Electric Vehicles Testing and Validation

Electric Vehicles Testing and Validation

Standard Fee : Rs 47,200 (Rs 40,000 + 18%  GST)

Last Date of Registration : 16th April, 2026

Register before 31st March, 2026 to avail an Early Bird discount of  Rs 47,200 Rs. 41,300 (Rs. 35,000 + 18% GST)

SKU: IIT Madras | Start Date: April 17,2026 Category:

Course Description

About The Course:

This comprehensive program provides an in-depth understanding of Electric Vehicle (EV) systems, validation methodologies, and automotive embedded processes. Participants gain exposure to the complete EV product development lifecycle, from concept to certification. The curriculum integrates industry-relevant frameworks such as the V-Model and Functional Safety standards including ISO 26262. It emphasizes Design Verification & Validation (DVVP), DFMEA, and structured testing approaches across vehicle and subsystem levels.

Learners will explore EV batteries, traction motors, controllers, charging systems, and vehicle-level integration. The program also covers homologation requirements, regulatory compliance, and embedded system certification processes. Advanced verification techniques including SIL, PIL, and HIL testing are introduced with industry-standard tools.

Designed for engineers, managers, and academicians, this program bridges the gap between theoretical knowledge and practical EV development practices.

Modules Covered:

Module 1 — Electric Vehicle (EV) Product Development Process
Module 2 — V Model Application
Module 3 — Design Failure Mode Effects Analysis
Module 4 — Functional Safety and CAE Tools
Module 5 — EV Verification - Proto Build
Module 6 — Homologation and Certification
Module 7 — EV Baweries
Module 8 — Electric Two Wheelers
Module 9 — EV Traction Motors
Module 10 — Electric Vehicle Level Testing and Validation
Module 11 — Process and homologation requirements for certification of automotive embedded systems
Module 12 — Verification and Validation of Embedded System

Duration of the Program : 3 Months

Course Start date: April 17,2026

Course End date: July 18 ,2026

Time: Pre- recorded lectures will be released on a weekly basis and Online Live sessions on Saturdays (IST)

Last date of Registration: April 16,2026

Name of the Faculty

Prof. B. Balaji

Department of Engineering Design - IIT Madras

With four decades of experience in almost all facets of Commercial Vehicle design and development defines Prof. B. Balaji as a professional. Armed with a B.E. Mechanical Engineering degree from College of Engineering Guindy, tempered with a PG Diplomas in Advanced Management and Marketing Management, Balaji has served Ashok Leyland in various capacities, and Retired as General Manager, - Product Development at the Technical Centre located in Chennai. In this role, Balaji offered the last line of development process through rigorous vehicle testing methods on and off roads that have rendered Ashok Leyland vehicles as the most reliable in the market. In several engineering domains ranging from vehicle design, analysis and testing, Balaji has been reckoned as a leader. His role in the design and engineering services domain Division of the Hinduja Group exposed him to the Japanese way of vehicle development. In the Product Development department, Balaji has been acknowledged as a technology leader and mentor and is a permanent member of the engineering Design review committees. Prof. Balaji is regarded as an expert in various domains including Vehicle Thermal Systems, Vehicle Dynamics, Suspension, Steering Systems, Vehicle and Component testing, Product Benchmarking and Value Analysis & Value Engineering, Virtual Analysis, Homologation. He has upgraded himself with expertise in electric mobility Under his tutelage, a team of young engineers were motivated to file for three patents in Vehicle Suspension and Thermal Systems development. A Patent for "A cooling System and a Method of cooling an Engine” was granted in 2018 -(Patent No. 295044). Balaji has co-authored technical papers presented in national and international conferences. Post Retirement, Balaji has been providing Technical Consultancy services in the areas of Design and development, VA VE – Cost reduction, Product Bench Marking and Tear down analysis, Electrical Vehicle Design and Development, to Automotive OEMs, Tier I propriety suppliers, EV Start-ups, Consultancy Firms, Engineering services companies.
Prof. Balaji was appointed as Professor of Practice in Engineering design Department in IIT Madras from October 2023. He is delivering Classes in Electric Vehicle Engineering and Development as Elective Course for the regular Students and e mobility Online Certificate Program Course for working professionals hosted by CODE. He is also Engaged with various CoEZET Projects providing technical guidance to the Team of Engineers.

