Chassis Lab Course

Chassis Lab Construction & Assembly

EAS-Chassis Lab: "Switch" Electric Vehicle Assembly

Chassis Lab is a step by step curriculum for teaching electric vehicle technology. The program is designed for grades 9th and up. It is a 16-week course taught and assembled in the automotive lab/shop and classroom. Watch the car on the Discovery Channel . Course sample video here.

Electric Auto Shop Overview

Course Goal: To educate high school, vocational, college, and technical school students about the design, construction, and viability of electric vehicles. The course involves assembly of an electric vehicle drivetrain (provided with course) into the Chassis Lab vehicle (provided with course). The resulting vehicle is a pure drive electric vehicle (EV).

The class will learn the advantages of using an electric drive train, including cost savings, environmental impact, and ease of use. The course includes background theory on electrical power, including definitions and terms (ex: amps, volts, watts, watt-hours, energy, power, aerodynamics, rms voltage, electric mpg, and more). The course also includes brief history and current status of EV technologies and career possibilities in electric transportation industry. The vehicle produced by the class will be street-legal and meet all licensing regulations.

Students will use basic automotive skills and knowledge, supplemented by the Electric Auto Shop Curriculum, to complete the project. No special engineering skills are necessary. All of the components to complete the project are included in the program.

The format for this course is 16 lesson plans in a bound workbook format with test questions and additional activities for each section. Video on DVD is used to demonstrate the hands-on activities taking place in the shop. A 146 page PowerPoint presentation is also included. The timeline to complete the class is one school semester.

Objectives: Electric Auto Shop will help create a professional working atmosphere such as in a technical college training class.

Students will be able to identify the major parts and describe the operation of an electric drive train.
Students will build a working electric vehicle in the conventional Auto Shop classroom under the supervision of the shop teacher.
Students will complete both hands-on and theoretical coursework through lab/shop work, assignments, and testing, to reach a comprehensive understanding of electric vehicle theory, construction, and operation.
Students will emerge with a better knowledge of electric vehicles and how electric transportation can work within the community.
Students will learn the history, facts and current status of EVs.
At the conclusion of the course the class will have produced a working EV which will be introduced to the local community.

Materials included in the curriculum:

Chassis Lab "Switch" Pre-fabricated Assembly Kit
Step-by-Step Vehicle Assembly Guide
25 Units in 8 Modules with Lesson Plans
Instructional DVDs with 50 video segments
146 Slide PowerPoint Presentation
Training Evaluation Form
Video
Machine Shop Video
Tools Video

Module 1: A History of Electric Vehicles
Unit A: Electric Vehicles Through History
Unit B: The Evolution of Manufacturers
Unit C: Advantages of the Electric Drivetrain (download Unit C)

Module 2: Politics and Planning for the Future of Alternative Transportation
Unit D: Energy and the Environment
Unit E: Fuel, Maintenance and Development Costs
Unit F: The Potential of Today's Technology

Module 3: The Basics of Physics and Power
Unit G: Mechanics of Power and Work
Unit H: Turning Electricity Into Motion
Unit I: Work, Energy and Power
Unit J: Energy Storage (download Unit J)

Module 4: Conversion Components
Unit K: Relays, Fuses & Contactors (sample video)
Unit L: Control Circuits (sample video)
Unit M: Motor Controller (sample video)
Unit N: The Electric Motor (sample video)
Unit O: Traction Battery (sample video)
Unit P: Battery Management System (sample video)
Unit Q: Battery Charger (sample video)
Unit R: DC-DC Charger (sample video)
Unit S: Chassis & Suspension (sample video) with Swing Arm (sample video)
Unit T: Gauges, Instruments & Accessories

Module 5: The Conversion Process
Unit U: Work Area Safety
Unit V: The Conversion Sequence

Module 6: Using the Vehicle
Unit W: Driving and Daily Commuting
Unit X: Licensing Maintaining Your EV

Module 7: Promotion, Competition & Careers
Unit Y: EV Events
Unit Z: Education and Careers

Module 8: Exams & Final Conclusions
Transportation Policy
Showrooms of today

Appendix A: Shop Checklists
Appendix B: Tools
Appendix C: Bill of Materials
Appendix D: MSDS Sheets
Appendix E: Schematics
Appendix F: Motor Perfomance Graphs
Appendix G: Component Quiz
Appendix H: Troubleshooting (download Appendix H)
Appendix I: Daily Commute Audit

Electric Auto Shop also provides on-site training for instructors preparing their Chassis Lab Course. During this intensive, five-day clinic, attendees gain hands-on experience by installing the EV components into the Chassis Lab Switch vehicle they will be using in their course. Read about Instructor Training for this course.