Four – Wheeler EV Motor Drivetrain with Electrical Loading Facility Experimental Setup with Data Acquisition, Data-Logging & Variable Loading Functionality with Programmable Motor Controller

The EV Powertrain Experimental Setup with Data Acquisition is a specialized platform designed to analyze and assess the performance of electric vehicle powertrains. Equipped with data acquisition capabilities, it allows in-depth examination and data logging, facilitating research and development in electric vehicle propulsion systems.

Technical Specification:

  • Rated Power – 5KW
  • Motor – Induction Motor
  • Motor Drive – Re Programmable
  • RPM: 3000
  • Peak Power – 9 KW
  • Input Data: Analog
  • Data Rate: up to 500 kbps
  • Device Support: CAN open, Nodes 2.0 other 11-bit identifier CAN protocols.
  • Mode (Motor Response Tuning): Speed Mode Express, Speed Mode, Torque Mode
  • Electrical MC4, 48V-12V-10A
  • Differential – 33 Inches (Or as per design of Workbench)
  • Weighing Loading System – Customized with Platform
  • Connector, Charger, Throttle & Brake Pedal
  • Data Acquisition with PC/Computer System etc.
  • PC with Monitoring Screen, Key pad and Mouse
  • Safety Switches

 

Features are:

  • Understanding the design methodology of Motor Selection
  • Testing of Motor at Different Load
  • Programming and reprogramming of different parameter following i.e. Motor field Effect, RPM, Motor Braking (re-generative Effect), Motor Temperature sensor
  • Motor Acceleration and Deacceleration Control
  • Motor Loading and Unloading and programming for different terrain
  • Data Acquisition System with Desktop provide data curve and cycle diagram; It can provide output and generate text, Excel, Word or MDB database format files
  • Plot Graphs through Experiments and for Academic Research
  • Controller with dual high-performance microprocessors (Understanding Controller for commercial vehicle i.e. MG. Tata and Rewa etc.)
  • Mode Selection for Electric Vehicle (Eco-mode, Sports Mode, Wrap/high Speed Mode)

3 – Wheeler Electric Vehicle Training Setup (E-rickshaw or EV Auto Loader) with BLDC motor

This setup will be mounted on actual original vehicle chassis in Open Format for learning, skill development & experimentation purpose.

Technical Specification:

  • Open Chassis – minimum 1.5 kW
  • BLDC or more, 48V, 3000 RPM
  • Controller – 50Amp
  • DC – DC Convertor – 48V – 12V, 10 Amp, 48V, 30Ah LFP Battery (minimum), with charger, Harness, Lighting, Indicator, Horn, Circuit Breaker, Hand Throttle etc.

2 – W Electric Vehicle Working Model Training Setup

The Two-Wheeler Electric Vehicle Training Workbench is an innovative platform designed to simulate real-world scenarios for electric two-wheelers, facilitating hands-on training and maintenance. It offers data-driven insights and interactive learning experiences, enhancing proficiency in electric vehicle technology.

Technical Specification:

  • Electric 2W -with Open Chassis
  • BLDC Hub Motor – 250W, 48V, 1000 RPM
  • DC – DC Convertor – 48V – 12V, 10 Amp
  • Circuit Breaker – 10Am
  • Load Roller for load & Performance Testing
  • Extern Power Supply/Battery – 48V
  • Harness, Lighting, Indicator, Horn, Circuit Breaker, Hand Throttle & Aluminum
  • Panel with wiring structure diagram etc.
  • Battery Meter for Data Acquisition.
  • Safety and Operational Switches

 

Features are:

  • Electric 2 W Architecture
  • DC Circuit and Component Study
  • Interactive Components Working
  • Digital Infotainment System for Current Consumption at Various Load Condition
  • Efficiency Monitoring of Electric 2W Hub Motor
  • Motor Reverse Potential & Application and Implementation of Convertors

EV Motors (Hub Motor, PMBLDC, PMSM, 3-phase IM, SRM) Cut Section, Li-ion Battery Cut-Section, Component Display Board & EV Wiring Harness Workbench with Informational Posters

The 5.EV Motors Workbench is a comprehensive educational tool designed to provide a hands-on learning experience in electric vehicle (EV) technology. It features cut sections of various EV motors, including Hub Motors, Permanent Magnet Brushless DC (PMBLDC) motors, Permanent Magnet Synchronous Motors (PMSM), and 3-phase Induction Motors (IM). These cut sections offer a detailed view of the internal components and mechanisms, enabling students to understand the construction and working principles of each motor type.

