6–9 Months | 30 Weeks | 400–500+ Hours — EV Design • Battery • BMS • Motors • Power Electronics • Charging • Embedded Systems • Diagnostics • AI. Theory + automotive lab + battery lab + electronics lab + simulation + vehicle lab + industry projects.
Program objective: Develop industry-ready EV engineers who understand the complete electric vehicle architecture — from battery chemistry and motor selection to BMS, power electronics, charging, vehicle control, diagnostics and connected/AI-enabled EV systems — not just EV servicing.
Student journey: Understand EV → Battery → Motor → Power Electronics → Design Battery Pack → Develop BMS → Control Motor → Integrate Vehicle → Implement Charging → CAN Communication → Diagnose EV → Thermal Management → Apply AI → Build & Test EV.
Core promise: Don't just learn how an EV works. Learn to engineer the complete electric vehicle.
Target career roles
- EV / Powertrain / Battery / BMS / Motor / Power Electronics Engineer
- Embedded EV, CAN, ECU, Controls, Vehicle Integration Engineer
- Battery Testing, Validation, Quality, Manufacturing, Diagnostics Engineer
- EV Service, Charging Infrastructure, ADAS, Connected Vehicle, EV Data/AI Engineer
Three RASA certification levels
- Level 1 — EV Technology Professional: EV fundamentals + battery + motor + charging + safety
- Level 2 — Professional EV Engineer: Battery + BMS + motor + power electronics + embedded + CAN + diagnostics
- Level 3 — Advanced EV Systems Engineer: Full powertrain + controls + simulation + AI + connected EV
Phase 1 — EV Fundamentals (Weeks 1–2)
Module 01 — Introduction to Electric Vehicles
- ICE → hybrid → PHEV → BEV → FCEV evolution; BEV, HEV, PHEV, FCEV, mild hybrid
- Architecture: battery → BMS → power electronics → motor → transmission → wheels
- Parallel: charging, thermal management, VCU, auxiliary systems
Module 02 — EV Energy & Power Fundamentals
- Voltage, current, resistance, power, energy, efficiency
- Motor power, battery energy, consumption, range, charging time, regen energy
- Example: 60 kWh battery, 15 kWh/100 km — estimate driving range
Phase 2 — Automotive Fundamentals (Weeks 3–4)
Module 03 — Vehicle Engineering
- Chassis, suspension, steering, braking, wheels/tyres, body, HVAC
- Rolling resistance, aero drag, gradient resistance; tractive force calculations
- Practical: Wheel force → motor torque → motor power
Module 04 — EV vs ICE Powertrain
- Compare energy source, prime mover, transmission, emissions, regeneration, control
- Why EV architecture differs — engineering rationale, not component memorization
Phase 3 — Battery Technology (Weeks 5–7)
Module 05 — Battery Fundamentals
- Cell, module, pack; voltage, capacity, energy, C-rate, SOC, SOH, DOD
- Chemistries: lead acid, NiMH, Li-ion, LFP, NMC, NCA, LTO — density, safety, cost, cycle life
Module 06 — Lithium-Ion Battery
- Cathode, anode, separator, electrolyte; cylindrical, prismatic, pouch formats
- Charge/discharge, internal resistance, voltage curves, temperature, degradation
Module 07 — Battery Testing
- Capacity, charge/discharge, cycle, IR, temperature, rate capability tests
- V vs SOC, I vs time, temperature, degradation, efficiency analysis
Phase 4 — Battery Pack Engineering (Weeks 8–9)
Module 08 — Battery Pack Design
- Cell → module → pack; nominal/max/min voltage, capacity, energy, peak/continuous current
- Design: 72 V, 100 Ah EV pack — series/parallel, energy, current capability
Module 09 — Battery Mechanical Design
- Cell arrangement, busbars, enclosure, mounting, vibration, sealing, IP, crash
