Hybrid and Electric Vehicle Design Boot Camp

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Course Overview

Upon completing this course, you will understand:

  • Hybridization levels and types (micro, mild, full, plug-in, and extended range hybrid vehicles, and battery electric vehicle)
  • Driving cycles and fuel economy test methods
  • Traction motor and generator choices and pro’s and con’s
  • Critical concepts such as field weakening and fault tolerance
  • Traction drive power electronics and dc/dc converters
  • Batteries and supercapacitors for traction applications
  • Battery management and battery-charging systems including wireless charging
  • Vehicle dynamics, driving cycles, and torque and power performance requirements
  • Subjects such as new wide bandgap switching devices (SiC and GaN) for traction applications 
  • Turbo and super charging using electric motors

Who Should Attend?

This course will be valuable if you are an engineer involved in designing, developing, specifying, and testing hybrid and electric vehicle systems.

Course Outline

Introduction to Electrified On-Road Vehicles

  • Electric Vehicle Terminology, Basics, and Overview
  • Short History of Electrified Vehicles
  • Legislative Compliance (CO2, Gas and Particulate Emissions) and CAFE rules
  • Environmental Impact and Statistics about Usage
  • Current and Projected Growth

Introduction to Off-Road Vehicles

  • Overview
  • Key Performance Requirements and Considerations

Hybrid and Electric Vehicle Overview

  • Hybridization Levels and types - Micro, Mild, Full, PHEV, EREV, BEV 
  • Hybrid Fuel Savings 
  • Hybrid Architecture Kinematics and Powerflow
  • Real World Benefits and Economic Aspects of Driving Electrically
  • Sustainability Aspects

Vehicle Dynamics and Performance Requirements

  • Equation of Motion
  • Vehicle Road Load Coefficients – Rolling Resistance, Aerodynamic Forces, and Coast Down Testing
  • Vehicle Performance Requirements
  • Peak Engine Power Requirement 
  • ICE Engine Basics and Efficiency Map 
  • System and Motor Efficiency 
  • Efficiency from Plug Power to Road
  • Torque Speed Curves

Driving Cycles and Fuel Economy Test Methods

  • Light Duty Vehicle Standard Drive Cycles
  • M-H Combined Cycle
  • Advantages of a 5-Cycle Combination
  • Heavy Duty Vehicle Drive Cycles
  • Fuel Economy Validation

Review of Traction Motor Candidates

  • Induction
  • Surface PM
  • Switched Reluctance
  • Internal PM
  • Sizing Equations, Pros and Cons

Traction Motor Choices –Internal PM Machine

  • Field Weakening and Fault Tolerance
  • Torque – Speed Curve, Definition of Constant Power Speed Range
  • Torque Production (Magnet vs. Reluctance)
  • Distributed vs. Concentrated Machines

E-boost (Compressors) - Turbochargers

  • Overview of Various Architectures 
  • Application of High Speed Machines

Power Electronics for EV/HEVs

  • Inverters
  • DC/DC Converters
  • Traction Drives (Inverters)
  • DC/DC Converters (300-600 V)
  • DC/DC Converters (300/12 V isolated)
  • Wide Bandgap (SiC and GaN) based Power Electronics

Battery Overview

  • Energy Storage Options and Comparison of Li Ion, NiMH, Lead Acid, Supecapacitor
  • Comparison of Battery and Fuel Cell Systems
  • State-of-the Art Energy Storage Review and Application Examples
  • Sizing Considerations and Projected Technology Development
  • Key Performance Metrics (Specific Power and Energy)
  • Thermal Management
  • Trends in Battery Use and Development
  • Battery Management Systems 
  • SOX functions
  • Functional Safety, ISO 26262

Battery Chargers

  • Level 1, 2, 3
  • Power Electronic Topologies
  • V2G, V2V, etc – Case Studies and Literature Review
  • Wireless Chargers 
  • Issues and Challenges of WPT Chargers
  • Basics of Gyrator Impedance Matching Networks
  • Health and Safety Considerations

Examples of Power Electronics in EVs/HEVs

  • Packaging
  • Capacitor sizing and design
  • Sensors
  • Power devices
  • Power module design
  • Stack-up: reliability and heat management
  • Controller and driver circuitry

Examples of Electric Machines in EVs/HEVs

  • Design trends
  • Magnet quantity, characteristics, and analysis
  • Lamination design
  • Winding techniques
  • Transmission/transaxle overview

Instructors

Timothy Burress

Tim Burress, Electric Machines Team Leader, Oak Ridge National Laboratory, Oak Ridge, Tennessee. Burress has led developments of motor controls and drives as well as comprehensive dynamometer evaluations for over 10 years. He also leads novel machine design projects for transportation applications.

