Assembly Technician

Mechanical Sub Assembly Technician

Assembling Parts

Service Technician Role

Industry Structure

Workshop

Assembly Standards (What is Assembly line?)

Assembly line Example& Types of assembly line methods

Step by Step Guide On Car Manufacturing Process

Design, Engineering & Car Manufacturing

Fire Safety

Classes of Fire

Types of Fire Extinguisher

Hight Voltage Safety

5 S’s & Types

5S Continued

Health & Hygiene

Frist Aid & Inhalation Protection

Hazards & Accidents

Manual Handling of loads & PPE

Tools & Handtools

Measuring tools

Nut & Bolt

How to Run an Efficient Assembly Line & Plan in Place

Set Realistic Targets

Communicate With Your Team

Implement Quality Control Measures

Minimize Part Count

Use Modular Components

Improve Ergonomics

Implement Quality Control Checks

Use Assembly Line Software

Avoid stress working in assembly line

Waste Reduction Management

Muda

7 Waste of Industry

Mura & Muri

What is Communication

Why Effective Communication

Importance of respecting personal space of colleagues

Constructive relationships between the organization

How employees judge respect

7 Steps to Respect

Managing Stress

Engineering drawing

Drawing Sheet Size

Standard Dimensioning Symbols/ Safety

Electrical Componets Symbols

Types of Electrical and Schematic Diagram

Pictorial and Block Diagram

Different Engineering drawings & Isometric view

Assembly Drawing

Orthographic projection

3D Projection & Geometrical Drawing

Reading Drawing

Basic Electricity (Generation, Advantages, Application)

Electrical Fundamentals Electron Theory, Atomic Structure, Atoms & Electrical Charges

Electrical Fundamentals (pt2):- Positive and Negative Ions ,Electron Flow

Insulators, conductors and semiconductor properties

Current Flow Theories, Terms Of Electricity

Voltmeter, ammeter, Ohmmeter Mulitmeter

Factors Affecting Resistance Ohm’s Law Electrical Power & Work

Activity; Identify the Phase, Neutral and Earth on power socket, use a tester to monitor AC power

Continuity test for fuses, jumper wires, fusible links, circuit breakers

Identify and Diagnose series, parallel, series- parallel circuits using Ohm’s law

Conductors & insulators, Wires, Shielding, Length vs. resistance

Resistor ratings, Capacitors and Coils

Activity: Perform the pratical on the connection of resistor and Continuity test for fuses

Introduction of Rectifier and inverter Circuit

Component Specification- Resistance, Inductor and Capacitor

Activity: Practice in joining wires using soldering Iron, Construction of Simple electrical circuits

Various terms such as +ve cycle, -ve cycle, Frequency, Time period. Single phase and Three phase supply. Terms like Line and Phase voltage/ currents.

Different type of electrical cables and their Specifications. Types of wires & cables, standard wire gauge (SWG)

Stripping wire insulation, cable colour codes and sizes ,, Crimping of connectors. Measure the gauge of the wire using SWG and outside micrometer

Activity: Prepare terminations, skin the electrical wires cables using wire stripper and cutter.

Quality Measurement Devices : – Checking of holes sizes by using Go/ No go gauge

GO & NO GO Inspection Practice, Plain Plug GO & NO GO Gauge

GO & NO GO Plain Ring Gauge

GO & NO GO Snap Gauge

Nut Thread Gauge

Feeler Gauge in Automobile

Vernier Caliper

Height Gauge

Bore Gauge

8 Dimensions of Quality

Overview of Vehicle Development Process

Material Inspection Report

Raw Material Inspection Report

In-Process Inspection Report

Inward Material Inspection Report

Pre Dispatch Inspection

Advance 5S for Quality Standard

Benefits of 7S

Monitoring and Controlling of 7S

Total Quality Management

Yellow Belt Certification Requirement

Fastening Methods: Bolting, Riveting, Welding

Bearings and Lubrication

Mechanical Joints and Assemblies Types of Materials: Metals, Plastics, Composites

Component Identification and Handling

Welding Machines: Tools used to join metals through processes like arc welding, MIG (Metal Inert Gas) welding, TIG (Tungsten Inert Gas) welding, etc.

Soldering and Brazing Equipment: Tools for joining metals using lower melting point filler materials.

Drills, Sanders, Grinders: Handheld power tools used for various tasks in fabrication and construction

Pneumatic Tools: Powered by compressed air, used for tasks like nailing, painting, etc.

Activity : Utilize hydraulic power for tasks like lifting heavy objects or powering machinery

Milling Machine,Drill Press

CNC Machine (Computer Numerical Control)

Injection Molding Machine

Milling Machine,Drill Press

CNC Machine (Computer Numerical Control)

Injection Molding Machine

History of EV

EV Scenario Global

Top EV Two-Wheeler Producers Company Market Share in % (2023)

Advantages and Disadvantages of EV Two Wheeler

Top 10 Electric 2 -Wheeler in India

Biggest Challenges Facing the EV Industry Today

Government Initiatives for Electric Vehicles in India

Introduction to Electric Vehicle Technology

Comparison of Electric Vehicle with IC engine vehicle based on emissions, range, fuel type.

