Junior Technician – Battery Electric Vehicle

Learning outcomes:

 (i) Comply with workshop health and safety guidelines.

 (ii) Assist to identify system and subsystem of Electrical Vehicle.
 (iii) Support in selection, testing & replacement of Motors, DC-DC Convertor,
Relays and wiring connection in EV.
 (iv) Assist to charge the EV Battery & support to identify the health of EV Battery.
 (v) Assist to support to maintain EV regulatory requirements & Safety precautions
for working on high voltage system.
 (vi) Assist in Repair and maintenance of Electric Vehicle system

S UNIT UNIT NAME HOURS

NO NO
1 Unit-1 Introduction, History and Types of Electric 8
Vehicles
2 Unit-2 Performing routine service and minor repairs on 8
a battery electric vehicle (BEV) and routine
service or minor repairs on 2/3-wheeler electric
vehicles
3 Unit-3 Assisting a lead technician in diagnosing or 8
troubleshooting faults on a battery electric
vehicle (BEV)
4 Standard Operating Procedure 8
5 Unit-5 Various Components and Working Principle 8
Total 40

Course Objective:

This course helps develop skills in Electrical Vehicle Service & Maintenance, preparing
candidates to work as Technicians in OEMs, Dealers, Service Centres, Workshops, etc. Skills
include understanding EV systems and subsystems, designing and assembling vehicle
systems, identifying components and their functions, and wiring connections. The course also
covers troubleshooting, repair, and maintenance of EV systems, and understanding regulatory
requirements. Additionally, it supports starting a workshop for 2, 3, and 4 wheelers.
Job Roles:

Applicable to various industries, including roles like Automobile Mechanic, Assistant

Technician, Auto Electrical Technician, Auto Electrician, Trainee Technician, Diagnostic
Mechanic, Spare Parts Salesman, Auto Service Center Storekeeper, Spare Parts Sales
Assistant, Assistant Engineer, Junior Engineer, and Service Support Assistant.

Job Description:

After completing this course, the candidate will be able to perform a number of jobs such as:

 Electrical wiring connection of electrical vehicles

 Identify root cause of failure
 Troubleshooting
 Perform repairs
 Service the vehicle
 Ongoing maintenance of Electric Vehicle systems
 UNIT - 1
Introduction, History and Types of Electric Vehicles
Classification of Electric Vehicle in Use Today
Developments of ideas from the 19th and 20th centuries are now utilized to produce a new
range of electric vehicles that are starting to make an impact. There are effectively six basic
types of electric vehicle, which may be classed as follows,
 Firstly, there is the traditional battery electric vehicle, which is the type that usually
springs to mind when people think of electric vehicles.
 However, the second type, the hybrid electric vehicle, which combines a battery and an
IC engine, is very likely to become the most common type in the years ahead.
 Thirdly there are vehicles which use replaceable fuel as the source of energy using either
fuel cells or metal air batteries.
 Fourthly there are vehicles supplied by power lines
 Fifthly there are electric vehicles which use energy directly from solar radiation.
 Sixthly there are vehicles that store energy by alternative means such as flywheels or
super capacitors, which are nearly always hybrids using some other source of power as
well.
What is an Electric Vehicle?

- An all-electric vehicle (often called a battery-electric vehicle, or EV for short) is a vehicle

that gets its energy for driving entirely from its battery and it must be plugged in to be
recharged.

- An Electric Vehicle is an alternative fuel automobile that uses electric motors and motor
controllers for propulsion, replacing more common propulsion methods like the internal
combustion engine (ICE).
History of Electric Vehicles

- In 1828, Ányos Jedlik invented an early type of electric motor and created a small model car
powered by his new motor.

- The first electric car was officially made in Wolverhampton in 1884.

- Elwell-Parker Company was established in 1882 for the construction and sale of electric
trams.

- German engineer Andreas Flocken built the first real electric car in 1888.

- On 31 July 1971, an electric car, the Lunar Roving Vehicle (also known as the "Moon
buggy"), became the first manned vehicle to drive on the Moon during the Apollo 15 mission.
It featured a DC drive motor in each wheel and was powered by a pair of 36-volt silver-zinc
potassium hydroxide non-rechargeable batteries.

- The introduction of the Toyota Prius in 1997 was a turning point; it became the world's first
mass-produced hybrid electric vehicle.

- In 2006, Tesla Motors, a small Silicon Valley startup, announced the production of a luxury
electric sports car that could go more than 200 miles on a single charge.

