Electric Vehicle (EV) Trainer

The EV Trainer provides students with a hands-on experiment set to learn the construction, functionality and benefits of hybrid electric vehicles and inquire the theoretical and practical aspects of Fuel Cell Electric Vehicle. The EV Trainer comes with experiment guide material and educational software.

a. The EV Trainer features cover:

  1. EV Trainer can be operated independently or with a test bench
  2. H2 filling station is used to demonstrate safe vehicle refueling
  3. The modular set-up allow user to examine separate subcomponents or the complete hybrid system
  4. Actual components for real qualitative and quantitative analyses – no simulation
  5. Highly -advanced didactic software for wireless system control, parameter monitoring as well as real-time data plotting
  6. Experiment guide with more than 15 experiments that facilitates auto didactical study and problem resolution.

b. Each set of EV Trainer should consist of:

  1. Electric Vehicle Model
  2. Vehicle Test Bench
  3. Electrolyzer
  4. Software with GUI
  5. Experimental Guide
  6. Accessories

A. Electric Vehicle Model

a. Electric vehicle model is a hybrid fuel cell model car. It consists of:

  1. Energy Control Board
  2. Hydrogen Tanks (including Water Absorber)
  3. Fuel Cell Stack
  4. Supercapacitor
  5. Fan
  6. Roaming Control Batteries
  7. Motor

b. The set must have specification as per below criteria:

  1. Width: 350 mm – 450 mm
  2. Height: 115 mm – 150 mm
  3. Depth: 115 mm – 150 mm
  4. Weight: 1.2 kg – 1.5 kg
  5. permissible ambient operational temperature: +10 °C – +35 °C
  6. motor : output current: 0.28 A – 0.34 A
  7. motor : output voltage: 2.5 V – 3 V
  8. fan : output current: 0.07 A – 0.09 A
  9. fan : output voltage: 5 V – 6 V


  1. Energy Control Board

This central control unit permits for wireless bluetooth system control (e.g. to adjust the vehicle velicity, the electrolyzer/supercapacitor recuperation ratio) besides data measurment and acquisition (e.g. individual cell voltages). The set must have specification as per below criteria:

  • Size

Width: 120 mm -150 mm

Height: 50 mm -70 mm

Depth: 80 mm -110 mm

  • Weight: 180 g – 220 g
  • Sample rate: 0.1 s -5 s
  • Workable with wireless communication
  • Rechargeable batteries with battery charger
  1. Hydrogen Tanks (Including Water Absorber)

The tanks in the car store and deliver hydrogen to the fuel cell stack. The water absorber between the tanks prevents water from entering the fuel cell stack. The set must have specification as per below criteria:

  • Size

Width: 95 mm-115 mm

Height: 95 mm – 115 mm

Depth: 80 mm – 100 mm

  • Weight: 140 g-170 g
  • Min Volume: 30 cm3
  1. Fuel Cell Stack

The fuel cell stack uses hydrogen and oxygen to generate electrical energy. The number of cells can be varied to experiment with different levels of output. The set must have specification as per below criteria:

  • Size

Width: 120 mm -150 mm

Height: 60 mm – 80 mm

Depth: 70 mm – 90 mm

  • Weight: 30 g – 70 g
  • Power Per Cell: 0.2 W – 0.25 W
  • Voltage Max: 1 V – 4.5 V


  1. Supercapacitor

The supercapacitor is used to simulate the battery module in a hybrid EV. It allows for the hybridization of the system using regain energy to power the vehicle by the capacitor only or in parallel with the fuel cell. The set must have specification as per below criteria:

  • Size

Width: 60 mm – 70 mm

Height: 15mm -20 mm

Depth: 35 mm -45 mm

  • Weight: 20 g – 25 g
  • Capacity: 3 F – 3.5 F
  • Output voltage: max. 5 V

B. Vehicle Test Bench (including Test Bench Control Board)

The test bench allows for simulation of typical load profiles and individual drive cycles (e.g. inner city stop-and-go vs highway) The set must have specification as per below criteria:

  • Size

Width: 320 mm -400 mm

Height: 100 mm – 150 mm

Depth: 120 mm – 150 mm

  • Weight: 1 kg – 1.2 kg
  • Motor: Output Current: 1.8 A – 2.2 A
  • Motor: Output Voltage: 2.0 V- 2.5 V
  • E-Load Current Max.: Up to 1 A
  • Power Supply with Internal Reverse Voltage Protection: Up to 5V /4A
  1. Test Bench Control Board

The test bench requires a control board to provide control and monitoring functions for the module. These functions include control the electrolyzer, recuperation of the car and e-load. The set must have specification as per below criteria:

  • Size

Width: 160 mm -200 mm

Height: 30 mm -50 mm

Depth: 100 mm -130 mm

  • Weight: 260 g -320 g

C. Hydrogen Filling Station (Electrolyzer Station)

The hydrogen filling station consists of a electrolyzer that utilizes electricity to decompose water into oxygen and hydrogen. The set must have specification as per below criteria:

  • Size

Width: 125 mm – 150 mm

Height: 265 mm – 320 mm

Depth: 125 mm – 150 mm

  • Weight: 470 g – 570 g
  • Voltage Max: 4 V – 5 V
  • Current Max: 2.5 A – 3 A
  • H2 production rate: 10 cm3- 12 cm3 / min
  • Distilled water: Electrical conductivity: 2 μS – 2.4 μS

D. Software with GUI

The software must have specification as per below criteria:

  1. Software designed to facilitate system control, data acquisition and graphical representation of the collected data.
  2. It serves as a tool for drive cycle simulation, real-time data recording and evaluation, helping users understand and visualize the dynamic flow of energy.
  3. Desirable model drive cycles that can be configured and visualized with the software are:
  • Highway, uphill or downhill
  • Inner city stop-and-go
  • Automatic versus manual data
  • interpretation and plotting
  • Fuel cell performance depending on oxygen supply
  • The recuperation of breaking energy


  1. Hardware and Software Requirements

The hardware and software requirements being supplied must be compatible with minimum specification as per below criteria:

  • Processor: Intel (R) Xeon (R) CPU E5-1603 v3 @2.80GHz 2.80GHz
  • RAM: 8.00GB
  • Graphic: NVIDIA Quadro K620 (2 GB)
  • Storage/Harddisk: 922GB
  • OS: 64bit windows 7 pro

E. Experiment Guide

The experiment guide must have specification as per below criteria:

  1. Experiment guide that is used in conjunction with the educational software to formulate real-life\questions and problems.
  2. The experiment guide also provides detail technical background information for resolving these specific problems such as below theoretical and practical topics:
  • Investigate a hybrid system consist of a fuel cell and supercapacitor.
  • Rolling and breaking: recuperation and electricity storage
  • Simulating load profiles and evaluating drive cycles: city VS. highway; uphill VS. downhill
  • Economic analysis: comparing the cost of a battery powered EV to FCEV to vehicles with an internal combustion engine
  • Electrolyzer efficiency: hydrogen production as a function of time

F. Accessories

Each set of EV Trainer must come with accessories as per below criteria:

1. Electric Vehicle Model:

  • For fuel cell stackelectrolyzer connection: hydrogen pipe for fuel cell stack, t-junction, 2 hose clamps (fre riding valve, purge valve)
  • Side parts, 2x
  • Knurled screws, 6x
  • 15-pins communication cable for car – test bench connection
  • RS232 fuel cell connection cable for car – fuel cell connection
  • Charging cable for supercapacitor
  • Power supply adapter: together with the charging cable for supercapacitor optionally connecting the car control board with the power supply, simulating fuel cell power

2. Vehicle Test Bench

  • Connection cable (1x red, 1x black)
  • Test bench – motor connection (preassembled)

3. Hydrogen Filling Station (Electrolyzer Station)

  • Preassembled: electrolyzer, hydrogen tank distilled water tank), hose clamp
  • Compensation tank
  • Hydrogen pipe
  • Electrolyzer valve

4. Electrolyzer valve

5. Purge valve

6. 2 x Power supply cable

7. Power supply adapter

8. Rechargeable batteries with battery charger

9. Distilled water: 1 bottle, 250ml

10. Bluetooth dongle

11. CD-Rom: Including software, driver and manuals