Project

No. 518423-LLP-1-2011-1-ES-LEONARDO-LMP

TRAINING DESIGN FOR ELECTRO MECHANIC SPECIALIZED IN

MAINTENANCE OF MAIN EV COMPONENTS: BATTERIES,
ELECTRIC MOTORS AND CHARGING STANDS

This project has been funded with support from the European Commission.
This publication reflects the views only of the author, and the Commission
cannot be held responsible for any use which may be made of the information
contained therein.


 TRAINING DESIGN FOR ELECTRO MECHANIC SPECIALIZED IN MAINTENANCE
OF MAIN EV COMPONENTS: BATTERIES, ENGINES AND CHARGING STATIONS


INDEX

Introduction and contextualization 2

Target group 3

Duration 4

General aim and specific objectives 5

Syllabus 6

Methodology 8

Evaluation 9

Material resources 10

Human resources 11

Project Partnership 12

 TRAINING DESIGN FOR ELECTRO MECHANIC SPECIALIZED IN MAINTENANCE
OF MAIN EV COMPONENTS: BATTERIES, ENGINES AND CHARGING STATIONS


Introduction and contextualization
The training design is based on the analysis of knowledge, skills and competences identified in
the professional profile, so that the course contents and methodology are established using a
minimum profile as a basis.

Therefore, it is important to take into consideration that this document not only reflects a
modular training content with specific units, but also includes some specifications required for
an appropriate training development.

 TRAINING DESIGN FOR ELECTRO MECHANIC SPECIALIZED IN MAINTENANCE
OF MAIN EV COMPONENTS: BATTERIES, ENGINES AND CHARGING STATIONS


Target group
The target groups of the course are technicians and engineers who have knowledge about
Electro-mechanics for (Non-Electric or Conventional) Automotive Vehicles (level EQF#3 at
least). According to the professional profile, the training will be designed to cover the
knowledge, skills and competences of level EQF#4.

Notice that there will not be gender bias because it is an objective training design based on
knowledge, skills and competences which were identified previously.

 TRAINING DESIGN FOR ELECTRO MECHANIC SPECIALIZED IN MAINTENANCE
OF MAIN EV COMPONENTS: BATTERIES, ENGINES AND CHARGING STATIONS


Duration
The duration of the course will be adjusted to the peculiarities of the e-learning system
although there will also be some contact hours.

This implies that the duration of the course will be estimated in 500 hours, which corresponds
to 20 ECVET (1 ECVET = 25 hours), divided between two modules with periods of 310 hours (70
practical) and 190 hours (30 practical) respectively. The duration of each unit is detailed in the
syllabus.

 TRAINING DESIGN FOR ELECTRO MECHANIC SPECIALIZED IN MAINTENANCE
OF MAIN EV COMPONENTS: BATTERIES, ENGINES AND CHARGING STATIONS


General aim and specific objectives
The general aim is that, at the end of this training, the participants will be able to acquire the
knowledge, skills and competences required to carry out diagnostic, maintenance and repair of
electric vehicles and their charging stations, including mounting accessories and
transformations in the areas of electricity-electronics, informatics, mechanical and hydraulic of
the electric automotive sector, in line with established procedures and timeframes, meeting
quality specifications, safety and the environment.

With this in mind, the specific objectives are that, at the end of the course, the students will be
able to:

Recognize the Electric Vehicle Architecture and describe the components of the
Electric Vehicle.
Identify the Charge Car Process and Infrastructure and describe the components and
main functions of the Charging Stand.
Select the machines, tools and safety tools, resources and procedures necessary to
carry out maintenance processes in the area of electric vehicles and charging stands.
Locate faults and repair the different subsystems and components of the Electric
Vehicle and of the Charging Stand.
Know the safety standards and regulations of application, identify the safety issues and
know specific preventative and corrective action protocols.
Assess the risks of the use of electro-mechanic systems, understanding the necessity of
safety elements, protections and signalling.
Know the basics of technical and economic management in companies, and the labour
market mechanisms, regulations and normative.
Acquire skills related to teamwork, critical reasoning, decision making and leadership.

 TRAINING DESIGN FOR ELECTRO MECHANIC SPECIALIZED IN MAINTENANCE
OF MAIN EV COMPONENTS: BATTERIES, ENGINES AND CHARGING STATIONS


Syllabus
In order to structure the course in an appropriate manner to facilitate understanding, this will
be divided in two main modules:

Module I: The Electric Vehicle. This module will focus on the Electric Vehicle
Architecture and the different components which comprise it.
Module II: The charging point. This module will focus on the Charging Car Process and
Infrastructure, and the components and main functions of the Charging Stand.

It must be taken into account that the knowledge, skills and competences related to Business
Management will not be taught in specific units but will be given within the two modules
which are the core of the training design.

In addition, each teaching unit will be illustrated with demos (pictures or videos) and there will
be some practical exercises at the end of each module.