Mr. Sundaresan

Department of Engineering Design - IIT Madras 

Mr. Sundaresan has been an entrepreneur and a technology innovator, designing both products and processes for the past 35 years. A mechanical engineer by education with degrees from IIT Madras and Stanford University, past experiences range from developing hermetic compressors, sheet metal engineering, plant and business digitalization, systems engineering, controls engineering, digital twin, embedded software development tools, and design of commercial electric vehicles. He was part of two start-ups – one wilted, and another got grafted into an MNC. After superannuating from Ashok Leyland after being the Head – New Technologies at its Product Development Center, he is currently a Professor of Practice at IIT Madras in the Department of Engineering Design, promoting industry academia collaboration and research into Zero Emission Trucking technologies, and embedded systems.

Module Description

Electric Vehicle (EV) Product Development Process

Module description

EV product overview, product development phases, and Design Verification & Validation Plan (DVVP) applicable for Electric Vehicles.

Concepts covered

  • Electric vehicle basics

  • Product development swim-line phases

  • Design Verification & Validation Plan (DVVP)

  • Systematic verification planning

Learning outcomes

  • Understanding of electric vehicles

  • Systematic EV product development approach at vehicle and aggregate levels

  • Structured plan for verification testing

Applications of this module

Design testing, simulation, EV laboratory engineering, and academic programs in automotive and EV engineering.

V Model Application

Module description

Application of the V-Model in EV systems engineering along with Design of Experiments (DOE) techniques.

Concepts covered

  • Introduction to V-Model systems engineering process

  • Engineering design workflow

  • DFMET concepts

  • Design of Experiments (DOE) fundamentals

Learning outcomes

  • Insights into V-Model approach for EV testing and verification

  • Application of DOE for testing and analysis

  • Understanding effectiveness of Design Failure Mode and Effects Analysis

Applications of this module

Design testing, simulation, EV laboratory engineering, and faculty involved in automotive and EV engineering.

Design Failure Mode Effects Analysis

Module description

Introduction to DFMEA methodology and its application in Electric Vehicle system design.

Concepts covered

  • DFMEA fundamentals

  • DFMEA for EV systems

  • DFMEA case examples

  • DFMEA process steps

  • Severity, Occurrence and Detection ratings

  • Risk Priority Number (RPN) calculation and interpretation

  • Functional safety requirements as per ISO 26262

Learning outcomes

  • Knowledge of DFMEA process, application, and implementation

  • Understanding functional safety requirements

Applications of this module

Design testing, simulation, EV laboratory engineers, testing and homologation engineers, faculty members, team leads, and functional managers.

Functional Safety and CAE Tools

Module description

Covers functional safety principles and Computer-Aided Engineering (CAE) tools used for EV virtual design and prototype development.

Concepts covered

  • Functional safety fundamentals

  • Introduction to CAE tools

  • Computer-aided virtual engineering software

  • Virtual prototype development

  • Physical prototype development

  • Benefits of prototype validation

Learning outcomes

  • Systematic virtual and physical prototype development process

  • Understanding advanced CAE tools applicable to Electric Vehicles

Applications of this module

Design testing, simulation, EV laboratory engineers, testing and homologation engineers, faculty members, team leads, and functional managers.

EV Verification – Proto Build

Module description

Covers EV prototype verification processes including virtual and physical prototype builds and sign-off procedures.

Concepts covered

  • EV prototype verification

  • Virtual prototype build process

  • Physical prototype build process

  • Prototype sign-off procedures

  • Hard point engineering fundamentals

  • Stakeholder and supplier approval processes

Learning outcomes

  • Understanding the importance of physical prototypes

  • Knowledge of prototype quantities and internal approvals

  • Supplier sign-off procedures

  • Non-conformity criteria and approval processes

Applications of this module

Design testing, simulation, EV laboratory engineers, testing and homologation engineers, faculty members, team leads, proto shop engineers, and managers.

Homologation and Certification

Module description

Introduces regulatory compliance requirements and homologation procedures for Electric Vehicles.

