Battery Electric Vehicle Jr.

Technician

EXPERIENTIAL LEARNING
IN
INDUSTRY SIMULATED ENVIRONMENT

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 REVISION HISTORY

Sr. No Version Revision Dated

1 1.0 30 May 2022

2
3

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Contents
1 COURSE OBJECTIVE: ........................................................................................................................ 4

2 JOB ROLES: ......................................................................................................................................... 4

3 JOB DESCRIPTION: ............................................................................................................................ 4

4 CAREER PROGRESSION: ................................................................................................................. 5

5 COURSE THEORY & PRACTICAL .................................................................................................... 5

6 LIST OF MINI INDUSTRIAL PROJECTS ........................................................................................... 8

7 LEARNING OUTCOME | HOURS | NSQF LEVEL: ........................................................................... 9

8 LEARNING OUTCOME DETAILS: ..................................................................................................... 9

9 ASSESSMENT CRITERIA: ................................................................................................................ 10

10 ANNEXURE-1-TOOLS & EQUIPMENTS ......................................................................................... 13

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1 Course Objective:
This course helps to develop skills in Electrical Vehicle Service & Maintenance where
candidates will be able to work as Technician on various opportunities in OEMs,
Dealers, Service Centres, Workshops etc.
Through this course, candidates will be able to develop skills on Electrical Vehicle
systems and sub-systems, Design and Assembly of simple vehicle systems, identify
components and their functions, wiring connections in electrical vehicle, furthermore,
perform Troubleshooting, Repair and maintenance of Electric Vehicle systems.
They also understand the regulatory requirements for Automobile.
It will also help to start their own workshop for repair and maintenance of 2 wheelers, 3
wheelers and 4 wheelers.
This is a short-term course.

2 Job Roles:
Own start up and applicable to all the industries (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, Service support assistant,
etc.)

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

 Electrical wiring connection of electrical vehicle,

 Identify root cause of failure
 Trouble shooting
 Perform Repair
 Service the vehicle
 Ongoing maintenance of Electric Vehicle system/s

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4 Career Progression:
The trained candidate can start the technical carrier as Technician promoting to
supervisor, Assistant Workshop Manager and then to Shop Manager and can also
become an entrepreneur.

In the academic field the carrier can be started as trainer promoting to senior trainer
and to Training in-charge.

5 Course Theory & Practical

Practical Knowledge (Theory)

OSH & Safety Practices:  Introduction

 History of Electrical Vehicle
 Fire Fighting in workplace &  Introduction to Electric Vehicle
Precautions Technology
 General Safety of Tools &  Modern Period of Electric Vehicle
Equipment History
 Awareness on OSH related to  Future of electrical vehicle.
the job  Stage Gate Process of Product
Development

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  Advantages and limitations of Electric
vehicle.

 Identification of Electric vehicle

components.  Dynamics of Electric vehicles
 Design Calculation for Motor power  Types of loads acting on vehicle.
calculation.  Motor power calculation.

 Practical on Electric Vehicle setup and

Chassis cut section.  Electric Vehicle Architecture
 Understanding the Electric Vehicle  Types of Electric Vehicle Technology
Architecture from EV setup.  BEV, HEV, PHEV and FCEV.
 Various system and subsystem of
Electrical Vehicle.
 Important systems of Electric Vehicle
and its function.
 Practical on Electric Vehicle Motor.  Electric Vehicle Motors
Remove and install rotor from stator and  Function and working principle of
diagnose motor rotor position sensor. motors used in Electric vehicle.
 Diagnose drive/traction motor-generator  Types of motors used in Electric
assembly for improper operation (such as vehicle.
an inoperative condition, noise, shudder,  Factors affecting on selection of
overheating, etc.). motors.
 Electric Vehicle Controller
 Practical on Motor Controller.  Introduction to Motor controller & its
 Understanding the Motor controller wiring types
diagram and its connection.  Selection of Motor controller.
 Troubleshoot orientation and function
working of motor controller.

 Energy Storage System

 Calculate the battery capacity as per  Introduction to Electric vehicle Battery.
provided inputs and range of vehicle.  Function of Battery and its working
 Test diagnose and repair: battery pack principle.
heating and cooling system, charging  Various types of batteries used in
electric vehicle.
problems, Voltage leaks/loss of isolation.
 Discuss the Advantages and limitations
 Calculation of range, power, voltage, of Electric vehicle batteries.
charging, time, energy requirement for  Introduction to the battery pack.
vehicle.  Cell selection and sizing, Battery layout
design, Battery Pack Construction.

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  Battery connection in series and
parallel.

 DC to DC converter
 Importance of DC-DC Convertor.
 Test, diagnose and determine the repair
 Function and working principle of DC to
needed: DC/DC converter.
DC converter.
 Wiring diagram of DC to DC converter.

