EV Engineering Course

Lesson 1 • EV System Architecture Overview

Maps the functional blocks of a complete EV: powertrain, energy storage, controls, and auxiliaries. Connects subsystem roles to overall vehicle performance.

Lesson 2 • Comparison of EV Drivetrain Types

Contrasts BEV, HEV, PHEV, and FCEV architectures by energy flow and component sets. Enables engineers to select the appropriate platform for a given application.

Lesson 3 • History and Evolution of EVs

Traces EV development from early prototypes to modern platforms, establishing industry context. Provides the historical baseline needed to understand current engineering priorities.

Lesson 1 • Cell Formats and Pack Architecture

Covers cylindrical, prismatic, and pouch cell formats and their assembly into modules and packs. Links cell geometry to structural, thermal, and electrical pack design.

Lesson 2 • Lithium-Ion Cell Chemistries

Compares NMC, LFP, NCA, and solid-state chemistries by energy density, cycle life, and safety. Equips engineers to match chemistry to vehicle requirements.

Lesson 3 • Electrochemical Principles of Batteries

Explains oxidation-reduction reactions, ion transport, and electrode chemistry that govern cell operation. Grounds subsequent pack-level analysis in fundamental electrochemistry.

Lesson 4 • Battery Safety and Failure Modes

Analyses thermal runaway, dendrite growth, and mechanical abuse scenarios with mitigation strategies. Prepares engineers to design packs that meet functional safety requirements.

Lesson 1 • BMS Validation and Testing

Outlines hardware-in-the-loop testing, fault injection, and field validation procedures for BMS software. Ensures engineers can verify BMS performance against functional safety targets.

Lesson 2 • Cell Balancing Techniques

Compares passive and active balancing topologies for equalising cell voltages across a pack. Demonstrates how balancing strategy affects efficiency and usable capacity.

Lesson 3 • BMS Communication and Integration

Details CAN bus, LIN, and isolated SPI protocols used to connect the BMS to vehicle systems. Prepares engineers to integrate BMS data into powertrain and charging control.

Lesson 4 • State Estimation Algorithms

Covers SOC, SOH, and SOE estimation using Coulomb counting, OCV lookup, and Kalman filtering. Connects algorithm accuracy to range prediction and pack longevity.

Lesson 1 • Motor Control Strategies

Details field-oriented control and direct torque control algorithms for precise torque and speed regulation. Prepares engineers to implement and tune motor controllers in real applications.

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

Covers bidirectional DC-DC converters and OBC topologies that manage voltage levels and charging power. Integrates power electronics knowledge into the full EV electrical architecture.

Lesson 3 • Traction Motor Types and Principles

Compares PMSM, BLDC, induction, and switched reluctance motors by torque-speed characteristics. Establishes the electromagnetic basis for motor selection decisions.

Lesson 4 • Motor Design and Sizing

Covers stator winding, rotor geometry, cooling integration, and peak versus continuous power ratings. Links design parameters to vehicle acceleration and gradeability targets.

Lesson 1 • Motor and Inverter Cooling

Covers water-glycol jackets, oil spray, and heat sink designs for motor and inverter thermal control. Ensures engineers can maintain component temperatures within safe operating limits.

Lesson 2 • Integrated Thermal System Modelling

Builds lumped-parameter and 1D thermal network models to simulate full-vehicle thermal interactions. Enables system-level optimisation before physical prototyping.

Lesson 3 • Cabin HVAC and Heat Pump Systems

Analyses vapour-compression and heat pump cycles used for cabin conditioning with minimal range impact. Integrates cabin thermal loads into the overall vehicle energy budget.

Lesson 4 • Battery Thermal Management

Compares air, liquid, and refrigerant-based battery cooling and heating strategies for temperature uniformity. Connects thermal management quality to battery life and fast-charge capability.

Lesson 1 • Charging Communication Protocols

Covers pilot signal, PLC-based, and wireless communication protocols between EV and charging equipment. Enables engineers to implement interoperable charging control systems.

Lesson 2 • Charging Levels and Standards

Defines Level 1, Level 2, and DC fast charging by power levels, connector types, and use cases. Provides the regulatory and technical framework for charging system design.

Lesson 3 • DC Fast Charging Architecture

Explains off-board charger topologies, power cabinet design, and thermal management for high-power DC charging. Prepares engineers to specify and evaluate fast-charging station hardware.

Lesson 4 • Vehicle-to-Grid and Smart Charging

Analyses V2G, V2H, and demand-response charging strategies and their grid and battery impact. Positions engineers to design bidirectional charging systems for energy management.

Lesson 1 • Energy Management Strategies

Covers rule-based and optimisation-based energy management for maximising efficiency and range. Connects control strategy design to real-world drive cycle performance.

Lesson 2 • Vehicle Control Unit Architecture

Defines VCU hardware, software layers, and real-time OS requirements for EV powertrain coordination. Establishes the control system framework used throughout the chapter.

Lesson 3 • Functional Safety for EV Controls

Applies hazard analysis, ASIL assignment, and safety mechanism design to EV control software. Prepares engineers to develop ISO 26262-compliant control systems.

Lesson 4 • Regenerative Braking Control

Details blended braking algorithms that coordinate hydraulic and regenerative braking for stability and energy recovery. Integrates brake-by-wire and ABS constraints into regen control design.

Lesson 1 • Durability and End-of-Life Testing

Outlines accelerated aging, vibration, and corrosion test protocols for EV powertrain durability sign-off. Ensures the powertrain meets lifetime reliability targets before production release.

Lesson 2 • Vehicle-Level Performance Validation

Defines range, acceleration, gradeability, and efficiency test procedures on proving grounds and public roads. Confirms that integrated powertrain meets all vehicle-level targets.

Lesson 3 • Component-Level Testing Methods

Details dynamometer, calorimeter, and climatic chamber testing for motors, inverters, and battery packs. Establishes the test methods used before system-level integration.

Lesson 4 • Powertrain Integration on Test Bench

Covers hardware-in-the-loop and full powertrain bench setups for integrated system validation. Bridges component test results to vehicle-level performance verification.