Hybrid and Electric Vehicle Design Boot Camp

Upon completing this course, you will understand:

• Hybridization levels and types (micro, mild, full, plug-in, and extended range hybrid vehicles, and battery electric vehicle)
• Driving cycles and fuel economy test methods
• Traction motor and generator choices and pro’s and con’s
• Critical concepts such as field weakening and fault tolerance
• Traction drive power electronics and dc/dc converters
• Batteries and supercapacitors for traction applications
• Battery management and battery-charging systems including wireless charging
• Vehicle dynamics, driving cycles, and torque and power performance requirements
• Subjects such as new wide bandgap switching devices (SiC and GaN) for traction applications 
• Turbo and super charging using electric motors

This course will be valuable if you are an engineer involved in designing, developing, specifying, and testing hybrid and electric vehicle systems.

Introduction to Electrified On-Road Vehicles

• Electric Vehicle Terminology, Basics, and Overview
• Short History of Electrified Vehicles
• Legislative Compliance (CO₂, Gas and Particulate Emissions) and CAFE rules
• Environmental Impact and Statistics about Usage
• Current and Projected Growth

Introduction to Off-Road Vehicles

• Overview
• Key Performance Requirements and Considerations

Hybrid and Electric Vehicle Overview

• Hybridization Levels and types - Micro, Mild, Full, PHEV, EREV, BEV 
• Hybrid Fuel Savings 
• Hybrid Architecture Kinematics and Powerflow
• Real World Benefits and Economic Aspects of Driving Electrically
• Sustainability Aspects

Vehicle Dynamics and Performance Requirements

• Equation of Motion
• Vehicle Road Load Coefficients – Rolling Resistance, Aerodynamic Forces, and Coast Down Testing
• Vehicle Performance Requirements
• Peak Engine Power Requirement 
• ICE Engine Basics and Efficiency Map 
• System and Motor Efficiency 
• Efficiency from Plug Power to Road
• Torque Speed Curves

Driving Cycles and Fuel Economy Test Methods

• Light Duty Vehicle Standard Drive Cycles
• M-H Combined Cycle
• Advantages of a 5-Cycle Combination
• Heavy Duty Vehicle Drive Cycles
• Fuel Economy Validation

Review of Traction Motor Candidates

• Induction
• Surface PM
• Switched Reluctance
• Internal PM
• Sizing Equations, Pros and Cons

Traction Motor Choices –Internal PM Machine

• Field Weakening and Fault Tolerance
• Torque – Speed Curve, Definition of Constant Power Speed Range
• Torque Production (Magnet vs. Reluctance)
• Distributed vs. Concentrated Machines

E-boost (Compressors) - Turbochargers

• Overview of Various Architectures 
• Application of High Speed Machines

Power Electronics for EV/HEVs

• Inverters
• DC/DC Converters
• Traction Drives (Inverters)
• DC/DC Converters (300-600 V)
• DC/DC Converters (300/12 V isolated)
• Wide Bandgap (SiC and GaN) based Power Electronics

Battery Overview

• Energy Storage Options and Comparison of Li Ion, NiMH, Lead Acid, Supecapacitor
• Comparison of Battery and Fuel Cell Systems
• State-of-the Art Energy Storage Review and Application Examples
• Sizing Considerations and Projected Technology Development
• Key Performance Metrics (Specific Power and Energy)
• Thermal Management
• Trends in Battery Use and Development
• Battery Management Systems 
• SOX functions
• Functional Safety, ISO 26262

Battery Chargers

• Level 1, 2, 3
• Power Electronic Topologies
• V2G, V2V, etc – Case Studies and Literature Review
• Wireless Chargers 
• Issues and Challenges of WPT Chargers
• Basics of Gyrator Impedance Matching Networks
• Health and Safety Considerations

Examples of Power Electronics in EVs/HEVs

• Packaging
• Capacitor sizing and design
• Sensors
• Power devices
• Power module design
• Stack-up: reliability and heat management
• Controller and driver circuitry

Examples of Electric Machines in EVs/HEVs

• Design trends
• Magnet quantity, characteristics, and analysis
• Lamination design
• Winding techniques
• Transmission/transaxle overview

Timothy Burress

Tim Burress, Electric Machines Team Leader, Oak Ridge National Laboratory, Oak Ridge, Tennessee. Burress has led developments of motor controls and drives as well as comprehensive dynamometer evaluations for over 10 years. He also leads novel machine design projects for transportation applications.

Oliver Gross

Oliver Gross is an energy storage systems specialist for High Voltage Energy Storage Solutions, at Chrysler Group, LLC, where he is responsible for the Battery systems technology roadmap for Chrysler and the Fiat Group. He holds both a BS and a master's degree in materials science from the University of Toronto. Gross has 20 years' experience in the advanced energy storage industry, working at Cobasys, Valence Technology, and Ultralife on various battery technologies prior to his position at Chrysler. He currently holds more than ten patents and has authored more than 20 publications.