Why Electric Vehicle

- Save money

- Cut emissions

- Better for the air we breathe

- Low maintenance requirements

- Performance vehicles

- High torque power and smooth pickup

- Comfortable ride

- Digital vehicles

Basic Concept of Electric Vehicle

- Battery

- Motor

- Controller
Battery electric vehicles
The concept of the battery electric vehicle is essentially simple and is shown in Figure. The
vehicle consists of an electric battery for energy storage, an electric motor, and a controller. The
battery is normally recharged from mains electricity via a plug and a battery charging unit that
can either be carried onboard or fitted at the charging point.
The controller will normally control the power supplied to the motor, and hence the vehicle
speed, in forward and reverse. This is normally known as a 2 quadrant controller, forwards and
backwards. It is usually desirable to use regenerative braking both to recoup energy and as a
convenient form of frictionless braking. When in addition the controller allows regenerative
braking in forward and reverse directions it is known as a 4 quadrant controller.

Fig 1.6
There is a range of electric vehicles of this type currently available on the market. At the
simplest there are small electric bicycles and tricycles and small commuter vehicles. In the
leisure market there are electric golf buggies. There is a range of full sized electric vehicles,
which include electric cars, delivery trucks and buses. Among the most important are also aids
to mobility and also delivery vehicles and electric bicycles. Some examples of typical electrical
vehicles using rechargeable batteries are shown in Figures. All of these vehicles have a fairly
limited range and performance, but they are sufficient for the intended purpose. It is important
to remember that the car is a very minor player in this field.

Electric Vehicles for the Future

The future of electric vehicles, of course, remains to be written. However, the need for vehicles
that minimize the damage to the environment is urgent. Much of the technology to produce
such vehicles has been developed and the cost is currently high in many cases, is likely to drop
with increasing demand, which will allow quantity production.
 The following chapters describe the key technologies that are the basis of electric
vehicles now and in the future:
 batteries ,
 other energy stores such as capacitors and flywheels,
 fuel cells,
 hydrogen supply, and
 electric motors.

Types of Battery Powered Vehicles:

- Electric Cars
- Power Electric Scooters
- Economy Scooters
- Electric Cycles
- Electric Motorcycles
- Electric Cargo Vehicles
- Campus Vehicles
- Bus
- Trucks

Electric Cars:
- Tata Nexon Electric Compact SUV:
- 30.20 kWh Li-Ion Battery
- 120 kmph Top Speed
- 94.87 kW Peak Power - 320 Volt system
- 245 Nm Torque
Power Electric Scooter: Hero Electric Optima ER
 Range: 90-100 km
 Battery: 2.68 kWh Lithium-Ion
 Top Speed: 45 km/h
 Max Power: 1.2 kW
 Setup: Double Battery

Okinawa R30 Economy Scooter

 Top Speed: 25-30 km/h

 Motor: 250-watt BLDC Hub Motor

 Battery: 1.25 KWh Lithium-Ion

 Charging Time: 4-5 hours

  Electric Motorcycles

o Model: Revolt RV 400

o Battery: 3.24 kWh Lithium Ion

o Top Speed: 80 km/h

o Max Power: 5 kW (Mid Drive Motor)

o Torque: 170 Nm

o Variants: RV 300

Electric Cycles
 Model: Hero Lectro e-Bikes

o Battery: 36V, 5Ah/10.9Ah

o Throttle Available: Yes/No

o Pedal Assist Sensors: 8/12 magnet

o Pedal Assist Levels: 3

o Physical Gears Available: 7 Speed

o
Electric Cargo Vehicle: Kinetic Green Safar Shakti Star
 Payload Capacity: 400 Kg
 Battery: 3.6 kWh Lithium Ion
 Top Speed: 25 km/h
 Peak Power: 6.5 kW

Campus Vehicles
 Motor: 48 VOLT AC MOTOR
 Battery: 8 VOLT 150 AH BATTERY
 Controller: 350 AMP AC CONTROLLER
 Electric Bus:
 250 kW battery, 150 kW motor

Electric Truck:
 UNIT-2
Performing routine service and minor repairs on a battery electric vehicle (BEV).
There are certain protocols to be followed while performing maintenance work in a BEV:
1. Safety Precautions:
 Disconnect the vehicle from the power supply.
 Turn off the main power switch and isolate the battery.
 Wear protective gloves and eyewear when handling electrical components.