 Electric Vehicle Charging System

 Types of Charging system.
 Diagnose and repair problems caused by  Discuss constant current and constant
failed harnesses, connectors, terminals voltage charging.
and fuses.  Electric vehicle charging level
 Develop the Changing system / make the standards.
set up to charge the EV battery.  Electric vehicle charging standards for
connectors.
 Battery charging and discharging
calculations,
 Battery Management System
 Need of Battery Management System
 Verify the BMS system & rectify if needed. (BMS)
 Understanding wiring connection of BMS.  Block diagram of Battery management
 Identify and rectify thermal management system.
system.  Functions and working principle of BMS
 Verify cell and load distribution system.  Thermal management system,
 Identify the SOC & SOH.  Cell load distribution,
 State of Charge (SOC) and SOH
determination.
 Electric vehicle wiring, communications
and safety systems.
 Safety tools and precautions for
 Test, diagnose and determine the repair
working on high voltage system.
needed: System main relay(SMR)
 Differentiation of high voltage and low
malfunctions, data communication bus
voltage system.
network.  Concept of wiring harness, connectors
 Remove and Install High Voltage battery & terminals used in electric vehicle.
pack (Perform high voltage disconnect;  Mechanical and Electrical connection in
reconnect Procedure). EV.
 Identify and rectify the problems raised in  Safety systems for EV.
Supporting systems & accessories,  Relays and wiring connection
 List out the Safety systems used in EV.  Bus networking of data communication
in EV.

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 Regenerative Braking
 What is regenerative braking.
 Functions and working on regenerative
braking.

 Electric vehicle Test Drive.  Latest Trends in Electric Vehicle

 Repair and maintenance of Electric
 List out various sensor used in
Vehicle system
autonomous vehicle.
 Electric vehicle testing.

 List out the Electric vehicle policy in India.  EV Regulation and Policy in India
 Basic Understanding of regulatory
 List out the regulatory requirements for
requirements.
EV
 Policy for Electric Vehicle in India.

6 List of Mini Industrial Projects

S.No. Project Description
1 Project on Electric two-wheeler system.
2 Mini Project on DC to DC convertor.
3 Obstacle avoidance system with Ultrasonic sensor.
4 Block diagram of sensor less controller
5 Parking system for Electric vehicle
6 Auto steering system.
7 IOT implementation for Electric vehicle.
8 Design of optimize battery pack.
9 Scale model of Regenerative breaking system.
10 Any other / Industry live problems.

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7 LEARNING OUTCOME | HOURS | NSQF LEVEL:

Learning outcomes Estimated size

Level
(Learning hours)
Comply with workshop health and
(i) 10
safety guidelines. 3
Assist to identify system and
(ii) 20
subsystem of Electrical Vehicle. 3
Support in selection, testing &
replacement of Motors, DC-DC
(iii) 20
Convertor, Relays and wiring
connection in EV. 3
Assist to charge the EV Battery &
(iv) support to identify the health of EV 20
Battery. 3
Assist to support to maintain EV
regulatory requirements & Safety
(v) 20
precautions for working on high
voltage system. 3
Assist in Repair and maintenance
(vi) 30
of Electric Vehicle system. 3
Assignments (Based on case
(vii) 60
studies and Industrial application) 3
Mini Project (Based on Industrial
(viii) 90
application) 3
Total (A) 270 3

8 LEARNING OUTCOME DETAILS:

 Automobile Mechanic is expected to assist in visual inspection
 Under mechanic’s instruction and perform minor repair.
 He has to maintain the work area, tools and instruments and ensure good working
condition of required tools and instruments.
 The activities identified requires routine and limited range of activities for him as
these activities are independent of job and worksite he is deployed on.
 Automobile Mechanic is expected to have basic knowledge of the instrumentation,
electrical and electronic systems of infrastructure equipment.
 Basic Knowledge of visual inspection techniques and methods and techniques to
check the tool’s calibration Generic knowledge of Common symbols and technique to
read the electrical diagram.

 Automobile Mechanic performs visual inspection of electrical/ electronic and

instrumentation as per the maintenance schedule/ manual and under technician’s
instructions He conducts the basic repair as per laid procedure using appropriate
tools, He keeps the tools and instruments in working condition Thus, he is practically

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 engaged in the maintenance of instrumentation/ electrical / electronic assemblies and
sub-assemblies.
 Automobile Mechanic is expected to conduct the basic visual inspection and report
the faults to mechanic and follow mechanic’s instructions He has to continuously give
and receive instruction and guidance from technician and supervisors in workshop for
repair and routine maintenance work hence they are expected to be good in
communication skills.
 Jobholder is expected to conduct themselves in ways, which show a basic
understanding of the social and professional environment of working at workshops
and on field visits.
The jobholder is responsible to:

 Assist in troubleshooting and diagnosis

 Assist in breakdown repair
 Assist in routine maintenance
 Maintain tools and work area He has the limited responsibility for own work and
majorly function in close supervision of technician.
 In his routine activity he is responsible for his own work.