Thomas Jahns

Dr. Thomas M. Jahns received his bachelors, masters, and doctoral degrees from MIT, all in electrical engineering.

Dr. Jahns joined the faculty of the University of Wisconsin-Madison in 1998 in the Department of Electrical and Computer Engineering.  He served for 14 years as a Co-Director of the Wisconsin Electric Machines and Power Electronics Consortium (WEMPEC), a world-renowned university/industry consortium in the electrical power engineering field.  Since 2021, he is the Grainger Emeritus Professor of Power Electronics and Electrical Machines.

Prior to coming to UW-Madison, Dr. Jahns worked at GE Corporate Research and Development (now GE Global Research) in Niskayuna, NY, for 15 years, where he pursued new power electronics and motor drive technology in a variety of research and management positions. His current research interests at UW-Madison include integrated motor drives and electrified propulsion for both land vehicles and aircraft.

Dr. Jahns is a Fellow of IEEE.  He received the 2005 IEEE Nikola Tesla Technical Field Award “for pioneering contributions to the design and application of AC permanent magnet machines”.  Dr. Jahns is a Past President of the IEEE Power Electronics Society.  He was elected to the US National Academy of Engineering in 2015 and received the IEEE Medal in Power Engineering in 2022.

John Miller

Dr. John M. Miller is owner and founder of J-N-J Miller Design Services PLLC.

He has over 39 years of experience in electrical engineering across various industries that include automotive electrical systems, electric traction drive systems, aerospace/military guidance systems, Dr. Miller held various engineering and senior management positions at Oak Ridge National Lab, Maxwell Technologies, Ford Motor Company, and Texas Instruments. He has published several books related to wireless charging, ultracapacitor applications propulsion systems for hybrid vehicles, automotive power electronics, and vehicular electric power systems.

He holds a Ph.D. from Michigan State University, East Lansing, MI. Dr. Miller is a Life Fellow of the IEEE and Fellow of the SAE.

Bulent Sarlioglu

Bulent Sarlioglu is a Professor at the University of Wisconsin-Madison and the Technology and Collaboration Director of WEMPEC of the Wisconsin Electric Machines and Power Electronics Consortium. From 2000 to 2011, he was with Honeywell International Inc.'s Aerospace Division, Torrance, CA, USA, most recently as a Staff Systems Engineer.  His expertise includes electrical machines, drives, and power electronics, particularly in electrifying transportation and industrial applications. He is the inventor or co-inventor of 22 U.S. patents and many international patents. In addition, he has more than 300 technical papers that are published in conference proceedings and journals. Dr. Sarlioglu received Honeywell's Outstanding Engineer Award in 2011 for his outstanding contribution to aerospace, the NSF CAREER Award in 2016, and the 4th Grand Nagamori Award from Nagamori Foundation, Japan, in 2018.  Dr. Sarlioglu received the IEEE PES Cyril Veniott Award in 2021. Dr. Sarlioglu became a fellow of the National Academy of Inventors in 2021 and an IEEE Fellow in 2022.

Peter Savagian

Peter Savagian is Founder and Principal at Electrified Future, Inc. and is a Senior Advisor to McKinsey and Company.  He advises and consults for companies and venture capital firms in the electrification of transport, mobility and related services.

Peter has pioneered in the EV industry for more than three decades.  At General Motors he was Chief Engineer and General Director of Propulsion systems.  His work included the GM EV1, several hybrids, the Chevy Volt, and the Chevy Bolt EV. He served on the Board of Directors at ElectraMeccanica vehicles, and has led engineering and purchasing activities as Sr VP of Engineering  EV startups Faraday Future, Ampaire and as CTO at Canoo. 

Pete is an advisor to Sibros Technologies, an automotive software connectivity company and H3X, an aviation propulsion company. He also is affiliated as a lecturer at the University of Wisconsin. Pete holds 46 patents and has authored 17 technical publications. His BS is from the University of Wisconsin, MS from the University of Southern California, and MBA from Duke.

Kent Wanner

Kent D. Wanner is a Sr. Staff Electrification Applications Engineer as well as an Engineering Fellow at John Deere in Fargo, North Dakota.

After receiving his BSEE in 1996 from North Dakota State University in Fargo, ND, he joined the Electronic Design Department of Phoenix International (now JDES). He spent the next decade designing robust controllers, displays, sensors, and telematics systems for ruggedized vehicle applications. In 2007, Kent became a Design Team Lead in power electronics, applying his vehicle application design expertise to vehicle electrification projects. He and his team have been recognized within John Deere, receiving numerous awards for outstanding innovation, collaboration, and product commercialization in the areas of power electronics and vehicle electrification. He has numerous patents and industry publications related to power electronics and electric motor drive systems. In his current role he provides hands-on vehicle electrification technical leadership for a wide variety of John Deere and non-competing OEM ruggedized vehicle platforms.