Technical Specification:

  • Electric Motors Architecture
  • BLDC, Hub Motor, SRM, PMSM & Induction Motor – 1000W
  • Controllers – 24Tube 50Amp
  • Extern Power Supply – 48V 28Ah
  • Throttle & On/Off Switch key etc.
  • Circuit and Component Study
  • Interactive Components Working
  • Harness, Lighting, Indicator, Horn, Circuit Breaker, Hand Throttle etc.
  • Electric Vehicle Wiring Harness System (Working)

EV Wiring Harness, IOT & Telematics Training Setup

The EV Wiring harness, IOT & telematics Setup is a specialized setup engineered for comprehensive training and assembly of intricate wiring system in electric vehicles. Equipped with ergonomic features and safety protocols, it offers a practical environment for learning wiring harness configuration and installation techniques in EVs.

Technical Specification:

  • Rated Power – 1KW BLDC Motor 48V, 1000 RPM
  • Controller – 20Tube 50Amp
  • DC – DC Convertor – 48V – 12V, 10 Amp
  • Circuit Breaker – 10Am
  • Harness, Lighting, Indicator, Horn, Circuit Breaker, Hand Throttle etc.
  • Electric Vehicle Wiring Harness System (Working)
  • Battery Meter for Data Acquisition.
  • IOT Kit with Features i.e. Voice Controlled/Alexa Enabled Indicator, Lighting, Navigation, ON/Off Etc.

 

Features are:

  • Architecture Electric Vehicle Wiring Harness System
  • Wire Selection Methodology
  • Blinking Light Power Calculation
  • Current Flow and Load in Electric Circuit
  • Concept of Charging and Discharging
  • Component Tuning and Diagnosis
  • Component Error Analysis
  • Measuring Current Flow in DC – DC Circuit
  • Measurement of hall Effect Sensor

Battery, BMS & CAN Protocol with Data Acquisition System

The Battery BMS and CAN Protocols Training Workbench is a comprehensive platform meticulously crafted to educate and simulate the management systems and communication protocols within electric vehicle batteries. Through hands-on modules and interactive interfaces, it offers practical insights into Battery Management Systems (BMS) and Controller Area Network (CAN) protocols, fostering expertise in EV powertrain technology.

Technical Specification:

  • Loading System Chain and Pully Type
  • Hub Motor – 1200W
  • Battery – 48V, 50Ah Li-Ion
  • Smart BMS 13S with Android Application
  • Controller – 24 tubes, 50Amp,
  • Throttle with Data Logger/Screen etc.
  • Data Acquisition System with i3 Computer system
  • Keyboard and Mouse
  • Workbench with Platform and Cabinet
  • Vehicle Steering System with Braking and Acceleration Provision.
  • Operational and Safety Switches.

 

Features are:

  • Desktop Computer with Application
  • Battery Cell Health Monitoring and Data Graphs for Different Condition under Load on Battery and BMS
  • Smart BMS & Loading System
  • Cell Temperature and Charging and Discharging
  • CAN Protocols – Communication with BMS and Other Components for real time data
  • Battery Parameter Programming & Setting
  • Cell Balancing by Individual cell Testing
  • Battery Performance Analysis while charging and Discharging
  • Battery Design Methodology as per Safety Parameters

Battery Testing Equipment, Battery Charger, Discharger Equipment

The Battery Pack Aging and Capacity Testing setup is a dedicated system crafted for simulating real-world conditions to evaluate the durability and performance of battery packs. Through rigorous load tests and aging simulations, it enables comprehensive analysis, ensuring the reliability and longevity of battery packs in various applications, including electric vehicles and energy storage systems.

Technical Specification:

  • Voltage Range – 48V, 60V & 72V
  • Charging – 10 Amp
  • Discharging – 20 Amp
  • Operation – Semiautomatic
  • Channel – 1C
  • Data Acquisition – With Monitor & wireless Keyboard & Mouse

 

Features are:

  • Computer System along with Installed Software
  • Integrated charge discharge cycle test system of low string lithium battery pack cycle
  • charge and discharge
  • Battery pack function test and charge discharge data monitoring
  • Management software: Based on the windows operation interface, the SQL database is used to store the test data
  • The charge discharge curve can be viewed according to the battery bar code, time and equipment number, and the curve can be exported at the same time
  • Safety protection: anti reverse connection protection function, power failure data protection, support continuous measurement, voltage upper and lower limit setting protection, and safe discharge current protection.