2. Review the job card and understand work to be carried out on two/three-wheeler electric
vehicle:
Examine the Job Card Details:
 Vehicle Information: Vehicle make, model, and year.
 VIN (Vehicle Identification Number) or chassis number.
 Battery type and capacity.
 Odometer reading.
 Owner/Customer Details:
 Name and contact information.
 History of previous visits, if available.
 Service/Repair Request:
 Description of issues reported by the owner (e.g., range drop, strange noise, poor
acceleration).
 Specific service or maintenance requested.

 Assigned Technician:
 Name and expertise level, if noted.

 Review Service or Repair Tasks

Routine Maintenance Tasks:
 Checking and tightening fasteners.
 Inspecting tire condition and pressure.
 Lubricating moving parts (if applicable).

 Testing and calibrating electrical systems.

Battery and Charging System:
 Inspecting battery for damage or corrosion.
 Testing battery health and state of charge (SOC).
 Ensuring proper charger functionality and cable connections.
Motor and Controller:
 Diagnosing motor performance (RPM, temperature, unusual noise).
 Checking controller software/firmware updates.
  Testing motor-controller synchronization.

 Electrical Systems:
 Verifying functionality of the display, lights, and indicators.
 Diagnosing wiring issues, such as short circuits or broken
connections.
 Testing regenerative braking system (if applicable).

 Chassis and Suspension:

 Inspecting for cracks, alignment issues, or wear.
 Checking suspension system for smooth operation.

 Technician's Observations:
Technician's notes on test ride or inspection outcomes.

 Diagnostic Tools Used:

 Software logs or error codes retrieved from the vehicle's
onboard diagnostics (OBD).
 Voltage and current measurements from battery or motor
systems.

 Warranty Coverage:
 Identify if the job is covered under warranty or if additional charges will apply.

 Parts Replacement:
 List of parts to be replaced (e.g., brake pads, tires, battery cells, or motor
components).
 Availability of spares.

 Cost Estimate:
 Ensure a clear breakdown of labor and parts costs for the customer.

 Closing the Job Card

Quality Check:
 Confirm all reported issues are resolved.
 Test ride to ensure the vehicle functions properly.

 Owner Approval:
 Obtain signature or confirmation from the owner for completed work.
 Documentation:
 Update the job card with completed tasks, replaced parts, and technician
remarks.
3. Routine Service Tasks
a. Battery Maintenance:
 Inspect Battery:
 Check for visible damage, corrosion, or leaks.
 Ensure connectors and terminals are tight and clean.
 Measure Voltage and SOC:
 Use a multimeter to confirm voltage levels.
 Verify the state of charge (SOC) aligns with expected levels.
 Battery Health Check:
 Test individual cell voltages to ensure balance.
 Look for signs of overheating or swelling.
 Charging System:
 Test the charger for proper functionality.
 Inspect the charging port for wear or dirt.

b. Electrical Systems:
 Wiring:
 Inspect for frayed, loose, or exposed wires.
 Ensure all connections are secure.
 Lights and Indicators:
 Test headlights, tail lights, turn signals, and dashboard indicators.
 Motor and Controller:
 Check motor for unusual noise or vibrations.
 Inspect the controller for error codes and update firmware if needed.

c. Mechanical Systems
 Tires:
 Check for wear, cracks, or embedded debris.
 Verify tire pressure and adjust to recommended levels.
 Brakes:
 Inspect brake pads, discs, or drums for wear.
 Adjust or replace components as needed.
 Suspension:
 Examine for smooth operation and any signs of damage.
 Fasteners:
 Tighten bolts, screws, and nuts across the chassis and frame.
 d. Cleaning and Lubrication
 Clean the vehicle thoroughly to remove dirt and debris.
 Lubricate moving parts like the stand, joints, and suspension points.

4. Minor Repairs
a. Battery Repairs
 Replace corroded terminals or damaged connectors.
 Rebalance battery cells if voltage discrepancies are detected.
b. Electrical Repairs
 Repair or replace damaged wires and connectors.
 Fix or replace malfunctioning switches, lights, or indicators.
c. Mechanical Repairs
 Replace worn-out brake pads or tires.
 Adjust loose handlebars, side stands, or footrests.
5. System Testing
 Conduct a test ride to ensure proper acceleration, braking, and handling.
 Verify regenerative braking functionality (if applicable).
 Test battery performance under load conditions.
6. Documentation and Customer Communication
 Record the service and repairs performed.
 Provide the customer with advice on further maintenance and charging practices.
 Highlight any issues that might need attention in the future.
 A: Inverter, motor
 B: Chassis
 C: HV cable
 D: HV Batteries
 UNIT-3
Assisting a lead technician in diagnosing or troubleshooting faults on a battery electric vehicle
(BEV)
1. Gathering Information:
Customer Feedback:
Ask for a detailed description of the problem faced by the customer (e.g.,
reduced range, failure to start, unusual noise, etc.).
Note when and under what conditions the issue occurs (e.g., after charging,
during acceleration).
Vehicle History:
Check the service log for past maintenance and repairs.
 Look for recurring issues or patterns.