- CAD: Battery pack enclosure in SolidWorks / Fusion / CATIA awareness
Phase 5 — Battery Management System (Weeks 10–11)
Module 10 — BMS Fundamentals
- Cell V/T monitoring, SOC/SOH, balancing, OV/UV/OC/SC/thermal protection
Module 11 — SOC & SOH
- Coulomb counting, OCV, model-based; capacity/resistance/degradation SOH
- Intro: Kalman filter, EKF, observer-based estimation
Module 12 — Cell Balancing
- Passive vs active balancing; imbalance causes, strategies, losses, thermal impact
Phase 6 — Electric Motors (Weeks 12–14)
Module 13 — Electric Motor Fundamentals
- Brushed DC, BLDC, PMSM, induction, SRM — torque, efficiency, density, cost, control
Module 14 — EV Motor Engineering
- Torque, RPM, power, efficiency, torque-speed curve; starting torque, gradeability, regen
- Practical: Motor selection for passenger EV from weight, acceleration, speed, grade
Module 15 — Motor Control
- PWM, commutation, FOC awareness, torque/speed control
- Regenerative braking: kinetic energy → generator → inverter → battery
Phase 7 — Power Electronics (Weeks 15–16)
Module 16 — EV Power Electronics
- MOSFET, IGBT, SiC, diodes, DC/DC, inverter, on-board charger; DC↔AC conversion
Module 17 — EV Inverter
- Battery DC → inverter → 3-phase AC → motor; PWM, gate drivers, DC link, sensing, protection
Module 18 — DC/DC & Auxiliary Systems
- HV battery → DC/DC → 12 V LV system; lights, infotainment, ECUs, sensors, pumps, fans
Phase 8 — EV Powertrain (Weeks 17–18)
Module 19 — Complete Electric Powertrain
- Battery → BMS → contactor → inverter → motor → transmission → wheel integration
- VCU: accelerator, brake, motor, BMS, charging, regeneration, safety coordination
Module 20 — EV Performance Simulation
- Acceleration, range, consumption, motor power, battery capacity, gradeability, regen
- Tools: MATLAB/Simulink, Python, AVL / equivalent automotive simulation
Phase 9 — EV Charging (Week 19)
Module 21 — EV Charging Technology
- AC/DC/fast charging; EVSE, connector, cable, charger, communication, protection
- Grid → EVSE → OBC/DC charger → battery architecture
Module 22 — Charging Standards
- Type 1/2, CCS, CHAdeMO, GB/T, NACS awareness
- Indian EV charging ecosystem and current standards/guidelines
Phase 10 — Thermal Management (Week 20)
Module 23 — EV Thermal Management
- Heat sources: battery, motor, inverter, charger, DC/DC
- Air, liquid, refrigerant cooling; heat exchangers; temperature → performance → safety → life
Module 24 — Battery Thermal Runaway
- Thermal runaway, propagation, venting, detection, prevention
- Monitoring, cooling, isolation, shutdown, venting safety engineering
Phase 11 — Embedded Systems & CAN (Week 21)
Module 25 — Automotive Embedded Systems
- STM32, ESP32, automotive MCU awareness; UART, SPI, I2C, CAN
Module 26 — CAN Bus (mandatory)
- CAN frames, IDs, arbitration, termination, errors; CAN, LIN, Automotive Ethernet intro
- Practical: BMS → CAN → VCU → inverter message monitoring
Phase 12 — EV Diagnostics (Week 22)
Module 27 — EV Diagnostics
- Fault codes, sensors, actuators, ECUs, CAN messages; OBD, DTCs, live data
- Practical: Simulated EV fault — symptom → data → root cause → repair
Module 28 — EV Service & Maintenance
- Preventive maintenance: battery, motor, cooling, brakes, tyres, charging, HV connectors
- HV isolation, insulation monitoring, battery health, cooling/charging fault diagnosis
Phase 13 — EV Software, Connectivity & AI (Week 23)
Module 29 — Connected EV
- Telematics, GPS, vehicle cloud, remote monitoring, OTA, mobile apps
- Vehicle → telematics → cloud → analytics → mobile/web
Module 30 — AI for EV Engineering
