E-Vehicle Assembly and Service Technology

Teacher

Dr P Anthony Sunny Dayal

Category

Certificate Courses

Course Attendees

Still no participant

Course Reviews

Still no reviews

Course Name : E-Vehicle Assembly and Service Technology

Code(Credit) : CUTMXXXX(1-1-0)

Course Objectives

  • This course introduces the fundamental concepts, principles, analysis and design of electric vehicles.
  • Understand working of Electric Vehicles and recent trends.

Learning Outcomes

  • Assembly, Production and Servicing of Battery Pack, Power Train, Invertor and Wiring Harness
  • Analyze different power converter topology used for electric vehicle application.

Course Syllabus

Module I: Overview of E-Vehicle

1. Introduction to E-Vehicle
2. Conversion to E-Vehicle
3. Classification of E-Vehicle and Subsystems of E-Vehicle
4. Norms and Standards as per ARAI, AIS (Automotive Industry Standard), AIS 048, AIS 049, AIS 138 (Part-1), AIS 138 (Part-2)

Module II: Battery Pack: Assembly, Wiring Harness and Servicing

1. Parameters of Battery Cell : Cell Voltage, AH, Capacity, Life Cycle, Charging and Discharging Curve, C Rating, Maximum Charge Rate and Maximum Discharge Rate, SOC (State of Charge), DOD (Death of Discharge), SOH (State of Heath).
2. Various connection of Cells: Series connection, Parallel connection, Combination of both series and parallel connection
3. Spot Welding Connections, Wiring Harness, Wire Connector and Soldering Connections joints
4. Sealing the battery pack with insulated Tape, anti-vibration Materials and water proof casing material
5. Performance Checking, Replacement of Cells and Regular Maintenance to increase life of EV

Module III: Battery Management System (BMS)

1. Various Kinds of Failure that can Occur in Li-Ion cells and Thermal Runaway
2. Safety Parameters for Battery, BMS Control Characteristics
3. Connecting the BMS, Balance Wiring and Continuity Checking
4. Heat Shrinking of BMS with Battery cells and Printing the Label of Battery Specification on Pack

Module IV: Electric Vehicle (EV) Charging Technology

1. Electric Vehicle Charging: Introduction, Types of Charging(AC and DC), Slow Charging and Fast Charging
2. On Board Charger (OBC) and Off Board Charger, Charging Infrastructure, DCDC converter for LV (Low Voltage) battery charging and LV load
3. Electric Vehicle Supply Equipment (EVSE): Types of EVSE, Portable EVSE, Wall mounted EVSE
4. EV conductive charge cable, EV connector, Vehicle inlet, Plugs and Socket for EV charging

Module V: Electric Motor Assembly and Servicing

1. Introduction to Electric Motors : DC Motor, BLDC Motor, 3-phase PMSM Motor, 3-phase Induction Motor
2. BLDC and Runner Motor Construction, Assembly and Working
3. Convertors, invertors and Controls, Regenerative braking system
4. Working Sefty of Electric Vehicle Motor Components

Module VI: Electric Vehicle Powertrain Assembly

1. Introduction to Powertrain, Motor Power and Torque Calculations
2. Weight Distribution and Thermal Management in EV : Air Cooling, Liquid Colling and Heating
3. BLDC Motor Controls, Motor Control Circuitry, Control Sequence and Power train Modelling

Module VII: Assembly Line and Servicing Bay

1. Construction, Cutting, Welding and Assembly of Chassis
2. Assembly of Batteries, BLDC Motors, Inverter Unit, Powertrain Unit and Couplers with Chassis, PDU(Power Distribution Unit), BCM (Body Control Module)
3. ECU and Tuning Parameters, Communication System in EV: CAN and LIN
4. Quality Check, Saftey Checklist and Dos and Donts

Practicals:

1. Battery Selection Depeding on Capacity and Construction of Cell Cage using CAD and Die Cut
2. Cutting the Joint Plates and Spot Welding : Parallel and Series Connections of Cells.Testing the Capacity and adding or removing the cells
3. BMS Installation with balance : Charging and Discharging Rate of Battery Pack
4. BLDC Motor Winding, Shaft, Stator, Rotor, Stiching, Coupling, Sealing and Testing
5. Power Train Assembly and Inverter : IGBTs , Controllers

Textbooks

1. Iqbal Husain, "Electric and Hybrid Vehicles Design Fundamentals", CRC Press, 2010 https://doi.org/10.1201/9781439894972

2. Ali Emadi "Handbook of Automotive Power Electronics and Motor Drives", CRC Press, 2017 https://doi.org/10.1201/9781420028157

3. Mehrdad Ehsani, Yimin Gao, Sebastien E. Gay, Ali Emadi, "Modern Electric, Hybrid Electric, and Fuel Cell Vehicles Fundamentals, Theory, and Design", CRC Press, 2004 https://doi.org/10.1201/9781420037739

4. James Larminie, John Lowry, "Electric Vehicle Technology Explained", Wiley 2012.

5. https://araiindia.com/downloads

Session Plan

Session 1

Introduction to E-Vehicle

click here for play

click here for ppt

Session 2

Conversion to E-Vehicle

click here for play

Session 3

Classification of E-Vehicle

click here for play

Session 4

Subsystems of E-Vehicle

click here for play

Session 5

Norms and Standards as per ARAI, AIS (Automotive Industry Standard), AIS 048, AIS 049, AIS 138 (Part-1), AIS 138 (Part-2)

Click Here for play

Session 6

Parameters of Battery Cell : Cell Voltage, AH, Capacity, Life Cycle, Charging and Discharging Curve, C Rating, Maximum Charge Rate and Maximum Discharge Rate, SOC (State of Charge), DOD (Death of Discharge), SOH (State of Heath)

click here for play

Session 7

Various connection of Cells: Series connection, Parallel connection, Combination of both series and parallel connection

click here for play

Session 8

Spot Welding Connections, Wiring Harness, Wire Connector and Soldering Connections joints

click here for play

Session 9

Sealing the battery pack with insulated Tape, anti-vibration Materials and water proof casing material

click here for play

Session 10

Performance Checking, Replacement of Cells and Regular Maintenance to increase life of EV

click here for play

Session 11

Heat Shrinking of BMS with Battery cells and Printing the Label of Battery Specification on Pack

click here for play

Session 12

Electric Vehicle Charging: Introduction, Types of Charging(AC and DC), Slow Charging and Fast Charging

click here for play

Session 13

Introduction to Electric Motors : DC Motor, BLDC Motor, 3-phase PMSM Motor, 3-phase Induction Motor

Click here to play

Session 14

BLDC and Runner Motor Construction, Assembly and Working

Click here to play

Session 15

Convertors, invertors and Controls, Regenerative braking system

Click here to play

Session 16

Torque Calculations

click here for ppt

Session 17

Weight Distribution

click here for ppt

Session 18

Thermal Management in EV

click here for ppt

Session 19

Air Cooling, Liquid Colling and Heating

click here for ppt

Session 20

Construction, Cutting, Welding

click here for ppt

Session 21

Assembly of Chassis

click here for ppt

Session 22

PDU(Power Distribution Unit)

click here for ppt

Session 23

ECU and Tuning Parameters, Communication System in EV: CAN and LIN

click here for ppt

Recent Comments

    Our Main Teachers

    Dr P Anthony Sunny Dayal

    Associate Professor, Department of Electronics and Communication Engineering, SOET
    VIEW PROFILE

    Dr P Anthony Sunny Dayal completed his M.Tech in Radar and Microwave Engineering from Andhra University and Ph.D in Antenna Array Design For Radar And Emc Applications from Centurion University. Recipient of “Young Scientist Award” from His Excellency Shri Biswabhusan Harichandan Governor of Andhra Pradesh, at Andhra Pradesh Science Congress – 2019 by Andhra Pradesh […]