Inside an EV Lab: A Hands-On Learning Experience with Ecosense

As the global transition to electric mobility accelerates, the need for practical, hands-on education in electric vehicle (EV) technologies has never been more urgent. To bridge the gap between theory and application, Ecosense has designed a comprehensive and modular Electric Vehicle Lab, tailored for universities, polytechnic institutes, and engineering colleges.

This lab does not just teach about EVs—it simulates the entire EV ecosystem, offering students, researchers, and educators a real-world platform to understand, experiment, and innovate.

Why Ecosense’s Electric Vehicle Lab?

While EVs offer clear advantages—low fuel costs, minimal emissions, and reduced maintenance—they also introduce new challenges. The workforce entering the EV industry must not only understand batteries and motors but also master drive cycles, charging protocols, power electronics, and vehicle dynamics.

To address this, Ecosense developed RTSCET (Real-Time Simulation and Control in Electrified Transportation)—a turnkey EV education solution based on four pillars:

• Wholesome knowledge and research opportunity
  
• Integrated learning environment
  
• Real-time simulations using actual EV components
  
• Open-source control algorithms and modifiable test cases

Key Focus Areas in the Lab

The EV Lab is divided into two major components:

• MECARP: Modular Electric Car Learning Platform
  
• CONSOLE: Control System of Integrated Learning Environment (acts like the VCU)

These together provide complete visibility and control over each part of the EV.

Let us walk through the hands-on systems that form the heart of the lab:

Battery Cycler with Data Analytics

This platform enables in-depth testing and analysis of EV traction batteries under various operating conditions.

Key Features:

• Charge/discharge using CC, CV, CP modes
  
• Analysis at various C-rates
  
• Simulations at varying temperatures using an environmental chamber
  
• Real-time state-of-health (SoH) evaluation
  
• Data-driven selection of batteries based on performance, cost, and lifecycle
  
• Continuous monitoring via FPGA controller + PC-based software

Students learn to compare new vs aged batteries, evaluate degradation, and select optimal battery configurations based on actual data.

BMS Training and Research System

Battery Management Systems (BMS) are essential for safety and efficiency. This platform allows students to:

• Experiment with SoC estimation algorithms (Coulomb counting, Kalman filter, etc.)
  
• Simulate and test overvoltage, overcurrent, thermal protection
  
• Analyze active cell balancing
  
• Understand thermal cut-offs and protective logic
  
• Bring their own battery (BYOB) for testing and training

 The platform is modular and open-source, enabling students to test and even develop their own BMS logic for customized applications.

EV Driveline Simulator

The EV drivetrain is simulated with all real components and supplemented by a dynamometer to emulate real driving resistance.

Components Include:

• PMSM Motor
  
• Motor controller with regenerative braking
  
• Power electronics and converters
  
• Dynamometer for road simulation
  
• Application software + FPGA controller for simulation and data analysis

·         Key Features:

• Drive Cycle Simulations
• Speed -Torque Curves
  
• Efficiency Maps
  
• Motor Analysis (4 quadrant)
  
• Open Source software with editable code

A critical system for drive testing, algorithm verification, and understanding motor-inverter-dynamometer coordination.

Modular and Adaptive EVSE (Electric Vehicle Supply Equipment)

This platform enables deep dives into EV charging—from AC slow charging to DC fast charging.

Learning Stages:

• Start-up Phase
  
• Communication between EV and charger using OCPP, CCS, CAN protocols
  
• Charging Cycle
  
• Charging via onboard and off-board chargers
  
• Monitoring voltage, current, temperature
  
• Shutdown Phase
  
• Controlled termination of charging with proper handshake

The system’s open-source platform allows users to modify charging algorithms and test charging strategies, enabling real-time learning and development.

Meet CONSOLE: The Brain of the Lab

CONSOLE acts as the VCU and integrates all subsystems under one umbrella. Built on LabVIEW and FPGA, it enables:

• Real-time monitoring of battery status, charging cycles, motor activity, and drive simulations
  
• Execution and recording of test cases across modules
  
• Export of data for post-processing and research

CONSOLE provides a single software window to control and analyze the complete EV ecosystem, ensuring unified learning and ease of use.

Sample Experiments from the Lab

A. Battery Testing:

• Charging/discharging under different C-rates
  
• SoH evaluation post multiple cycles
  
• Performance at varying ambient temperatures
  
• Fuel economy vs battery aging

B. BMS Testing:

• SoC estimation algorithm comparison
  
• Thermal cutoff analysis
  
• Overvoltage and overcurrent testing

C. Drive Simulation:

• Torque-speed and dynamic characteristics
  
• Drive cycle-based performance mapping
  
• Inverter power flow analysis under varying loads

D. EVSE Testing:

• AC vs DC charging characteristics
  
• Effect of algorithm tuning on charge efficiency
  
• Communication diagnostics between EV and charger

Education Meets Innovation

The EV Lab is designed to progress from beginner-level to advanced research, enabling:

• Student projects and internships
  
• MTech thesis support
  
• B.Tech/M.Tech final year projects
  
• Faculty-led R&D and publications
  
• Industry collaboration for product development

It also serves as a Centre of Excellence where industry professionals and trainers can be upskilled in a structured environment.

Technical Edge

• Fully modular and scalable system
  
• Integrated vehicle simulation without the need for a physical EV
  
• Detailed software control with data export for research
  
• Support for multiple drive cycles and component configurations
  
• Safety-integrated system suitable for classroom use
  
• Allows open algorithm development for BMS, motor control, and charging

Ecosense’s Electric Vehicle Lab is not just a set of tools—it is a complete learning environment designed to prepare students for the future of mobility. By focusing on real components, open development, and holistic understanding, it empowers students to innovate, question, and build solutions for a cleaner tomorrow.

Whether you are a university planning a new curriculum or an engineering college aiming to lead in clean mobility education, the Ecosense EV Lab offers the right blend of practicality, scalability, and academic depth.