2. Visual Inspection:
Perform a quick external check for:
 Battery: Signs of damage, swelling, or leaks.
 Wiring: Frayed cables, loose connections, or corrosion.
 Tires and Suspension: Visible wear or damage.
 Motor and Chassis: Unusual marks, dirt, or misalignment.

3. Use Diagnostic Tools

Assist the technician in setting up and using the necessary tools for data collection:
a. Onboard Diagnostics (OBD) System
 Retrieve error codes from the Battery Management System (BMS), Motor
Controller, or Vehicle Control Unit (VCU).
 Record codes like "High Voltage Fault," "Overcurrent Error," or "Cell
Imbalance."
 b. Multi-meter Testing
Voltage Check:
 Measure the voltage across the battery terminals.
 Check individual cell voltages if accessible.
Continuity Check:
 Ensure there are no breaks in wiring or circuits.
Ground Fault Detection:
 Test for electrical leaks to the chassis.
c. Specialized Software
Assist in connecting diagnostic software to analyze real-time data for:
 Battery performance (e.g., SOC, SOH, temperature).
 Motor parameters (e.g., RPM, torque, and temperature).
 Charging system performance (e.g., voltage and current levels).

4. Assist in Isolating the Fault

Battery Issues:
 Identify imbalanced cells or temperature inconsistencies in the BMS logs.
 Look for excessive voltage drops or signs of wear.
Motor and Controller:
 Observe abnormal power output, overheating, or communication errors between
motor and controller.
 Record motor noise, vibrations, or irregular RPM behavior.
Wiring and Connections:
 Highlight loose, corroded, or damaged connectors.
 Report if continuity is lost in key circuits.
5. Assist in Test Procedures
Static Testing:
 Support stationary tests like voltage checks, current draws, or software resets.
Test Ride:
Accompany or observe as the technician conducts a controlled test ride to
evaluate:
 Acceleration and deceleration.
 Regenerative braking functionality.
 Handling and range performance.

6. Document the Findings

 Record all observed symptoms, test results, and error codes.
 Note any deviations from normal operating parameters.
 Prepare a detailed report for the lead technician to analyze.

7. Provide Support in Repairs

Help with basic tasks like:
 Tightening connectors or replacing damaged wiring.
 Balancing battery cells or replacing a failing module.
 Assisting in motor controller recalibration or firmware updates.

8. Post-Repair Verification
Support the technician in verifying that all faults have been resolved
 Repeat diagnostics to confirm normal readings.
 Conduct another test ride to ensure no residual issues.

Post service/repair/diagnostic activities

1. Conduct Final Inspections

. Visual Inspection
 Verify all components are reassembled correctly.
 Check for loose screws, bolts, or connectors.
 Ensure wiring and terminals are properly secured and insulated.

. Functional Tests
Test electrical systems, including:
 Battery voltage and state of charge (SOC).
 Lights, indicators, and dashboard displays.
 Charging port and cable functionality.
2. Check the mechanical systems:
 Brake responsiveness and tire alignment.
 Suspension smoothness and absence of unusual noise.

3. Perform System Diagnostics

Use diagnostic tools to confirm:
 No error codes are present in the Battery Management System (BMS) or
Vehicle Control Unit (VCU).
 Battery cells are balanced and operating within safe temperature ranges.
 Motor and controller are functioning optimally, with correct RPM and torque
output.

4. Test Drive
Conduct a controlled test ride to verify:
 Smooth acceleration and deceleration.
 Proper handling and braking.
 Regenerative braking effectiveness (if applicable).
 Noise and vibration levels are within acceptable limits.

5. Clean the Vehicle

 Remove any dirt, grease, or residue from the repair process.
 Clean sensitive components, such as the battery compartment and connectors,
using appropriate cleaning agents.
 Perform a general wash or wipe-down for overall cleanliness.

6. Document Service/Repair
a. Update the Job Card
Record details of all work performed, including:
 Replaced parts and consumables.
 Adjustments made (e.g., tire pressure, brake alignment).
 Diagnostic findings and resolved issues.

b. Test Results
 Log results of voltage checks, error code resolutions, and test rides.
 Note any unresolved issues or recommendations for future service.

c. Customer Report
Prepare a summary for the customer, including:
 What was diagnosed and repaired.
 Maintenance tips for the vehicle.
 Warranty coverage for replaced parts (if applicable).