Oliver Gross

Oliver Gross is an energy storage systems specialist for High Voltage Energy Storage Solutions, at Chrysler Group, LLC, where he is responsible for the Battery systems technology roadmap for Chrysler and the Fiat Group. He holds both a BS and a master's degree in materials science from the University of Toronto. Gross has 20 years' experience in the advanced energy storage industry, working at Cobasys, Valence Technology, and Ultralife on various battery technologies prior to his position at Chrysler. He currently holds more than ten patents and has authored more than 20 publications.

Thomas Jahns

Thomas M. Jahns is a Professor with the Department of Electrical and Computer Engineering at the University of Wisconsin–Madison. Previously with GE Corporate R&D and Massachusetts Institute of Technology, Jahns has research interests in electric machines, drive system analysis and control, and power electronic modules.

John Miller

Dr. John M. Miller is owner and founder of J-N-J Miller Design Services PLLC.

He has over 39 years of experience in electrical engineering across various industries that include automotive electrical systems, electric traction drive systems, aerospace/military guidance systems, Dr. Miller held various engineering and senior management positions at Oak Ridge National Lab, Maxwell Technologies, Ford Motor Company, and Texas Instruments. He has published several books related to wireless charging, ultracapacitor applications propulsion systems for hybrid vehicles, automotive power electronics, and vehicular electric power systems.

He holds a Ph.D. from Michigan State University, East Lansing, MI. Dr. Miller is a Life Fellow of the IEEE and Fellow of the SAE.

Bulent Sarlioglu

Bulent Sarlioglu is an associate professor at the University of Wisconsin–Madison and the associate director of the Wisconsin Electric Machines and Power Electronics Consortium (WEMPEC). He previously worked at Honeywell International Inc.'s aerospace division for 11 years, most recently as a staff systems engineer, earning Honeywell's technical achievement award in 2003 and an outstanding engineer award in 2011. Bulent’s expertise includes electrical machines, drives, and power electronics and he is the inventor or co-inventor of 15 US patents as well as many international patents. He received his PhD from University of Wisconsin–Madison, MS from University of Missouri–Columbia, and BS from Istanbul Technical University, all in electrical engineering.

Peter Savagian

Peter J. Savagian is the SVP of Engineering at Ampaire. He also founded Electrified Future, Inc. Prior to working at Ampaire, Pete worked at Faraday Future, a California based start-up Electric Vehicle company.  There Pete led the engineering and supply chain management for a new generation of fully-electric vehicles. Prior to Faraday, Pete worked at General Motors, leading the development of power electronics and electric machines on all electric and hybrid vehicles.  At GM, his accomplishments in the field of electrified drives spanned a range of vehicles, beginning with the first modern Electric Vehicle, the 1996 GM EV1 to the first Plug-in Hybrid, the 2011 Chevy Volt, to the EV value benchmark, the 2017 Chevy Bolt.  He holds 40 patents and has authored 17 technical publications in the field of electrified vehicles. 

 Pete has a BS in Mechanical Engineering from the University of Wisconsin, an MS in Operations Research Engineering from the University of Southern California, and an MBA from Duke University.

Kent Wanner

Kent D. Wanner is a Sr. Staff Power Electronics Design Engineer at John Deere Electronic Solutions (JDES) in Fargo, North Dakota.

After receiving his BSEE in 1996 from North Dakota State University in Fargo, ND, he joined the Electronic Design Department of Phoenix International (now JDES). He spent the next decade designing robust controllers, displays, sensors, and telematics systems for ruggedized vehicle applications. In 2007, Kent became a Design Team Lead in power electronics, applying his vehicle application design expertise to vehicle electrification projects. He and his team have been recognized within John Deere, receiving numerous awards for outstanding innovation, collaboration, and product commercialization in the areas of power electronics and vehicle electrification. He has numerous patents and industry publications related to power electronics and electric motor drive systems. In his current role he provides hands-on vehicle electrification technical leadership for a wide variety of John Deere and non-competing OEM ruggedized vehicle platforms.

Upcoming dates (0)

Take this course when it’s offered next!

Program Director

Bulent Sarlioglu

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