EV Engineer Course

Lesson 1 • Electrochemical Energy Storage Basics

Covers fundamental electrochemistry behind lithium-ion cells and pack construction. Connects cell-level behavior to vehicle-level performance metrics.

Lesson 2 • Vehicle Energy Consumption Modeling

Teaches methods to estimate driving range using load cycle analysis and efficiency maps. Grounds abstract component specs in real-world vehicle performance.

Lesson 3 • EV System Architecture Overview

Introduces the major subsystems of a battery electric vehicle and their interactions. Establishes the mental model needed for all subsequent technical chapters.

Lesson 4 • Power Electronics Fundamentals

Introduces inverters, converters, and switching devices that manage energy flow. Prepares students for detailed power electronics design in later chapters.

Lesson 1 • Battery Management System Design

Explains BMS functions including cell monitoring, balancing, and protection logic. Students configure BMS parameters to meet safety and performance targets.

Lesson 2 • Cell Selection and Characterization

Covers criteria for selecting cells based on energy, power, cycle life, and safety. Links cell-level data sheets to pack-level design requirements.

Lesson 3 • Thermal Management of Battery Packs

Addresses heat generation, cooling strategies, and thermal runaway prevention. Ensures students can design thermal systems that maintain safe cell temperatures.

Lesson 4 • Pack Safety and Abuse Testing

Covers mechanical, electrical, and thermal abuse test protocols for battery packs. Prepares students to validate pack designs against international safety standards.

Lesson 1 • Motor Topology Comparison

Compares permanent magnet, induction, and switched reluctance motor types for EV use. Establishes trade-offs that guide motor selection decisions.

Lesson 2 • Gearbox and Drivetrain Integration

Covers single-speed and multi-speed transmission options and their integration with traction motors. Prepares students to match gear ratios to motor and vehicle requirements.

Lesson 3 • Electromagnetic Design Principles

Covers stator winding, rotor geometry, and magnetic circuit design for traction motors. Connects design parameters to torque density and efficiency outcomes.

Lesson 4 • Motor Thermal Management

Addresses heat dissipation in windings, magnets, and bearings under continuous and peak loads. Ensures students can size cooling systems for target duty cycles.

Lesson 1 • Wide-Bandgap Semiconductor Devices

Covers silicon carbide and gallium nitride device properties and their advantages in EV inverters. Prepares students to select and apply next-generation switching devices.

Lesson 2 • EMC and Filtering in Power Converters

Teaches sources of conducted and radiated emissions in EV power converters and mitigation methods. Prepares students to meet electromagnetic compatibility requirements.

Lesson 3 • Thermal Design of Power Modules

Addresses junction-to-coolant thermal path design and power cycling reliability. Ensures inverter thermal design meets lifetime requirements under real drive cycles.

Lesson 4 • Traction Inverter Architecture

Explains three-phase inverter topology, switching sequences, and modulation strategies. Builds on power electronics fundamentals to address traction-specific requirements.

Lesson 1 • Cabin HVAC and Thermal Comfort

Addresses cabin heating, ventilation, and air conditioning design for EVs with limited waste heat. Connects HVAC energy consumption to driving range impact.

Lesson 2 • Integrated Thermal System Architecture

Introduces the thermal domains of an EV and their interconnections via coolant loops. Establishes the system-level view needed to optimize thermal energy flows.

Lesson 3 • Coolant Circuit Design and Simulation

Teaches coolant flow network design, pump sizing, and 1D thermal simulation methods. Ensures students can validate thermal designs before hardware build.

Lesson 4 • Thermal System Validation and Testing

Covers climatic chamber testing, thermal soak tests, and cold-start validation procedures. Prepares students to verify thermal system performance across operating extremes.

Lesson 1 • Calibration and Embedded Diagnostics

Covers parameter calibration workflows and onboard diagnostic system design for EV controllers. Prepares students to tune control strategies and support field diagnostics.

Lesson 2 • Functional Safety in EV Software

Introduces automotive functional safety concepts applied to EV powertrain software development. Ensures students can identify hazards and implement safety integrity requirements.

Lesson 3 • Torque and Power Management Strategies

Teaches driver demand interpretation, torque arbitration, and power limiting algorithms. Connects control logic to motor and battery constraints established in earlier chapters.

Lesson 4 • Vehicle Control Unit Architecture

Covers VCU hardware selection, real-time operating system configuration, and I/O mapping. Establishes the control platform on which all powertrain strategies run.

Lesson 1 • Vehicle-to-Grid and Bidirectional Charging

Covers V2G, V2H, and V2L power flow architectures and their control requirements. Prepares students to design bidirectional charging systems for grid services.

Lesson 2 • Charging Communication Protocols

Covers pilot signal control, power line communication, and high-level charging protocols. Prepares students to implement compliant vehicle-to-EVSE communication.

Lesson 3 • AC and DC Charging Standards

Compares Level 1, Level 2, and DC fast charging architectures and connector standards. Establishes the infrastructure context for onboard and off-board charger design.

Lesson 4 • DC Fast Charging Station Design

Addresses power conversion, thermal management, and protection in DC fast chargers. Connects station-level design to vehicle charging acceptance and battery limits.

Lesson 1 • Hardware-in-the-Loop Testing

Teaches HIL simulation setup for testing VCU, BMS, and inverter software before vehicle build. Accelerates validation by replacing physical hardware with real-time plant models.

Lesson 2 • Vehicle-Level Validation Testing

Addresses range, performance, durability, and safety testing at the complete vehicle level. Ensures all subsystem interactions are validated under real operating conditions.

Lesson 3 • Regulatory Homologation Process

Introduces the type approval and homologation process for EVs in major markets. Prepares students to plan compliance activities and manage certification documentation.

Lesson 4 • Powertrain Bench Testing

Covers e-axle and powertrain test bench setup, instrumentation, and drive cycle execution. Validates integrated motor, inverter, and gearbox performance before vehicle installation.