7. Obtain Customer Approval

Review the work with the customer:
 Explain the repairs and tests performed.
 Address any remaining concerns or questions.
 Obtain the customer's signature or confirmation on the service report.

8. Reset Systems (if applicable)

 Clear all error codes from the diagnostic tool.
 Reset BMS or controller settings to default after calibration or updates.
 Ensure firmware or software updates are properly installed.

9. Final Handover
 Ensure the vehicle is fully charged or at an adequate charge level for immediate
use.
 Return all original parts replaced (if requested by the customer).
 Provide clear instructions on:
1. Proper charging practices.
2. Follow-up service recommendations or schedules.

10. Post-Service Feedback

 Request customer feedback on the service experience.
 Record any suggestions or complaints to improve future services.

Diagnosis kit Static analysis

Battery charging diagnosis Control system diagnosis
 UNIT-4
Standard Operating Procedure
Here is a Standard Operating Procedure (SOP) for handling the entire service
workflow of a two- or three-wheeler electric vehicle, from receiving the vehicle to
addressing complaints.

A. Vehicle Receiving Process

Objective: To systematically inspect and register the vehicle for service.
Steps:
1. Greet the Customer:
 Welcome the customer politely and inquire about the issue or required service.
 Make them feel comfortable and enquire about the issue.

2. Collect Initial Information:

Record the following details:
 Customer’s name, contact number, and address.
 Vehicle model, registration number, and odometer reading.
 Service history, if available.

3. Inspect the Vehicle:

Perform a quick visual check for:
 Scratches, dents, or damage.
 Battery level, lights, and tire condition.
 Loose or worn components (e.g., wiring, suspension).
 Document the condition with photos for reference.

4. Confirm Customer Concerns:

Note specific complaints (e.g., “reduced range,” “motor noise,” “charging
issues”).

5. Tag the Vehicle:

Attach a unique identification tag for tracking the vehicle.
B. Opening a Job Card
Objective: To create a detailed service record for the vehicle.
Steps:
1. Prepare the Job Card:
Use the customer’s details and vehicle information collected during receiving.
Include:
 Reported issues.
 Observations during initial inspection.
  Recommended services or repairs.
Obtain Customer Approval:
 Explain the service scope and estimated cost.
 Get the customer’s signature or approval before proceeding.

2. Assign Job Priority:

Mark the job as routine service, urgent repair, or diagnostics.

C. Allocation of Work

Objective: To delegate tasks efficiently to technicians.

Steps:
1. Assess Technician Availability:
 Check the current workload and assign based on expertise.
(Example): Assign battery diagnostics to a technician experienced in BMS.
2. Detail the Work Scope:
 Provide technicians with the job card and vehicle inspection notes.
 Include any specific instructions (e.g., firmware updates, battery testing).

3. Track Progress:
Use a tracking board or software to monitor job status (e.g., In Progress, Awaiting
Parts, Completed).

D. Invoicing

Objective: To prepare and finalize the billing process.

Steps:
1. Review Work Performed:
 Verify that all tasks listed on the job card are completed.
 Check for any additional work performed that was not pre-approved.

2. Prepare the Invoice:

Include:
 Service charges (e.g., labor, diagnostics).
 Cost of replaced parts.
 Applicable taxes and discounts.
3. Customer Approval:
 Review the invoice with the customer.
 Explain charges and resolve any queries.

4. Payment Collection:
 Accept payment through cash, card, or digital modes.
  Provide a receipt to the customer

E. Vehicle Delivery
Objective: To ensure a smooth handover to the customer.
Steps:
1. Final Inspection:
 Check the vehicle for cleanliness, functionality, and charge level.
 Ensure the customer’s complaints are resolved.

2. Demonstrate Repairs:
 Explain what was repaired or replaced.
 Show the vehicle in operation, if applicable.

3. Provide Documentation:
Hand over:
 Invoice and service report.
 Warranty documents for replaced parts.
 Next service due date.

4. Collect Feedback:
 Ask for the customer’s feedback on the service experience.
 Record suggestions or complaints for future improvement
F. Handling Complaints
Objective: To address customer concerns effectively and maintain satisfaction.
Steps:
1. Listen Actively:
 Allow the customer to explain the issue without interruption.

2. Acknowledge the Concern:

 Apologize for any inconvenience and assure prompt resolution.