Cylindrical & Prismatic EV Cell Capacity Tester – 5V, 6A, 8Ch

Battery Charging and Discharging and Capacity Testing: A specialized setup for charging, discharging, and capacity testing of batteries, crucial for understanding and optimizing battery performance and efficiency.

Technical Specification:

  • 5V 6Amp – 8 CH
  • Charging Voltage 0-5V
  • Discharging Voltage 5-0.7V
  • Charging Current 0.02A~6A
  • Discharge Current 0.02A~6A
  • Voltage accuracy + 0.05% FS ± 0.05% (RD)
  • Accuracy of + 0.05% FS ± 0.05% (RD)
  • Voltage 1 mV & Current 1 mV
  • Power Output 5~6000W
  • The input power AC 380V/220V + 10% / 50HZ
  • Data acquisition system

 

Features are:

  • Cylindrical, Prismatic & Pouch cell testing
  • Calculate constant current charging ratio, capacity loss, discharge efficiency, average voltage, median voltage and other data, and provide data curve and cycle diagram; It can provide output and generate Text, Excel, Word or MDB database format files
  • 8 Channel Charging and Discharging for Grading and Balancing
  • HPC measurements (coulombic efficiency)
  • Battery/Cells Capacity Testing/Cells IR Testing
  • Battery/Cells scanning system
  • System software

EV Battery Cell Balancer, Bluetooth Enabled and Battery Pack Balancer

The EV Battery Cell Balancer Workbench is an advanced educational tool designed for in-depth learning about battery management systems in electric vehicles. It features a Bluetooth-enabled cell balancer, allowing real-time monitoring and control via mobile devices or computers. The workbench also includes a battery pack balancer, which ensures optimal performance and longevity of the battery by maintaining uniform charge levels across all cells. This hands-on workbench provides students and professionals with practical experience in battery balancing, crucial for the efficient and safe operation of electric vehicle battery packs.

Features

  • Support 2 ~ 24 cells battery packs.
  • Active, balanced energy transfer, the delta-voltage between cells of
  • battery ≤ 5mV.
  • Cell voltage acquisition range 1V ~ 5V, accuracy ±1mV.
  • Support all battery on the market.
  • The balance-current is set independently within the range of 0.3 ~ 4A.
  • Bluetooth function, equipped with mobile APP, support Android and IOS.
  • Balance-Wire resistance detection to find wiring errors in advance.
  • Operating power supply: 25V~100V

 

Operating conditions

  • Temperature range: -20℃~70℃.
  • Operating power supply: 25~100V,Battery power or external power supply can be used.
  • Total current consumption: Work mode 10mA@100V,Idle mode
  • 6mA@100V

Battery Spot Welding Machine for Prototyping

The Li-Ion Battery Assembly for Prototyping and Projects is a versatile kit that provides the essential components and resources for assembling and experimenting with lithium-ion batteries. For assembly of the batteries, the Spot Welding is required and it is the essential welding tool for industry and academia for experiments. Ideal for prototyping and educational projects, this machine empowers users to create custom battery configurations, fostering hands-on learning and innovation in energy storage technology.

Technical & Features are:

  • Welder – 10KVA | Power Supply – AC 380V/ 220V
  • Welding Type – Pneumatic
  • Cell type support – Cylindrical Cell (EV Grade)
  • Assembly of Battery Pack
  • Demonstration on Joining Process

EV Charging Station – AC – 10 KW or Above CCS 2 Type

The AC Charging Station Workbench is a comprehensive setup designed to replicate and analyze alternating current (AC) charging protocols for electric vehicles, providing a controlled environment for studying and optimizing On Grid charging infrastructure and protocols in the EV industry.

