Full Curriculum Breakdown
1. Day 1-3 : EV System Architecture & Safety Protocols
• Introduction to the overall layout of a four-wheeler EV: powertrain, battery, controller, motor.
• Cover safety standards, high-voltage system precautions, PPE (Personal Protective Equipment), and isolation procedures.
• Practical: Identify orange high-voltage cables, understand shutdown circuits, and practice safe disconnects.
2. Day 4-7 : Battery Pack Construction & Management
• Dive into battery chemistry, cell formats (prismatic, cylindrical), and pack design principles.
• Introduction to Battery Management System (BMS): cell balancing, temperature monitoring, SOC, SOH.
• Practical: Simulate battery pack wiring, measure voltages, check temperature sensors and connectors.
3. Day 7-10 : Electric Motor & Inverter Control
• Learn different motor types used in EVs (BLDC, PMSM, induction) and why they’re selected.
• Understand inverter and controller interaction: throttle to torque translation.
• Practical: Monitor motor RPM, torque commands, and observe inverter feedback via software tools.
4. Day 10-12 : EV Charging Systems & Communication
• Cover AC and DC charging, charging levels (L1, L2, DC fast), and EVSE hardware.
• Introduction to CCS, CHAdeMO, and Bharat EV protocol basics.
• Practical: Perform AC charging, interpret charger status lights, and use public charging infrastructure.
5. Day 13-15 : Powertrain Integration & CAN Communication
• Understand integration of battery, motor, and controller through CAN bus.
• Introduction to CAN tools and interpreting signals between components.
• Practical: Use basic CAN software to sniff live data and check for DTCs (Diagnostic Trouble Codes).
6. Day 16-18 : Troubleshooting & Diagnostics
• Learn structured approach to identify EV system faults (motor not responding, low power, thermal shutdown).
• Practical: Simulate common issues (connector faults, undervoltage), read error codes, and resolve.
7. Day 18-20 : EV Walkthrough & Live Demonstration
• End with a complete vehicle inspection and performance review.
• Participants map each system live: battery flow, charging, motor response, and diagnostics.
• Optional: Driving experience on closed track or monitored test bench to apply learned theory.
8. Day 21 : Wrap-Up & Certification
- The training program will conclude with Certificate Distribution, a Career Guidance Session, Participant Feedback, and an interactive Q&A, providing a complete wrap-up and future direction for all attendees.