3. Investigate the Issue:

 Re-inspect the vehicle and cross-check the job card and service notes.
 Identify if the issue is due to:
 Incomplete service.
 New, unrelated problems.
 Customer mishandling.

4. Resolve or Escalate:
 Offer immediate solutions where possible (e.g., free adjustments or rechecks).
 Escalate unresolved complaints to a supervisor or service manager.

5. Follow-Up:
 Ensure the customer is satisfied with the resolution.
 Record the complaint and resolution in the system for reference.

Electric two- and three-wheelers are becoming increasingly popular due to their efficiency and
eco-friendliness. Here's an overview of the technology, systems, and components commonly
used in such vehicles:

Mechanical Systems
1. Brakes:
Types:
 Disc Brakes: Use a rotor and caliper system to provide strong and precise
braking.
 Drum Brakes: Common in cost-effective or rear-wheel braking systems.
Functioning: In electric vehicles, brakes often work in conjunction with
regenerative braking systems, which recover energy during deceleration.
2. Suspension:
 Telescopic Forks: Common for front suspension, offering good
damping and handling.
 Swing-arm Suspension: Used for the rear, often combined with shock
absorbers or spring-damper systems.
 Mono-Shock Systems: Found in some performance-oriented models,
enhancing ride stability.

3. Steering:
 In two-wheelers, the handlebar directly controls the front wheel.
 For three-wheelers, the steering may involve a rack-and-pinion or
linkage system for precise control.

4. Drive System:
 Hub Drive: The motor is integrated into the wheel hub, eliminating the
need for chains or belts. This system is compact, efficient, and low-
maintenance.
 Chain Drive: Transfers power from the motor to the wheel using a
sprocket and chain. It is robust and common in high-torque applications.
 Belt Drive: Quieter and requires less maintenance than chain drives but
is less common in two-wheelers.
Electrical and Electronic Systems
1. Electric Motor (Drive Motor/Hub Motor):
Types:
 Brushless DC Motor (BLDC): Most common due to high efficiency,
reliability, and low maintenance.
 Permanent Magnet Synchronous Motor (PMSM): Offers higher power
density and efficiency, used in performance models.
Functioning: Converts electrical energy into mechanical energy to drive the
wheels.

2. Power Converters:
 DC/DC Converters: Regulate voltage levels for auxiliary systems like
lights, horns, and displays.
 DC/AC Inverters: Convert DC battery power to AC for motors requiring
AC input (e.g., PMSM).

3. Battery and Charging System:

Battery Types:
Lithium-ion: Preferred for high energy density, longevity, and
fast charging.
Lead-acid: Cheaper but heavier and less efficient.

Charging Systems:
Onboard Chargers: Integrated into the vehicle
convenience.
 Fast Chargers: External, high-power units for rapid
charging.

4. Regenerative Braking:
 Captures kinetic energy during braking and converts it into electrical energy to
recharge the battery.
 Functionality relies on the motor acting as a generator during deceleration.

5. Controller:
 Acts as the vehicle's brain, managing motor speed, torque, and power delivery
based on throttle input and other sensors.

6. Generator:
 Sometimes used in hybrid models for generating electricity, though purely
electric two/three-wheelers generally don’t have standalone generators.

Advanced Features
 Battery Management System (BMS):
 Monitors and optimizes battery health, charging, and discharging
processes.
o IOT and Connectivity:
 Features like GPS tracking, app-based controls, and real-time
diagnostics are becoming common.
o Sensors:
 Various sensors monitor speed, temperature, and braking force,
enhancing safety and performance.

Integration of Systems
The seamless integration of mechanical and electrical systems ensures efficient functioning:
 The motor drive and controllers work with the suspension and steering to provide a
smooth ride.
 Regenerative braking reduces wear on mechanical brakes while extending battery
life.
 Power management systems ensure efficient energy usage across all components.

Electric two- and three-wheelers utilize fundamental electrical principles and laws to ensure
efficient operation and integration of various components. Here's a breakdown of key concepts:

Fundamental Terms and Laws

 Ohm's Law:

 Voltage (VVV) across a conductor is directly proportional to the current

(III) flowing through it and inversely proportional to its resistance
(RRR).
 Formula: V=I×R
 V = I \times R
 V=I×R
 Application: Used in designing circuits for optimal voltage and current
flow in motors, batteries, and controllers.
1. Voltage (V):
The potential difference that drives current through a circuit.
Types:
 AC Voltage: Alternating current voltage, less common in EVs but may
appear in charging infrastructure.
 DC Voltage: Direct current voltage, used in batteries and most vehicle systems.
 High Voltage (HV): Seen in some high-performance EVs for enhanced power
delivery.
2. Current (I):
The flow of electric charge.
Units: Amperes (A).
Application: Motors and controllers require precise current management for torque and speed
control.

