monitoring | Predictive maintenance algorithms |
| Assignments: | ||
| Assignment 1: Design integrated thermal management system | Assignment 2: Create IoT-enabled EV monitoring platform | |
| Mini-Projects: | ||
| Smart EV Management System: Complete IoT solution with predictive analytics and remote monitoring | ||
| Electric Vehicle Standards and Testing (10 Hours) | ||
|---|---|---|
| Standards and Regulations (4 Hours) | ||
| Theory (1 Hour): | ||
| International EV standards (ISO, IEC, SAE) | Regional regulations and compliance requirements | Homologation processes and certification |
| Documentation (1 Hour): | ||
| Compliance checklist development | Testing protocol documentation | |
| EMI/EMC Considerations (2 Hours) | ||
| Theory and Design: | ||
| EMI sources in EVs and mitigation techniques | PCB layout guidelines for ESP32 designs | Filtering and shielding strategies |
| ESP32 Testing Framework (1 Hour): | ||
| • Unit testing for embedded systems | • Continuous integration for EV controllers | • Filtering and shielding strategies |
| Assignments: | ||
| Assignment 1: Develop comprehensive testing protocol for EV systems | Assignment 2: Create EMI/EMC compliant ESP32 design | |
| Capstone Project: | ||
| Complete EV System Integration: Students integrate all modules into a comprehensive virtual EV system with hardware controllers, demonstrating end-to-end knowledge | ||
