Electric Vehicle Manufacturing

Introduction to Electric Mobility 101

This class introduces users to topics and trends in electric vehicle (EV) manufacturing. Governments and manufacturing organizations are transitioning to EV technology in order to reduce the dependency on fossil fuels. EVs can help reduce carbon dioxide emissions and also lead to financial advantages associated with shifting from combustion fuels. Types of EVs include fully electric, hybrid electric, and fuel cell electric vehicles. Each type has different components and different cost and convenience considerations. As more renewable energy sources are used to develop facilities for EV charging infrastructure, additional environmental and cost benefits can be realized.

After taking this course, users will be able to distinguish between types of EVs, understand the benefits and challenges associated with each type, and become familiar with current trends in electric mobility manufacturing.

  • Difficulty Beginner

  • Format Online

  • Number of Lessons 10

  • Language English

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Course Outline
  • Introduction to Electric Mobility
  • Types of Electric Vehicles
  • Charging Options for EVs
  • Advantages of EV Adoption
  • Intro to EVs Review
  • Electric Mobility and the IIoT
  • Commercial Fleet Electrification
  • Developing Infrastructure and Supply Chain for EVs
  • Future of Electric Mobility Manufacturing
  • Final Review
Objectives
  • Describe electric mobility manufacturing.
  • Distinguish between general types of electric vehicles.
  • Distinguish between charging options for electric vehicles.
  • Describe some advantages of electric mobility.
  • Describe the enhanced IIoT connectivity of EVs.
  • Describe tools and trends for electric vehicle fleets.
  • Describe the goals and challenges of developing EV infrastructure.
  • Describe trends in electric mobility manufacturing.
Glossary
Vocabulary Term
Definition

AC

Alternating current. A current formed when electrons flow in one direction and then the opposite direction. AC is not steady and must often be converted to DC.

acceptance rate

The maximum amount of energy in kilowatts (kW) per hour that an onboard charging device is equipped to handle. Acceptance rates vary for different EV batteries.

aerospace

The industry concerned with the research, design, manufacture, and operation of air and space craft. Aerospace products include airplanes, helicopters, rockets, missiles, satellites, space capsules, space planes, and related systems.

alternating current

AC. A current formed when electrons flow in one direction and then the opposite direction. Alternating current is not steady and is converted to DC to charge EV battery.

battery electric vehicles

BEVs. A type of electric vehicle that uses battery energy alone to power its electric motor. Battery electric vehicles typically use lithium-ion batteries.

battery management system

BMS. A computer that monitors, regulates, and coordinates the operations of a battery pack. The battery management system in an EV may be either centralized or distributed.

BEV

Battery electric vehicle. A type of electric vehicle that uses battery energy alone to power its electric motor. BEVs typically use lithium-ion batteries.

charge ports

A component on an electric vehicle used for connecting electric vehicle supply equipment to charge the vehicle battery. Charge ports vary based on the type of battery and the vehicle manufacturer.

cloud-based

A combination of hardware and software computing technology that allows organizations to access, store, and process data remotely through an internet connection. Cloud-based platforms can provide multiple clients with access to unlimited storage and processing capabilities but require additional cybersecurity considerations.

cobalt

Co. A relatively soft, ductile, magnetic metal. Cobalt is an element in permanent magnets made from samarium cobalt (SmCo) alloys that are used in electric motors.

Combined Charging System

CCS. A connector with additional high-power DC pins to accommodate higher charging power. Combined Charging Systems are the general standard for fast charging in North America.

commercial fleet

A group of vehicles owned by an organization for the purpose of providing a service to customers. Commercial fleets are used for transporting goods and materials or as modes of public transport.

DC

Direct current. Current that travels in one direction. Direct current does not reverse the direction of flow, and used is in the form of electricity used to charge batteries.

direct current

DC. Current that travels in one direction. Direct current does not reverse the direction of flow.

drones

A compact mobile robot that can be guided through programming or the use of a remote control. Drones used in aerospace and military applications often fly, swim, or both.

electric mobility

The use of partially or fully electric motor power to propel a vehicle forward. Electric mobility includes a wide range of vehicle types.

electric motor

A machine that converts electricity into mechanical energy or motion. Electric motors operate on the principle of magnetic induction.

electric motor drive assist

A capability of electric vehicles that uses an electric motor to supply additional power to a car that also uses a combustion engine. Electric motor drive assist capabilities provide power to move a vehicle at lower speeds without combustion power.