Types of electric vehicle, BEV, HEV, PHEV and FCEV.

Brief description of powertrain components.

Experiment 1: List of Parts and Specifications of a 2Wheeler

History of Battery

Types of energy storage system

Cells – Cell Types Lead Acid / Liion/ NiMH/NiCad

Cell Selection and sizing, Handling Cells

Why Li-Ion Cells

Lithium Cells Working

Experiment 2: Perform the pratical to verify the Battery Nominal Voltage.

Battery Terminologies

Lithium Chemistry

Battery C- Rating

Cell Types – Form Factors

Lithium Cell Materials

Experiment 3:Check the Charging & Discharging techinques as per the C- rate of the battery.

Cell Assembly Model

Lekage Rate of the battery

Battery Case Design Principles

Battery Case Design – Model (series & parallel connections).

Experiment 4:To obtain the desire Output from Battery (series & parallel connections).

Role of the BMS

Function and parameter of bms

Types of BMS

About Battery thermal mangement System and their types.

Experiment 5:Perform the paratical to understand the Connection and role of BMS.

Making a Cell Arrangement

Assembling complete battery pack.

Experiment 6: Design a Complete Battery pack of 48V Output Voltage.

Introduction to motor

Construction of the motor

Working of the motor

Classification of the motors – Dc motor & Ac motor

Different Industrial appliances with different motors

Electric Vehicle Motors

Introduction of BLDC Motor

Hub Motor

Induction motors

Experiment 7: Introduction about the Different motors and their Wiring Connections.

Comparison of different types of Ev motors

V-I Characterstics of motor

Experiment 8: Measuring the Motor Power with the use of Multimeter.

Speed Regulation of the motor

Experiment 9: Measuring the motor RPM with different Rating Speed.

Torque Characterstics of motor

Peak Load

Balance and Unbalance Conditions

Experiment 10: Measuring Motor Torque and Plot the Torque vs. Speed Curve.

Power Train Components – Controller

Power Electronics Devices – Diode,Mosfet,Transistor

Converter Devices(AC – DC/DC -DC )

Experiment 11: Measurement of Voltage and current parameter.

Working of Motor Control System

Wire Harnesses and Connectors

Standard Colour code the controller

Experiment 12: Draw a Circuit Diagram of Wiring Harness of a 2Wheeler

Chassis mechanical Strength

Wheelbase & Castorl angle

Counter measure to prevent the parts from dropping

Experiment 13: Ergonomic measurement of the Chassis Inspection

To check the air pressure inside the vehicle tires is maintained at the recommended setting.

Experiment 14: Tires specification and its calculations

Drivetrain System

Brake and Suspension

EV Components Assembly

Tips for Removal and Installation

Steps Follow to Dismantle all the Body Parts of a 2/3 Wheeler Vehicle

Making the proper connection of 12 V and 48 V Circuit

Block Diagram of circuit Connections

Experiment 15:Perform the Complete circuit Connection of 2-wheeler

Change the direction of BLDC motor

Interchange the Polarity of power Flow

Experiment 16:Perform the practical while interchange the phase Sequences

 Linear Hall Effect Sensor

Speed apporach of the BLDC motor

Experiment 17:Perform the practical how the Speed various with the use of throttle.

Fault Diagnosis System on motor,controller & throttle

Detection Techniques of components and Wiring harness

Experiment 18:Fault detection and diagnosis(FDD) on the EV components.

Charger Technologies

AC Charging Levels

DC Charging Levels

Charging Modes

Fast Charger Safety

Experiment 19:Understand the Simulation of On – board charging type.

Vehicles charging station –

Type of Charging station

Selection and Sizing of charging station, Components of charging station

Activity Sheet : Draw a Single line diagram of charging station.

QC and Testing (after Assembly 2/3 Wheeler EV)

Inspection of Cable connector

Experiment 20:Perform the Practical of Assemble and Disassemble Along with the Tag system.

Inspection of nuts, bolts and fasteners

Inspection of Control Switches

Steps to Carry out Inspection

Activity Sheet : Fill the Check list Box With observations

Diagnose, repair, and testing of EV vehicles and subsystems

Trace the light circuit – test bulbs, align head lamps, Aiming headlights

Trace the wiring circuit of lighting system

Activity Sheet : Fill the Check list Box With observations

Familiarization and Types & Classification of Switches, Steering lock cum ignition switch

Instrumentation and signaling system Gauges & Meters

Motor temperature gauge, Charging gauge, Speedometer, Tachometer diagnostics

Troubleshoot and Repair –

Acceleration and Braking in EV Functional Safety Understanding driving pattern, accessories usage (HVAC) and drive cycle and driver dependency.