9 ASSESSMENT CRITERIA:
Outcomes to be Assessment criteria for the outcome
assessed/NOSs to be
assessed
• Comply with safety, health, security and environment
Comply with workshop health
related regulations/ guidelines as per organizational/
and safety guidelines.
manufacturer’s policy.
• Carry out maintenance operations as per the
manufacturers and workshop related health and
safety guidelines/ standard operating procedures.
• Follow safety regulations and procedures with regard
to service workshop hazards and risks.
• Use appropriate protective clothing/ equipment for
specific tasks and work conditions as per service
manual.
• Record and report details related to operations,
incidents or accidents, as applicable.
• Identify various systems and sub systems of vehicle
Assist to identify system and
such as BIW, Chassis, Powertrain, Interiors, climate
subsystem of Electrical
control, seating system, safety system etc.
Vehicle.
• Draw Sketch EV architecture
• Practical on Electric Vehicle setup and Chassis cut
section.

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 • Identify various e power train components and
systems.
• To understand wiring colour codes and its gauge
requirements.
• Practical on electric vehicle components
connect/disconnect and installation procedure.
• Remove and Install battery pack (Perform high
voltage disconnect; reconnect Procedure)
• Tests diagnose and repair: battery pack heating and
cooling system, charging problems, Voltage
leaks/loss of isolation.
• Diagnose and repair problems caused by failed
harnesses, connectors, terminals, and fuses.
• Identify various types of Motors used in EV
Support in selection, testing &
• Power Requirement Calculation
replacement of Motors, DC-
DC Convertor, Relays and • Motor selection
• Assembly and Disassembly of Motors and Motor
wiring connection in EV.
Controller
• Diagnose drive/traction motor-generator assembly for
improper operation (such as an inoperative condition,
noise, shudder, overheating, etc.)
• Repair of AC / DC Motor
• Test, diagnose and determine the repair needed:
DC/DC converter.
• Practical on Motor Controller. Remove and install rotor
from stator and diagnose motor rotor position sensor
• Test, diagnose and determine the repair needed:
System main relay (SMR) malfunctions, data
communication bus network.
• Calculation of range, power, voltage, charging, time,
Assist to charge the EV
energy requirement.
Battery & support to identify
• Calculate the battery capacity as per provided inputs
the health of EV Battery
and range of vehicle.
• List the types of energy storage for EV
• Assembly of Battery Pack
• Practical on battery series/parallel connection.
• Understanding of battery pack thermal management
• Understanding battery management system (BMS)
• Understanding the charging system for EV battery
• EV Safety requirements
Assist to support to maintain
• List out the regulatory requirements for EV.
EV regulatory requirements &

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Safety precautions for working
on high voltage system

• Trouble shooting and Repair and Maintenance

Assist in Repair and
of EV components and systems.
maintenance of Electric
• Understanding electric vehicle wiring system and
Vehicle system
connect/disconnect with various electric vehicle
components
• Identify and rectify thermal management system.
(Verify cell and load distribution system.)
• Identify the State of Charge (SOC) & State of Health
(SOH).
• Identify and rectify the problems raised in Supporting
systems & accessories
Means of assessment 1
The assessment is carried out as below,
 On course Assessment carried out during the period course by providing the
assignment and surprise tests.
 Theory Examination by means of MCQ, written test,
 Practical assessment Role plays, Demonstration, Skill test
 Project work carried out, Presentation of work done and VIVA Voce
Means of assessment 2
The marks allotted for the assessments are as below.
In total of 100 marks are allotted for the Assessments.
SL. No. Description Marks allotted
(100)
(a) On course assessment (Assignments) 15

(b) Theory Examination 20

(c) Practical Assessment 40

(d) Project work, Presentation, Viva Voce 25

Total 100

Result
Minimum passing marks for the Assessment is 60%. The candidate is declared pass
subject to the attendance during the course, the minimum criteria for attendance is 80%.

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10 Annexure-1-Tools & Equipments

Sl.no Item Quantity

1. EV Vehicle 1

2. Electric Vehicle Training Kit 1

3. EV Kit Chassis 1

4. Wheel Rim & Tyre 1 Learning Set

5. Battery 1

6. Motor Controller/ AC Drives 1

7. Solar Charge Controller/ PLC 1

8. Electrical wiring and Accessories 1

9. Next ion TFT Display 1
10. Current Limiting Sensor 10
11. Arduino Mega Controller 1
12. Temperature Sensor 10
13. Thermal Resistive Sensor XR Station 2

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