3. Resistance (R):
 Opposition to the flow of current.
 Units: Ohms (Ω).
Application: Understanding resistance helps in minimizing power losses and improving
efficiency.
 4. Power (P):
 The rate of energy transfer in an electrical system.
 Formula: P=V×IP = V \times IP=V×I (For DC systems).
 Application: Power ratings of motors and batteries determine vehicle
performance.

5. Capacitance (C):
 The ability to store electrical energy in an electric field.
 Units: Farads (F).
 Application: Used in regenerative braking and smoothing voltage in electronic
circuits.

6. Electrostatics:
 Study of electric charges at rest.
 Application: Relevant for insulating materials and understanding battery
charge storage.

7. Magnetics:
 Interaction of electric current with magnetic fields.
 Application: Crucial for motor operation (e.g., BLDC and PMSM motors
rely on magnetic fields for rotation).

8. Inductance (L):
 The ability of a coil to store energy in a magnetic field when current
flows through it.
 Units: Henry (H).
 Application: Used in motor windings and DC/DC converters for energy
transfer.

Electronic Components
1. Discrete Electronic Components:
 Resistors: Regulate current flow.
 Capacitors: Store and release energy; used for noise filtering and power
stabilization.
 Inductors: Store energy in magnetic fields; used in converters and motor controllers.
 Diodes: Ensure current flows in one direction; used in rectifiers.
 Transistors: Act as switches or amplifiers; integral in controllers.
 Semiconductors: Used in power electronics like MOSFETs and IGBTs to manage
high currents and voltages in motor drives and converters.
 UNIT-5
VARIOUS COMPONENTS AND WORKING PRINCIPLE

Key Components and Systems:

1. Battery: Provides electricity to power vehicle accessories.
2. Electric Traction Motor: Drives the vehicle's wheels using power from the traction
battery pack.
3. Power Electronics Controller: Manages the flow of electrical energy from the
traction battery, controlling motor speed and torque.
4. Charge Port: Connects the vehicle to an external power supply for charging the
traction battery pack.
5. DC/DC Converter: Converts higher-voltage DC power from the traction battery pack
to lower-voltage DC power for vehicle accessories and recharging the auxiliary
battery.
6. Onboard Charger: Converts incoming AC electricity to DC power for charging the
traction battery and monitors battery characteristics during charging.
7. Transmission: Transfers mechanical power from the electric traction motor to the
wheels.
8. Traction Battery Pack: Stores electricity for use by the electric traction motor.
9. Thermal System (Cooling): Maintains a proper operating temperature range for the
engine, electric motor, power electronics, and other components.
BATTERIES IN ELECTRIC VEHICLES:
The image contains text that describes different types of commercial automotive
batteries and their characteristics and advantages. The text is divided into sections,
each detailing a specific type of battery. The sections are as follows:

Lead-Acid
Lead-acid batteries are used in conventional cars and trucks for starting, ignition,
lighting and other electrical functions. They are relatively inexpensive and have a
high-power density but a relatively low energy density.

Nickel-Metal-Hydride
Nickel-Metal Hydride (Ni-MH) batteries are commonly used in today’s hybrid
vehicles, and in low-cost consumer applications, such as electric razors,
toothbrushes, cameras and camcorders. They have moderate cost, energy density
about twice that of lead-acid batteries, but lower power density. They have a
higher self-discharge rate and better suit hybrid applications than BEVs, which
typically experience deep discharge cycles.

Lithium-Ion (Li-Ion)
Lithium-ion batteries are commonly used in cell phones and laptop computers and
are becoming the battery of choice for plug-in hybrids and BEVs, as well as some
conventional hybrids. They have several times the energy density and power
density of lead-acid and NiMH batteries, higher charge/discharge efficiency, but
they are more expensive and their temperature must be well controlled.

Lithium Polymer (Li-poly)

Lithium polymer batteries are like other lithium-ion batteries but use a solid
plastic (polymer) electrolyte, making their cell shape more adaptable to specific
spaces within a vehicle. Their other characteristics are like those of other Li-ion
batteries, and they are already being used in some hybrid vehicles.

Lithium Iron Phosphate (LFP)

The lithium iron phosphate battery uses lithium-ion chemistry but with an iron
phosphate cathode. It offers superior heat and chemical stability with no risk of
fire in the event of overcharge or short circuiting, compared to other lithium-ion
batteries.

