This lab course, "Introduction to Hybrid and Electric Vehicle Engineering," is a senior-level mechanical engineering curriculum that integrates theoretical vehicle dynamics with hands-on experimentation. The lab sequence transitions from computer-based modeling of series hybrid powertrains to physical testing using industrial-grade hardware. Students perform power curve analysis on full-scale hybrid vehicles using a chassis dynamometer, parameterize PID control loops on specialized hydraulic trainers, and program autonomous obstacle avoidance for an unmanned ground vehicle (UGV). The course is heavily dependent on specific institutional laboratory equipment and proprietary software environments for simulation and hardware interfacing.

Fragile Dependencies and Hardware Requirements

• NI DaNI Robotics Starter Kit: The UGV lab is built entirely around this discontinued National Instruments platform. It requires a specific hardware stack:
  • Controller: NI Single-Board RIO (sbRIO) featuring an onboard FPGA and Real-Time processor with 256 MB of nonvolatile memory.
  • Motor Driver: Sabertooth 2X10 R/C (Dimension Engineering) dual motor driver. This must be interfaced with the sbRIO to drive the TETRIX motors.
  • Motors: Two TETRIX DC Drive Motors (W39083) with a 1:52 gear ratio and 400 PPR optical quadrature encoders.
  • Sensors: A 40 kHz ultrasonic rangefinder (2cm to 3m range) integrated via the sbRIO digital I/O.
• MDSP 7000 Series Chassis Dynamometer: The vehicle testing lab requires this specific series of dynamometer for individual wheel control and power curve testing. The lab manual assumes the use of a 2008 Ford Escape Hybrid (Full Hybrid/Parallel configuration) as the test subject; using a different HEV model would require significant recalibration of expected performance values (e.g., the 133 hp engine and 155 hp combined system output).
• FESTO Hydraulic Trainer Kits: The hydraulics labs (modules 2.5, 8.10, and 13) require specialized FESTO equipment. This includes:
  • FESTO Hydraulic Station with a three-way spool valve.
  • Modular PID controllers (P, PI, and PID components).
  • Pressure control loops and dynamic valves capable of introducing disturbance variables like leakage and hysteresis.
• Software Environments:
  • MATLAB/Simulink: Used for the HEV Computer Workshop. The lab requires modeling a Lithium-Ion battery (40 A-hr, 160V nominal) and vehicle dynamics (rolling resistance fr = 0.01, drag Cd = 0.3). While specific versions are not mentioned, the complexity of the "Series HE powertrain mathematical model" suggests a dependency on the Simulink Powertrain Blockset or Simscape.
  • National Instruments LabVIEW: Required for the UGV labs and the "Inverse dynamics-based control of a tire-surface interactive dynamics" workshop. The lab documentation describes algorithms but does not provide the source .vi files, meaning the logic must be manually reconstructed within the LabVIEW environment.
• Digital Access and Documentation: The primary source for the course materials is the ATE Community repository (ate.community), which is a niche educational platform. The specific download URLs for the full 11-module course (e.g., https://ate.community/downloads/870/LTU%20Course.zip) are highly susceptible to link rot or site reorganization.
• Battery and Power Specifications: The UGV requires a specific NiMH battery pack to power the sbRIO and motors, while the HEV simulation assumes a high-voltage Lithium-Ion battery pack with an initial State of Charge (SOC) of 0.75 and a maximum current of 25 A. Variations in these physical parameters will invalidate the provided math models.