- SOH/RUL prediction, fault detection, range prediction, energy optimization, predictive maintenance
- Project: Battery health prediction from V/I/T/cycles/capacity using ML
Phase 14 — EV Safety & Regulations (Week 24)
Module 31 — High Voltage Safety (mandatory)
- HV architecture, isolation, interlocks, contactors, pre-charge, insulation monitoring
- HV PPE, lockout/tagout, isolation procedure, emergency response, battery safety hazards
Module 32 — EV Standards & Regulatory Awareness
- Automotive, battery safety, charging, electrical safety, EMC, functional safety awareness
- Indian EV regulations and certification ecosystem (periodic review recommended)
Phase 15 — Advanced EV Engineering (Weeks 25–26)
Module 33 — Vehicle Control
- VCU: accelerator/brake, motor command, battery limits, regen, torque request; drive modes
Module 34 — Functional Safety Awareness
- Hazard analysis, risk assessment, safety goals, fail-safe, redundancy, diagnostics
Module 35 — EV Cybersecurity Awareness
- Connected vehicles, CAN vulnerabilities, secure comms, OTA security, data privacy
Specialization Tracks (Week 27)
Tracks A–D
- A — EV Battery Engineering: Li-ion, pack, thermal, BMS, SOC/SOH, testing, recycling
- B — BMS Engineering: monitoring, balancing, protection, CAN, embedded, diagnostics
- C — EV Powertrain: motor, inverter, VCU, torque, regen, sizing
- D — EV Power Electronics: inverter, DC/DC, OBC, SiC, PWM, thermal design
Tracks E–H
- E — EV Charging: AC/DC, EVSE, communication, load management, infrastructure
- F — EV Embedded & CAN: STM32, CAN, protocols, embedded C, ECUs
- G — EV AI & Data Analytics: battery analytics, range, fault detection, optimization
- H — EV Design & CAD: architecture, enclosure, motor mounts, cooling, packaging
Phase 17 — RASA EV Engineering Challenge Capstone (Weeks 28–30)
Capstone options
- Option 1 — Electric Two-Wheeler: battery, BMS, controller, motor, range/speed/grade
- Option 2 — Electric Go-Kart: full build + acceleration/range/thermal/energy tests
- Option 3 — EV Battery Pack: 48/72 V system with CAD, BMS, thermal, safety, testing
- Option 4 — EV Charging System: AC charging station architecture
- Option 5 — AI EV Diagnostics: CAN/sensors → cloud → AI fault prediction
- Option 6 — EV + Solar: solar → charge controller → EV charger → battery
Hybrid Electric Mobility Lab (cross-program)
- Compare BEV vs PEMFC-EV vs hybrid PEMFC+battery architectures
- Efficiency, weight, range, power, energy density, cost, thermal, control strategy
- Links to PEMFC Engineering and Drone Engineering
Labs, toolkit, portfolio & assessment
Eight dedicated labs
- Electrical, Battery, Motor, Power Electronics, Embedded, EV Vehicle, Diagnostics, Simulation
Software & hardware
- CATIA/SolidWorks/Fusion, MATLAB/Simulink, LTspice, STM32, CAN tools, Python ML, KiCad
- Li-ion cells, BMS, BLDC/PMSM, inverter, DC/DC, CAN, battery cycler, HV platform (shared lab)
8–10 mini projects
- Capacity test, cell characterization, pack design, BMS prototype, BLDC control, regen sim, DC/DC, CAN, range calculator, AI SOH
Assessment framework
- EV fundamentals (5%), automotive (5%), battery (10%), pack (10%), BMS (10%), motors (10%), power electronics (10%), powertrain (10%), charging (5%), embedded/CAN (5%), thermal (5%), diagnostics (5%), AI (5%), capstone (10%)
Five engineering layers: ENERGY (battery + charging) → POWER (motor + inverter + DC/DC) → CONTROL (BMS + VCU + embedded + CAN) → VEHICLE (powertrain + dynamics + thermal + safety) → INTELLIGENCE (AI + diagnostics + connectivity).
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