Technical Specification & Features are:

  • Phase/ Power Rating – 3 Phase/9.9 kW
  • Operating Type/ IP Rating – IEC60309/16A Socket (optional)/ IP 54
  • AC Power Input Rating – 240±15%
  • AC Power Output Rating – 3X3.3 kW
  • Input Voltage Range – 190Vac-450Vac
  • Charger Connector Type – IS/IEC 60309
  • Ambient Temp – -20°C to 55°C
  • OCPP Protocol 2.0 / App Charging – Yes / Yes
  • User Interface & Control – Ethernet/WiFi/4G Module
  • Cooling Method – Natural Cooling

DC Fast Charging Station

A DC fast charger for a four-wheeler EV (Electric Vehicle) is designed to provide a quicker charging solution compared to traditional AC chargers. DC fast chargers use direct current (DC) to rapidly charge the vehicle’s battery. They are commonly used for public charging stations and are suitable for on-the-go charging scenarios. The charging standard often used for DC fast charging in four-wheeler EVs includes CCS (Combined Charging System) or CHAdeMO, depending on the vehicle and region. These chargers can significantly reduce charging time, making them convenient for long-distance travel and quick pit stops.

Technical Specification:

  • Max Power Output – 30 KW
  • User Aesthetician – with Wifi/GSM/OCPPI6
  • Phase – 3 Phase
  • Operating Temperature & Cooling System – -10 to 55 Degree & Natural / Force Cooling
  • AC Power Input Rating – 415V AC ±10%
  • AC Power Output Raing – 200 – 1000V DC
  • GUN Type – CCS Type 2
  • OCPP Protocol – OCPP 1.6
  • App Charging – Yes
  • Enclosure Protection – IP64 or better
  • Grid Responsive Metering and Billing
  • Smart Charging Solution – Take Care of Grid Load and Varying Charging Demand
  • Support IEC60309 & IEC62196 Standard Connections
  • User Friendly with Application to Monitor Charging and Billing
  • Able to manage charging load

Learning & Development Kit

This kit provides a practical platform for students and researchers to work on innovative projects focused on EV Battery Pack, fostering creativity and practical learning.

Features are:

  • Complete Learning & Development Kits for Battery Prototyping
  • Study on Sub-Component
  • Assembly of Battery Pack (Including All Components with BMS)

 

Technical Specifications:

Learning & Development Kit (for 1 NMC+ 1 LFP + 1 Prismatic Battery Pack of 48V 30Ah each)

  • NMC Cells, LFP Cells & Prismatic Cells
  • BMS 15S 30Amp
  • Cell Holder, Connector & Nickle Strips
  • Battery Indicator
  • Soldering Wire
  • Silicon Wire 7AW (Red + Black)
  • Heat Gun & PVC Heat Shrink Sleeve

Cylindrical Cell LiFePO4 (3.2V, 6000mAh), 32140 (3.2v 15Ah), Prismatic Cell (3.2V 100Ah)

This kit provides a practical platform for students and researchers to work on innovative projects focused on EV Battery Pack, fostering creativity and practical learning.

Electric Vehicle Components Set

Specification:

  • 1 BLDC Motor 1 KW 3000 RPM 48 V
  • 1 HUB Motor 1 KW 1500 RPM 48 V
  • 1 Three Phase Induction Motor
  • 1 CY Controller 48 V
  • 1 Bluetooth Enable Kelly Controller 48 V
  • 1 Normal BMS
  • 1 Daly Bluetooth Enable BMS
  • 1 Differential with BLDC Motor 48 V with Leaf Spring
  • 1 Two-Wheeler Retrofitting KIT with all Equipment’s

Mechanical Toolkits

Mechanical Toolkits are the basic tools that are required for performing the experiments and hands-on training within the lab.

Technical Specifications & Features are:

  • Vernier Caliper, 0-25mm (1)
  • Micrometer 0 – 25 mm (1)
  • Toolkit Box (1)

Electrical Toolkits

Electrical Toolkits are the basic tools that are required for performing the experiments and hands-on training within the lab.

Technical Specifications & Features are:

  • Multimeter (1)
  • Clamp meter (1)
  • Tachometer (1)

Safety Kits

Safety kits will be the essential toolkits for ensuring/precaution the safety during the performing of the practical and hands-on training.

Features are:

  • Safety Kits to ensure the Safety during the Practical’s & Hands-On Training
  • Safety Gloves – 12 Pairs
  • Eye/Face Shield – 5 Pcs
  • First Aid Kit – 1
  • Fire Extinguisher (1)

Technology Layout Poster

Technology Layout Posters are the poster that are being installed on the Wall along with the Workbenches for demonstration and Study purpose of the EV Technology.

Features are:

  • Demonstration & Study Purpose
  • Architecture of the Components &Subcomponents
  • EV Technologies awareness
  • Poster Size – 5×3 Feet
  • Poster Material – Sunboard