Principles in Electric Vehicle Systems

1. Principles of Storing Electrical Voltage:
 Batteries: Store energy chemically (e.g., lithium-ion).
 Super capacitors: Store energy electro-statically for rapid charge and
discharge.

2. Electromagnetic Induction:
 Faraday's Law: Voltage is induced in a conductor when it experiences a
changing magnetic field.
 Application: Used in regenerative braking and charging systems.
3. Energy Conversion:
 Electric motors convert electrical energy into mechanical energy.
 Regenerative systems convert kinetic energy back to electrical energy.

4. Power Electronics:
o Convert and manage power flow between the battery, motor, and auxiliary
systems.

Communication Protocols
1. Controller Area Network (CAN):
 A robust communication protocol that enables various electronic control units
(ECUs) to exchange data efficiently.
 Application: Used for motor control, battery management, and system
diagnostics.

2. Local Interconnect Network (LIN):

 protocol for non-critical communications, such as controlling lights or HVAC.
Advanced Concepts
3. Radio Frequency (RF) Communication:
 Used in keyless entry, remote vehicle monitoring, and IoT-enabled features.
4. Automotive Digital Computers:
 Handle real-time data from sensors, motor controllers, and BMS for optimal vehicle
performance.

Safety Protocols and Equipment Handling

Understand safety precautions while working with high-voltage systems.
Activities:
 Identify and wear personal protective equipment (PPE), including insulated
gloves, goggles, and safety boots.
 Practice using insulated tools and equipment.
 Locate and safely disconnect the high-voltage battery (using service disconnect
switches).
Battery Inspection and Maintenance
Learn to inspect, test, and maintain the battery system.
Activities:
 Visual inspection for physical damage, corrosion, and leaks.
 Measure battery voltage using a multimeter.
 Use a diagnostic scanner to check the battery state of charge (SOC) and state of
health (SOH).
 Perform thermal management system checks, ensuring proper coolant flow and
temperature.

3. Electric Motor and Controller Diagnosis

Test and troubleshoot motor and controller functionality.
Activities:
 Inspect motor connections for wear or damage.
 Test motor windings using a megohmmeter for insulation resistance.
 Use diagnostic software to monitor motor temperature, torque, and speed.
 Analyze motor controller fault codes and replace components if necessary.

4. Charging System Testing

Verify proper functioning of the onboard and external charging systems.
Activities:
 Inspect the charging port for dirt, wear, or damage.
 Test the onboard charger and external charger compatibility.
 Measure charging current and voltage during operation.
 Simulate faults (e.g., interrupted charging) and identify errors.

5. Regenerative Braking System

Test the regenerative braking functionality.
Activities:
 Inspect brake pads, discs, and mechanical components.
 Test the regenerative braking system's energy recovery using diagnostic tools.
 Adjust brake system settings if necessary via the control unit.

6. Electrical System Diagnostics

Diagnose faults in auxiliary electrical systems.
Activities:
 Inspect DC/DC converter for proper voltage output.
 Test lighting, horn, and display systems.
 Diagnose faults in wiring harnesses using a continuity tester.

7. Software and Firmware Updates

Update software to optimize system performance.
Activities:
 Connect the vehicle to diagnostic software via the OBD-II or proprietary port.
 Perform firmware updates for the battery management system (BMS), motor
controller, and display unit.

8. Suspension and Steering Check

Ensure proper alignment and smooth functioning.
Activities:
 Inspect suspension components for wear.
 Check steering alignment and adjust if needed.
 Test ride the vehicle to assess ride comfort.

9. Drive System Maintenance

Inspect and maintain chain drive, hub motors, or belt drives.
Activities:
 Clean and lubricate the chain or belt drive.
 Check the hub motor connections and bearings.
 Test torque output using a dynamometer.
10. Diagnostic Practice on Communication Protocols
Understand and diagnose communication protocols like CAN and LIN.
Activities:
 Use a CAN analyzer tool to monitor communication between ECUs.
 Simulate communication faults and troubleshoot them.

11. Hands-on Battery Replacement

Safely replace a battery pack.
Activities:
 Disconnect the old battery and properly handle it for recycling.
 Install a new battery, ensuring all connections are secure.
 Test the system post-replacement for proper functioning.

12. Testing and Final Checks

Ensure all systems are operational.
Activities:
 Perform a full system diagnostic.
 Conduct a road test to validate performance, range, and braking.
 Generate a service report summarizing all tasks completed.