Electric Vehicle Engineering


Electric car engineers can be any type of engineer who works on electric cars, such as electrical and mechanical engineers who focus their work on electric car design, development and testing. Electric car engineers often collaborate with scientists and managers to design and produce new or improved electric vehicles. They also test the efficiency of the these vehicles to determine the success of their designs.

Education Bachelor’s degree as a minimum
Job Skills Math and science, inquisitive, creative, analytical skills
Median Salary (2017) $95,060 for electrical engineers, $85,880 for mechanical engineers*
Job Growth (2016-2026) 9% for mechanical engineers, 9% for electrical engineers*


Required Education

A minimum of a bachelor’s degree is typically required for electric car engineers. While there are many individuals working in electric car technologies who do not have a degree, a position with a research facility usually requires an advanced degree in electrical engineering.

Skills Required

It is important for a person pursuing a career in electric car engineering to have an aptitude for math and science. He or she must also be inquisitive, creative and analytical. Electric car engineers should be able to function well as part of a team.

1. The Battery Pack

Arguably the most important part of the car is the battery pack. This is usually made up of up to 7000 lithium-ion cells batteries that produce direct current.

The batteries are stacked together with coolant pumped between them to keep them cool and efficient. Batteries are continually getting more and more efficient, so where once an EV could only drive short distances, new cars have ranges of several hundred miles.

2. Inverter

The cars inverter convert the batteries direct current to alternating current. The inverter also plays an important role during regenerative braking that it transfers energy back to the battery.

The inverter also plays an important role during regenerative braking. The kinetic energy of the decelerating vehicle is converted into electricity through the motor and sent back to the battery pack for later use.

3. Induction Motor

Electric cars use induction motors . Depending on the making of the car, this will be either a permanent magnet electric motor, like what you’d find inside a Tesla Model 3, or an AC induction motor.

In both cases alternating current produces a rotating magnetic field that causes it to turn. The difference between the two types is that permanent magnet motor doesn’t need electricity to get the motor to spin as the rare-earth metals are always on.

4. Drivetrain

A single transmission engine transmits this power from the motor to the wheels of the car, and thus drives it forward.

5. Charging

Finally, the charging of the car works when you plug your car into an external power source.

Electric cars can be charged in three ways.

The first is at home using a standard power supply to charge your vehicle, this method takes about 3-8 kilometers per hour to charge. The second method is at a public charge station using 220/240 volt circuit that improves charging time to 16 to 25 kilometers per hour of charge.

The final way is with a DC fast charging station at a specialized charging station. These are only compatible with some vehicle but can provide an 80% charge in just 30 minutes.


DIYguru has specialized electric vehicle engineering capabilities ranging  from design and development to system integration and testing across;

  •  Battery Management System
  •  Power Convertor
  •  Electric Motor control and
  •  Charging infrastructure.

Our In-house electric vehicle prototype is a testimony to our extensive association with development and testing of electric drives, embedded systems and our deep association with Automotive industries.



  • 48V & HV (600V)
  • Cooling System Design
  • Thermal Analysis
  • Enclosure Design
  • Schematic & Board Design, Analysis & Prototype Building
  • 48V & HV (600V)
  • Diagnostics Application Development
  • Algorithm Development – SOC, SOH, Cell Balancing
  • Isolation Measurement
  • Software & Hardware Testing – ASIC C/D Compliance
  • HIL Tester with Battery Simulator


  • High Voltage – High Power DC-DC Converters & Inverters
  • On-Board/Off-Board Battery Chargers
  • Power Electronics Lab with Dynamic Loading
  • High Power Density & Efficiency > 97%
  • Thermal Analysis
  • Active Filters & Rectifiers
  • Modelling & Simulation
  • Harmonic & Sub-Harmonic Design, Analysis & Optimization


  • BLDC/PMSM/Induction
  • Selection/Design & Development


  • CAE – FEM, FEA, Thermal Analysis
  • Lightweighting
  • Forced Air/Liquid Cooling Systems
  • Mechanical Packaging


  • AUTOSAR CoE with Specialists & Engineers
  • Safety Engineering: ISO 26262
  • Model Based Approach for System Behaviour Modelling & Algorithm Development
  • Plant Modelling & HIL


  • PCB Design & Design Analysis (Thermal, Reliability, EMI/EMC, Timing, WCCA)
  • Safety Engineering: ISO 26262
  • Hardware software Integration
  • Prototype Production


  • Multi-protocol support
  • Charger interface module
  • Underbody charger


  • SW safety function, library qualification and testing for ISO26262 ASIL B/C/D
  • Compliance for HEVs & EVs
  • Multiple BMS programs
    with ASIL C
  • Programs with vehicle
    dynamic controller & ESCL with ASIL D
  • Functional safety support for Delphi – SDM 40 and PODS


  • Schematic design & simulation
  • Sizing & optimization
  • Manufacturing drawing & BOM


  • Motor
  • Drive
  • Power system

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Category: Electric Vehicle Engineering

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