Electric vehicle supply equipment

EVSE. The electrical plugs, connectors, and other components used to connect fully electric and plug-in hybrid vehicles to a power source. Electric vehicle supply equipment includes standard or proprietary hardware and software components to communicate digital information and transfer power to the vehicle battery.

electric vehicles

EVs. A vehicle that uses full or partial electric motor power to propel itself forward. Electric vehicles produce less emissions than internal combustion engine vehicles and have better fuel economy.

electrical grid

A network of electrical connections used to transfer electrical power from a source to multiple points of use. Many electrical grid infrastructures use fossil fuel energy, such as coal, natural gas and atomic power as a power source but can also be developed using wind turbines and other renewable energy sources.

EVs

Electric vehicles. A vehicle that uses full or partial electric motor power to propel itself forward. EVs produce less emissions than internal combustion engine vehicles and have better fuel economy.

Fast Charging

A method of charging electric vehicles that converts large amounts of AC from the electric grid to DC within the external charging components, then transfers it directly to the battery engine. Fast Charging provides much faster charging speeds since it converts much higher levels of AC, from 480V to 1,500V and higher.

FCEVs

Fuel cell electric vehicles. A type of electric vehicle that uses an electric motor powered by hydrogen fuel cells to move and operate the vehicle. FCEVs have faster charging speeds than battery electric vehicles but require more energy and cost investment.

fleet management system

A software platform designed to track and manage the activities and logistics of commercial fleet vehicles. Fleet management systems for electric vehicles can track and manage fleet data in greater detail due to the inherent connectivity of EV software systems.

fossil fuels

Any naturally occurring organic fuel formed in the Earth's crust, such as petroleum, coal, and natural gas. Fossil fuels are burned to release stored energy.

fuel cell

A device that uses gases to convert chemical energy into electrical energy. Fuel cells are potentially very efficient power sources.

fuel cell electric vehicle

A type of electric vehicle that uses an electric motor powered by hydrogen fuel cells to move and operate the vehicle. Fuel cell electric vehicles have faster charging speeds than battery electric vehicles but require more energy and cost investment.

fuel economy

The balance between a vehicle's travel distance and the cost of powering the vehicle. Cars with better fuel economy ratings can travel further distances with lower fuel costs than vehicles that require more fuel to travel the same distance.

fully hybrid electric vehicle

FHEV. A type of electric vehicle that uses an electric motor, combustion engine, and internal battery charging to power and operate the vehicle. Fully hybrid electric vehicles do not include charge ports like plug-in hybrid vehicles.

graphite

A soft, black form of carbon (C) that is semimetallic and highly conductive. Graphite is often used as the anode in batteries for electric vehicles.

hydrogen

A colorless, odorless gas, and the most abundant element on the planet. Hydrogen is abundant but requires lots of energy to be converted to fuel and is highly combustible.

ICE

Internal combustion engine. A type of engine in which heat energy and mechanical energy are produced inside the engine. ICEs include gas turbines and types of diesel motors.

IIoT

Industrial Internet of Things. A network of physical devices used in manufacturing that contain computing systems that allow them to send and receive data. The IIoT allows devices to exchange data and automate processes without any human intervention.

Industrial Internet of Things

IIoT. A network of physical devices used in manufacturing that contain computing systems which allow them to send and receive data. The Industrial Internet of Things allows devices to exchange data and automate processes without any human intervention.

infrastructure

The physical equipment and components that make up an electrical grid. Building a sustainable infrastructure for electric vehicles requires upgrading to more renewable energy sources.

internal combustion engine

ICE. A type of engine in which heat energy and mechanical energy are produced inside the engine. Internal combustion engines include gas turbines and types of diesel motors.

iridium

Ir. A hard, brittle metal that is one of six metals in the platinum group. Iridium is expensive since it is one of the rarest of earth elements.

ISO 15118

A digital communication standard for data communication protocols between electric vehicle software and charging equipment. ISO 15118 specifies a plug and charge feature that enables an EV to identify and authorize itself to a compatible charging station on behalf of the driver.

J-plug

A connector, also known as SAE J1772, that is standard for North American electric vehicles. J-plug connectors can handle Level 1 and Level 2 charging power.

Level 1 Charging

A method of charging electric vehicles with alternating current power that uses equipment capable of transferring 120 volts of electrical energy. Level 1 Charging uses power sources commonly equipped in residential homes but has the slowest charging speeds.

