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Engineering Professional Development

Hybrid and Electric Vehicle Design Boot Camp

epd.wisc.edu/RA01497 See upcoming dates

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

Past dates