EV Design Course

Lesson 1 • Core EV Subsystem Overview

Maps the primary subsystems: powertrain, energy storage, thermal, and controls. Establishes vocabulary used throughout the course.

Lesson 2 • EV Classification and Architectures

Distinguishes BEV, HEV, PHEV, and FCEV configurations. Helps students select appropriate architecture for a given application.

Lesson 3 • Electric Power Fundamentals

Covers DC and AC electrical concepts essential for EV design. Connects circuit theory to real vehicle power flows.

Lesson 4 • History and Evolution of EVs

Traces EV development from early prototypes to modern platforms. Provides context for understanding why current design choices exist.

Lesson 1 • Pack Thermal Management

Addresses cooling and heating strategies to maintain cells within optimal temperature ranges. Directly supports battery longevity and fast-charge capability.

Lesson 2 • Lithium-Ion Cell Chemistries

Compares NMC, LFP, NCA, and solid-state chemistries on energy density, safety, and cycle life. Guides chemistry selection for specific EV use cases.

Lesson 3 • Battery Management Systems

Details BMS functions: cell balancing, state estimation, fault detection, and communication. Shows how BMS protects and optimises pack performance.

Lesson 4 • Cell, Module, and Pack Design

Covers cylindrical, prismatic, and pouch cell formats and their assembly into modules and packs. Connects cell format to structural and thermal design constraints.

Lesson 5 • Electrochemical Principles of Batteries

Explains oxidation-reduction reactions, electrode chemistry, and electrolyte behaviour. Links chemistry to measurable electrical performance.

Lesson 1 • Motor Control Strategies

Covers field-oriented control and direct torque control algorithms. Shows how control strategy affects responsiveness, efficiency, and NVH.

Lesson 2 • DC-DC Converters and On-Board Chargers

Details bidirectional DC-DC converters and on-board charger topologies. Links auxiliary power supply design to overall vehicle energy efficiency.

Lesson 3 • Motor Types for EV Applications

Compares PMSM, induction, switched reluctance, and axial-flux motors on performance and cost. Guides motor selection for passenger, commercial, and performance EVs.

Lesson 4 • Inverter Design and Operation

Explains three-phase inverter topology, switching devices, and modulation strategies. Connects inverter design to motor control quality and efficiency.

Lesson 1 • Braking System Integration

Addresses blended braking systems that combine regenerative and friction braking. Ensures students can design systems meeting safety and energy recovery targets.

Lesson 2 • Gearbox and Reduction Gear Design

Covers single-speed reducers, multi-speed gearboxes, and differential design for EVs. Explains how gear ratio selection affects acceleration and top speed.

Lesson 3 • Drivetrain Layout Options

Compares single-motor, dual-motor, and in-wheel motor configurations. Connects layout choice to traction, packaging, and cost outcomes.

Lesson 4 • Vehicle Dynamics and Handling

Applies mass distribution, centre of gravity, and suspension geometry to EV-specific layouts. Enables students to predict and improve handling balance.

Lesson 1 • Heat Transfer Principles for EVs

Reviews conduction, convection, and radiation as applied to EV components. Provides the analytical tools used in all subsequent thermal design sections.

Lesson 2 • Motor and Inverter Cooling

Covers water jacket, oil spray, and heat sink cooling for motors and inverters. Ensures students can maintain components within safe operating temperatures.

Lesson 3 • Cabin HVAC and Heat Pump Systems

Integrates cabin heating and cooling with the vehicle thermal loop using heat pump technology. Minimises range penalty from climate control loads.

Lesson 4 • Battery Thermal System Design

Designs liquid and refrigerant-based cooling circuits for battery packs. Directly supports battery longevity and fast-charge performance goals.

Lesson 1 • Charging Standards and Levels

Defines Level 1, Level 2, and DC fast charging levels and their connector standards. Provides the framework for all subsequent charging system design decisions.

Lesson 2 • DC Fast Charging Architecture

Covers off-board charger topologies, power delivery protocols, and battery interface requirements. Enables design of systems supporting high-power charging.

Lesson 3 • Charging Infrastructure Planning

Addresses site assessment, load management, and network communication for charge points. Connects vehicle design requirements to real-world deployment constraints.

Lesson 4 • Vehicle-to-Grid and Bidirectional Charging

Explains V2G, V2H, and V2L capabilities and their power electronics requirements. Positions EVs as grid assets and expands the designer's value proposition.

Lesson 1 • In-Vehicle Network Protocols

Covers CAN, LIN, Ethernet, and FlexRay protocols and their EV-specific applications. Enables students to design reliable, low-latency communication networks.

Lesson 2 • Functional Safety in EV Software

Applies functional safety principles to software development for safety-critical EV functions. Ensures students can design systems that meet required integrity levels.

Lesson 3 • Electronic Control Unit Architecture

Maps ECU types, their responsibilities, and physical placement in the vehicle. Establishes the hardware foundation for all software and control discussions.

Lesson 4 • Energy Management Strategy

Develops rule-based and optimisation-based energy management algorithms. Directly impacts range, battery life, and driver experience.

Lesson 1 • Homologation and Type Approval

Navigates the regulatory submission process for EV type approval in target markets. Ensures students can plan and execute compliance programmes efficiently.

Lesson 2 • Performance and Durability Testing

Executes range, acceleration, thermal, and durability test protocols on complete vehicles. Verifies that design targets are met under real-world conditions.

Lesson 3 • Systems Engineering for EVs

Applies requirements decomposition, interface management, and V-model development to EV programmes. Provides the process framework for all integration activities.

Lesson 4 • Hardware-in-the-Loop Testing

Uses HIL simulation to validate ECU software against virtual plant models before physical integration. Reduces integration risk and accelerates development cycles.