Level 2 Charging

A method of charging electric vehicles with alternating current power that uses equipment capable of transferring 240 volts of electrical energy. Level 2 Charging uses power sources often equipped in residential homes and offers faster charging speeds that Level 1 capabilities.

lithium

Li. A lightweight, silver-white metal that is energy-dense, lightweight, and highly reactive. Lithium is the most common element used in electric vehicle batteries.

lithium-ion batteries

A type of secondary cell battery that uses a lithium compound as a cathode and usually graphite or carbon as an anode. Lithium-ion batteries are widely used in portable electronics and electric vehicles.

manganese

Mn. A grayish-white, metallic element that is not naturally magnetic but that can easily be magnetized. Manganese is an element in lithium nickel manganese cobalt (Li-NMC) oxides commonly used as cathode materials in lithium-ion batteries.

neodymium

Nd. A silver-white, rare-earth metal that can be easily shaped. Neodymium is a key element for the high-quality neodymium iron boron (NdFeB) permanent magnets used in some electric motors.

neodymium iron boron

NdFeB. A permanent magnet material made from neodymium (Nd), Iron (Fe), and Boron (B). Neodymium iron boron magnets are typically stronger than samarium cobalt (SmCo) magnets but have lower maximum operating temperatures.

nickel

Ni. A corrosion-resistant, nonferrous metal commonly added to electrodes and stainless steels to prevent corrosion. Nickel is a key element in lithium nickel manganese cobalt (Li-NMC) oxides, which are used as cathode materials in lithium-ion batteries.

onboard charger

A device installed in an electric vehicle that converts alternating current collected and stored from a power source into direct current to power the electric motor. Onboard chargers are equipped on fully electric and plug-in hybrid vehicles, but not fully hybrid electric vehicles.

permanent magnets

A magnet that retains its attractive force once it is removed from a magnetic field. Permanent magnets are used in electric motor components.

PHEV

Plug-in hybrid electric vehicle. A type of electric vehicle that uses both an electric motor, combustion engine, and an onboard charging device to power and operate the vehicle. PHEVs are equipped with charge ports and must be plugged in using electric vehicle supply equipment (EVSE).

plug-in hybrid electric vehicles

PHEV. A type of electric vehicle that uses both an electric motor, combustion engine, and an onboard charging device to power and operate the vehicle. Plug-in hybrid electric vehicles are equipped with charge ports and must be plugged in using electric vehicle supply equipment (EVSE).

propulsion

The force or forces that drive an object forward. Propulsion from electric motor power is used in some varieties of aircraft.

rare-earth elements

One of seventeen known chemical elements found in the earth's crust and various minerals. Rare-earth elements are used in superconductors, electric vehicles, and many other modern technological devices.

regenerative braking

A capability used in electric vehicles that collects and stores energy used from braking to supplement power to the electric motor. Regenerative braking is equipped in both fully electric and hybrid electric vehicle types.

renewable energy

Energy that is naturally and continually replenished without being depleted. Renewable energy sources include solar, wind, and water energy sources.

SAE J1772

A connector, also known as a J-plug, that is standard for North American electric vehicles. SAE J1772 can handle level 1 and level 2 charging power.

samarium

Sm. A silver-white rare-earth metal that is moderately hard. Samarium is a key element for high-quality samarium cobalt (SmCo) permanent magnets used in some electric motors.

samarium cobalt

SmCo. A permanent magnet material formed from cobalt and the rare-earth element samarium. Samarium cobalt magnets can operate under harsher temperatures and conditions than neodymium iron boron (NdFeB) magnets but are slightly less powerful.

Society of Automotive Engineers

SAE. An organization of engineers that sets most industry standards for the testing, measuring, and designing of automobiles and their components.

supply chain

A complex series of exchanges between multiple companies involved in obtaining raw materials, transforming those materials into a product, and delivering the finished product to the customer. Supply chains for electric vehicles rely heavily on the mining and processing of rare-earth elements and other materials.

sustainable

Capable of being maintained without any negative impact on the environment. Sustainable manufacturing involves the use of green manufacturing processes that are nonpolluting, that conserve energy and resources, and are economically sound and safe for all.

Travel range

The maximum distance an electric vehicle can travel on a fully charged battery. Travel ranges for batteries in fully electric vehicles are higher than batteries in hybrid electric vehicles, which also have a combustion engine.

vehicle to grid standard

A digital communication standard for data communication protocols between electric vehicle software and charging equipment. The vehicle to grid standard, ISO 15118, specifies a plug and charge feature that enables an EV to identify and authorize itself to a compatible charging station on behalf of the driver.

vertical takeoff and landing

VTOL. A type of aircraft capable of lifting from the ground, flying, hovering, and landing without the use of a runway. Vertical takeoff and landing aircrafts include both manned and unmanned aircraft types.