Free EV Fundamentals & Charging Technologies Lab Manual
Download the EV Fundamental Course Experimental Manual with 4 hardware-focused experiments. Give students hands-on exposure to EV bike architecture, hub motor performance under mechanical loading, power electronics converters, and safe wiring practices on a 2D EV board.
Real Vehicle Architecture
Battery, BMS, hub motor & converters in one integrated manual
4 Hands-On EV Fundamentals Experiments
Build a complete understanding of 2-wheeler EV architecture, hub motor performance, power converters and professional wiring practices.
EV Bike Internal Architecture & Wiring
Open up a commercial EV bike to map every subsystem, connector and harness in the powertrain.
- Identify battery pack, hub motor, controller and BMS layout
- Trace high-voltage and low-voltage wiring paths
- Map DC-DC converter, throttle, brake and display connections
- Inspect wiring harness integrity and routing practices
- Prepare a complete internal architecture diagram
- Discuss safety and maintenance recommendations
Hub Motor Analysis with Mechanical Loading
Use a 2-wheeler simulator and spring balance to study hub motor behaviour under real-world loads.
- Relate throttle position to motor voltage, current and speed
- Apply no-load, half-load and full-load mechanical resistance
- Measure input/output electrical parameters at each load
- Observe brake light, headlight and indicator behaviour
- Discuss efficiency, heating and torque response
- Interpret results for actual road and gradient conditions
Power Electronics Converters & Test Points
Explore DC-DC converters, inverters and motor controllers that manage energy flow in the EV.
- Locate step-down DC converter, controller and inverter sections
- Measure input/output voltage and current using multimeter
- Use oscilloscope to study inverter waveforms and frequency
- Observe converter response to throttle changes
- Record performance at multiple test points across the kit
- Relate converter behaviour to overall vehicle efficiency
EV Wiring on a 2D Board
Practice neat, colour-coded wiring by laying out a complete EV circuit on a 2D training board.
- Interpret the EV wiring diagram for battery, controller and loads
- Use colour codes for power, ground and signal lines
- Cut, strip and terminate raw wires to correct length
- Bundle and secure harnesses using tape and cable ties
- Label each connection and create a final wiring schematic
- Review safety, insulation and troubleshooting practices
Complete EV Fundamentals Package
Use the manual as the base for a full 2W EV fundamentals & charging technologies lab.
- Step-by-step procedures for all 4 experiments
- Equipment and safety requirement checklists
- Observation tables and evaluation templates
- Block diagrams and suggested circuit layouts
- Analysis questions and viva prompts
- Scope for project extension and mini-projects
Who Is This Lab Manual For?
Designed for institutes building EV fundamentals, power electronics and charging-related lab courses.
Engineering Programs
EV, Electrical, Electronics, Automobile, Mechatronics and related branches.
Polytechnic & Diploma
Ideal for diploma-level EV technician and service training labs.
Skill Centres & COEs
Use as a standard lab module in Centres of Excellence in e-mobility.
Industry Skilling
Upskill technicians on modern 2W EV architecture and charging systems.
Key Skills Students Will Gain
- Reading and interpreting EV wiring diagrams and harness layouts
- Identifying and explaining EV subsystems: battery, BMS, motor, controller and converters
- Using multimeters, oscilloscopes and loading devices on an EV simulator
- Measuring performance of hub motors under different throttle and load conditions
- Understanding DC-DC converter and inverter operation through real test points
- Executing safe, professional wiring on 2D training boards
- Documenting observations and preparing analysis reports
- Following safety protocols while working around high-voltage systems
Download Your Free EV Fundamentals Manual
Get the complete EV Fundamental Course Experimental Manual with procedures, tables and analysis guidelines for all 4 experiments.
Complete Lab Manual
One PDF covering objectives, theory, procedures, tables and conclusion points for all experiments.
- EV bike internal architecture & wiring
- Hub motor analysis with mechanical loading
- Power electronics converters & test points
- EV wiring on a 2D board
Instructor Planning Sheet
Use this alongside the manual to schedule experiments, evaluation and safety briefings.
- Session-wise experiment planning template
- Equipment and consumable checklists
- Assessment rubric for practical exams
- Viva-voce sample questions
- Lab logbook structure recommendations
- Space to customise for your university scheme
Integration With Other EV Kits
Extend this manual by integrating with DIYguru 2W hardware, BMS and analytics manuals.
- Link Course 1 fundamentals to 2W hardware training kits
- Bridge experiments to BMS and battery diagnostics
- Ideas to add charging infrastructure experiments
- Guidelines for capstone project formation
- Mapping to EV PG & Nano-degree programs
- Industry project collaboration options
Need support in aligning with your university syllabus? Contact our curriculum team
Deploy a Complete EV Fundamentals Lab
Combine this manual with DIYguru hardware kits and simulators to launch a modern EV lab in weeks.
What DIYguru Can Provide
- 2W EV simulator rigs with hub motor, controller and loading arrangements
- Demo EV bikes for architecture and wiring exploration
- 2D wiring boards and colour-coded wiring harness kits
- Faculty orientation sessions and train-the-trainer modules
- Student handbooks, logbooks and certification support
- Integration pathways into PG and Nano-degree EV programs
How Deployment Works
- Requirement Discussion: Share programs, student strength and lab space.
- Lab Design: DIYguru proposes equipment, manuals and experiment mapping.
- Implementation: Kits shipped, faculty trained and lab commissioned.
Typical Equipment Required
Core Hardware:
- 2-wheeler EV simulator kit with hub motor and controller
- Spring balance / mechanical loading arrangement
- Multimeters and clamp meters
- Oscilloscope for waveform observation
- 2D wiring boards and raw wire bundles
- EV bike (or mock-up chassis) for architecture study
Tools & Safety:
- Insulated screwdrivers, wire strippers and crimping tools
- Personal protective equipment (gloves, goggles, mats)
- Lockout/tagout arrangements for high-voltage isolation
- Fire extinguisher suitable for electrical fires
For a detailed BoM and commercial proposal, write to support@diyguru.org or call +91 99109 18719.
Frequently Asked Questions
Everything you need to know about the EV Fundamental Course Experimental Manual.
Ready to Launch Your EV Fundamentals & Charging Lab?
Start with the free manual and scale up with DIYguru hardware kits, faculty training and certification pathways.