Concepts covered

  • Regulatory and homologation processes

  • Verification and validation architecture

  • EV testing standards

  • Certification procedures

  • Type approval process

  • Retrofit certification

  • EV battery fundamentals

Learning outcomes

  • Understanding regulatory certification processes at component, system, and vehicle levels

  • Knowledge of type approval procedures

  • Fundamentals of EV batteries

Applications of this module

Design testing, simulation, EV laboratory engineers, testing and homologation engineers, faculty members, team leads, and proto shop engineers and managers.

EV Batteries

Module description

Provides knowledge of Electric Vehicle battery technologies, testing standards, and Battery Management Systems.

Concepts covered

  • EV battery basics

  • Battery testing methodologies

  • Battery simulation tools

  • Battery Management Systems (BMS)

  • Battery Thermal Management Systems (BTMS)

  • Validation standards and safety requirements

Learning outcomes

  • Understanding battery validation tests and standards

  • Knowledge of simulation tools

  • Understanding BTMS requirements and importance

Applications of this module

Design testing, simulation, EV laboratory engineers, testing and homologation engineers, faculty members, team leads, proto shop engineers, system supplier engineers, and battery module designers.

Electric Two Wheelers

Module description

Focuses on testing and simulation methodologies for electric two-wheelers considering their rapid adoption.

Concepts covered

  • Electric two-wheeler systems

  • Testing methodologies

  • Virtual simulation processes

  • Performance validation techniques

Learning outcomes

  • Understanding testing methods for electric two-wheelers

  • Knowledge of virtual simulation techniques

Applications of this module

Design testing, simulation, EV laboratory engineers, testing and homologation engineers, faculty members, team leads, proto shop engineers, system supplier engineers, and professionals from two-wheeler industries.

EV Traction Motors

Module description

Explains traction motor technologies and controllers used in EVs along with testing and validation procedures.

Concepts covered

  • EV traction motor fundamentals

  • Motor testing and verification processes

  • Testing standards and methodologies

  • Types of EV controllers

  • Controller functions

  • Vehicle Control Units (VCUs)

Learning outcomes

  • Understanding traction motor functional requirements

  • Knowledge of motor testing and verification

  • Understanding controller validation methods

Applications of this module

Design testing, simulation, EV laboratory engineers, testing and homologation engineers, faculty members, team leads, proto shop engineers, system supplier engineers, and professionals from two-wheeler industries.

Electric Vehicle Level Testing and Validation

Module description

Covers vehicle-level testing procedures including sensors, charging systems, and overall EV performance validation.

Concepts covered

  • EV sensor types and testing

  • Sensor functional validation

  • EV charging system types

  • Charging control parameters

  • Vehicle-level testing methods

  • EV simulation techniques

Learning outcomes

  • Understanding EV sensor testing procedures

  • Knowledge of charging system validation

  • Understanding vehicle-level testing and simulation methods

Applications of this module

Design testing, simulation, EV laboratory engineers, testing and homologation engineers, faculty members, team leads, proto shop engineers, system supplier engineers, and professionals from two-wheeler industries.

Intended Audience

Working professional, Connected with electrical vehicle, Engineering development, Testing validation and simulation from OEM's,Tier 1 Tier 2 companies, Engineering service companies, EV startup's

Eligibility

Working Professionals

Fees

Course fee:

Standard Fee : Rs 47,200 (Rs 40,000 + 18% GST)

Last Date of Registration : 16th April, 2026

Register before 31st March, 2026 to avail an Early Bird discount of  Rs 47,200 Rs. 41,300 (Rs. 35,000 + 18% GST)

Certification

Certification of completion would be awarded to the participants on fulfilling the following criteria:

1. Attending and active participation during all the Live Online Interactive sessions.

2. Submission of Weekly assignments and Module Assessment for all modules.

3. Submit feedback forms for all Modules.

Certificate criteria for this course would be as follows:

Total % will be calculated from all 3 categories 

(Assignments, Quizzes and Attendance of Live sessions)

Type of certificate that will be issued
75% -100% Successfully completed
50% -74% Completed
25% – 49% Participated
<25% No Certificate

Sample Certificate Template:

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