Key features:

• Six integrated EV training modules on a single platform.
• Real, upcycled vehicle components for realistic feel.
• Fault-injection and diagnostic training modules.
• Interconnectable modules to demonstrate full-vehicle workflows.
• Training panels with color-coded schematics and test points.
• Mobile caster bases for classroom reconfiguration.
• Suitable for vocational schools, universities and OEM/aftermarket training.

Module 1 — Battery Management & Pack Training:

Purpose: Practical and theory training on traction battery design, BMS functions and safe handling.

Includes: battery pack, high-voltage harness, BMS ECU, low-voltage harness, color-coded test panel, fault-injection module, locking swivel casters.

Hands-on labs / learning outcomes:

• Battery pack structure and safety procedures.
• Charge/discharge testing and capacity measurement.
• Temperature and voltage sensing.
• BMS data logging, diagnostics and fault tracing.
• Pack removal, sealing strip assembly/disassembly.
• Over-temperature and over-current protection tests.

Module 2 — Motor Drive & Drivetrain

Purpose: Teach electric motor operation, inverter interaction and mechanical drive components.

Includes: drive motor with gearbox, half-shaft, braking hardware (master cylinder, booster, claw), vacuum pump, cooling tank/fan, dashboard & shift interface, start switch, OBD diagnostic set, HV/LV cables, test panel, fault module, casters.

Hands-on labs:

• Motor and transmission disassembly/assembly.
• Speed and torque signal measurement.
• Drive-system voltage and temperature monitoring.
• Fault simulation and troubleshooting procedures.

Module 3 — Vehicle Control & Inverter

Purpose: Demonstrate inverter, vehicle control logic, and integration with BMS and motor systems.

Includes: inverter assembly, charging port, HV relay, HV/LV cabling, control test panel, fault-injection module, casters.

Hands-on labs:

• Control system wiring and signal flow.
• Real-time signal detection and scope-friendly test points.
• Control system fault diagnosis and repair procedures.
• Integration exercises with BMS and motor modules.

Module 4 — Electric HVAC (Air Conditioning)

Purpose: Illustrate EV HVAC operation and its interaction with vehicle electrical systems.

Includes: evaporator box, condenser, compressor, cooling fan, pressure and temperature sensors, heater and circulation pump, HVAC control panel, HV/LV cabling, test panel, fault module, casters.

Hands-on labs:

• HVAC system operation and component identification.
• Pressure and temperature diagnostics.
• Fault simulation for compressor, fans and sensors.
• Integration with battery and drive systems.

Module 5 — Electric Power Steering (EPS)

Purpose: Teach structure and control of electric steering systems vs hydraulic alternatives.

Includes: steering wheel and column, steering actuator/motor, front axle interface, steering sensors, associated cabling, diagnostic test panel, fault module, casters.

Hands-on labs:

• EPS component functions and architecture.
• Signal and torque sensing tests.
• EPS fault diagnosis and repair workflows.
• Comparison of EPS vs mechanical/hydraulic steering.

Module 6 — Body Electrical & Vehicle Systems

Purpose: Cutaway vehicle body showcasing instrument clusters, lighting, door systems, windows, wipers, audio and body network signals.

Includes: cutaway body section, headlights/fog/lights, door assemblies, window motors, door lock actuators, wiper/wash motors, fuse box, body ECU, low-voltage battery, test panel with terminal points, CAN-BUS test points, fault-injection module, casters.

Hands-on labs:

• Lighting and accessory electrical troubleshooting.
• Central locking and window motor diagnostics.
• Wiper system disassembly/assembly and testing.
• CAN-BUS signal monitoring and error tracing.

General Specifications:

• Power: Standard mains; separate isolated HV training harnesses and clearly labeled LV circuits.
• Mobility: Modules mounted on lockable swivel casters for classroom layout flexibility.
• Safety: Clearly marked HV barriers, emergency disconnects, protective covers and operator safety procedures.
• Diagnostics: Color-coded test panels, labelled probe points and integrated fault injection per module.
• Data: BMS and control modules expose telemetry for monitoring and classroom exercises.
• Materials: Reconditioned OEM components mounted on robust training frames.

Typical applications:

• Automotive technical colleges and vocational centers.
• University EV labs and research teaching.
• OEM/aftermarket technician upskilling.
• Corporate training for EV service teams.