The units which are part of the course are detailed below:

MODULE I: The Electric Vehicle

Unit I (40 h) - General concepts of electricity, mechanics, electro-mechanics and
electronics, including fundamentals of electric motors, electro-mechanic parameters
and magnitudes.
Unit II (30 h) - Electric Vehicle Architecture.
o Simple replacement of engine by EM, Optimized GB for EM, Motor hubs, In-
wheel motors, etc.
Unit III (60 h) - Technical analysis of components:
o Traction system
electric motors,
power electronic drives
Transmission, suspension, steering
o Storage systems
batteries, fuel cells, ultracapacitors, flywheels
charging interface,
o Sensors, control and supervision unit.
o Ancillary systems, etc.
Unit IV (20 h) - Considerations prior to servicing.
Unit V (50 h): Safety issues.
o Safety standards and regulations
o Safety issues in EV
Specific issues for tools and equipment
Electro-mechanical measurement, diagnostic and repair tools safety
issues
Personnel protection equipment and systems
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 TRAINING DESIGN FOR ELECTRO MECHANIC SPECIALIZED IN MAINTENANCE
OF MAIN EV COMPONENTS: BATTERIES, ENGINES AND CHARGING STATIONS


High Voltage conditions
High Speed rotating parts
Hazardous substances
Unit VI (20 h) - EV Action Protocols - preventative maintenance
Unit VII (20 h) - EV Action Protocols - corrective maintenance

MODULE II: The charging point

Unit I (40 h) - General concepts of Charge Car Process and Infrastructure.
o Electric Vehicle Charging System (conductive vs. inductive)
o Electric vehicle Supply Equipment (EV power outlets, EV cord sets, EV level
1&2 charging stands)
o Personnel protection systems for EV Supply Circuits
Unit II (40 h) - The Charging Stand
o Components, working principles and main functions
o Charging levels: definitions, electrical & time parameters
Level 1: Slow charging
Level 2: Faster charging
Level 3: Ultra-fast charging
o Wireless charging systems
Unit III (40 h): Safety issues in charging stands.
o Safety standards and regulations
o Safety operation issues
Electrical interlocks
Automatic de-energization of cable
Personnel protection against electrical shock
Ventilation interlocks
o Safety maintenance, diagnostics and repair issues
Specific issues for tools and equipment
Electro-mechanical measurement, diagnostic and repair tools safety
issues
Unit IV (20 h) - PR Action Protocols - preventative maintenance
Unit V (20 h) - PR Action Protocols - corrective maintenance

 TRAINING DESIGN FOR ELECTRO MECHANIC SPECIALIZED IN MAINTENANCE
OF MAIN EV COMPONENTS: BATTERIES, ENGINES AND CHARGING STATIONS


Methodology
Following the European Quality Assurance Reference Framework for Vocational Education and
Training-EQAVET, the methodology of the course will be an e-learning system, although there
will also be face-to-face sessions.

The course content will be developed theoretically with a platform provided for that purpose,
so that students can acquire the knowledge, skills and competences with the help of demos
arranged in the corresponding units.

In addition, efforts will be made to arouse the interest of participants to continue the learning
process, taking into consideration the objectives to be achieved.

 TRAINING DESIGN FOR ELECTRO MECHANIC SPECIALIZED IN MAINTENANCE
OF MAIN EV COMPONENTS: BATTERIES, ENGINES AND CHARGING STATIONS


Evaluation
In order to assess the training, a quantitative evaluation focused on levels I and II of Kirkpatrick
(satisfaction and learning) will be performed.

Furthermore, a monitoring of the training process will be done by the tutors provided by each
entity to verify the achievement of the training objectives, and the participation in the training
will be supervised through the e-learning platform. It should be noted that the evaluation will
be carried out continuously.

Given the specificities of the course and its characteristics as testing activity, framed within the
ELEVTRA Project which is funded by the Lifelong Learning Programme of the European
Commission, data will be collected to produce an evaluation document of the learning
material.

 TRAINING DESIGN FOR ELECTRO MECHANIC SPECIALIZED IN MAINTENANCE
OF MAIN EV COMPONENTS: BATTERIES, ENGINES AND CHARGING STATIONS


Material resources
To carry out the course, it is required to have a personal computer with internet connection, as
well as animation viewer software if necessary. Similarly, there will be an electric vehicle for
the development of practices at the end of each module.

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 TRAINING DESIGN FOR ELECTRO MECHANIC SPECIALIZED IN MAINTENANCE
OF MAIN EV COMPONENTS: BATTERIES, ENGINES AND CHARGING STATIONS


Human resources
To perform the teaching work, the participating entity will propose a collaborator with proven
training in e-mobility. The minimum profile of the collaborator would have to be an engineer
or technician with specific knowledge of:

Electric machines and automotive vehicles.

Power electronics and control systems.
Electronic instrumentation and sensors.

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 TRAINING DESIGN FOR ELECTRO MECHANIC SPECIALIZED IN MAINTENANCE
OF MAIN EV COMPONENTS: BATTERIES, ENGINES AND CHARGING STATIONS


Project partnership

This document has been prepared by:

Project Promoter:
Fundacin Metal Asturias
(Spain)

In colaboration with:

University of Oviedo
(Spain)

Hochschule Bochum
(Germany)

Integrovan stedn kola automobiln ISSA

(Czech Republic)

olski Center Velenje
(Slovenia)

shecco sprl
(Belgium)

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