AutoCad Technician

Module 3 session 1

Hello and welcome to this video on the Process of coordinating with co-workers to achieve work
efficiency. Today we are going to learn the layout design process.

It is key to remember that as an AutoCAD technician, you shall be responsible for creating and
designing various designs that help in the construction of various types of machineries.

In this session, we will discuss how to read and interpret electrical drawings and understand the
basics of simulation tools and electric vehicles.

Let’s begin with Reading and Interpreting Electrical Drawings

Electrical drawings are the technical documentation that show and record designs for electrical
systems.

Technicians use these documents to install systems, showing every connection and component
with a unique symbol.

For large projects, a full set of working drawings includes: a plot diagram, floor drawings with
panel boards, single-line diagrams, general arrangement diagrams, and control wiring
schedules.

Understanding these diagrams helps technicians properly install electrical systems.

To read and interpret these drawings, it’s important to first identify common symbols like
resistors, capacitors, transformers, and switches.

Wiring diagrams show how components are connected using lines for wires and symbols for
components.

Single-line diagrams simplify the entire system, showing only the main components and flow of
electricity.

Understanding electrical drawings allows technicians to troubleshoot systems, ensure safety,

and maintain compliance.

Now, let’s discuss how to identify the simulation tools necessary during product design.

Simulation tools are essential for decision-making in design, allowing engineers to assess,
compare, and optimize designs.

Start by analyzing the car's performance requirements, such as speed, fuel efficiency, and
safety standards.

Next, assess the car's components like the chassis, engine, and electrical systems. Each part
may require a specific simulation tool to evaluate its performance and robustness.
Don’t forget to consider regulatory compliance. Tools should be capable of ensuring the vehicle
meets noise, emission, and safety standards.

Remember..Virtual prototyping is key. It allows engineers to simulate and optimize designs

before physical testing begins, using tools like CFD and FEA.

Ensure the simulation tools can integrate with CAD software and other simulation platforms to
facilitate seamless design workflows.

It’s also important to choose tools that align with the expertise of your team, ensuring they can
effectively use them.

Ensure that the simulation tools are cost-effective and resource-efficient. Balance the
investment against the benefits in terms of time saved and improved product quality.

By carefully selecting the right simulation tools, engineers can optimize the design process from
concept to production.

Now, let's discuss the key components of an electric vehicle (EV) that are tested using these
tools.

First - The battery pack stores electricity, while the electric motor converts this energy into
mechanical power to drive the vehicle.

Next is the Power electronics, including inverters and converters, manage the flow of electricity
between the battery, motor, and other systems.

Moving on to The charging system. It allows the vehicle to recharge from an external power
source, while the thermal management system ensures components stay cool.

Next are the regenerative braking that the EV’s use to convert kinetic energy into electrical
energy, which is stored back in the battery.

Lastly, The Vehicle Control Unit (VCU) manages the power train and other systems, monitoring
battery status and energy flow.

Understanding these components and how they work together is crucial for designing efficient
and reliable electric vehicles.

Finally, we’ll look at basic technology used in vehicles, including mechanical, electrical, and
electronic systems.

Mechanical systems include the engine, transmission, suspension, and brakes, responsible for
power generation and control.

Electrical systems power everything from the starter motor to sensors and switches, while
electronic systems control functions like ABS and airbags.

So….by understanding how these systems interconnect, engineers can ensure a safe, efficient,
and seamless driving experience.

Thank you for watching

MODULE 3 SESSION 2

Greetings and welcome to our video on Process of coordinating with co-workers to achieve
work efficiency. Today we are going to learn how to Support Manager in Finalising the Layout
Design

It is key to remember that as an AutoCAD technician, you should be able to create a 3D model
of a product using CAD techniques based on customer information. This includes preparing
layouts and various views to illustrate relationships between components and assemblies.

Additionally, you should apply drawing and drafting aids, such as colours and symbols, to
highlight key areas in the

drawings.

Helping the line manager develop criteria and specifications for a car product requires careful
attention to detail, teamwork, and continuous communication. This involves gathering input from
engineers, designers, and market analysts

to understand functional, aesthetic, and regulatory requirements. By evaluating consumer

needs, technological advances, and competitive benchmarks, these specifications are
documented clearly and revised as needed based on feedback. Additionally, proactive risk
management, addressing production viability, costs, and market acceptance, ensures the
product meets both consumer

expectations and industry standards.

Supporting the line manager in creating a system for collecting design output in the automotive
sector involves key steps for precision and efficiency. First, collaborate with engineers and
product managers to define design requirements. Then, implement tools like PLM, CAD, and
ERP to manage data, while standardising workflows with templates and version control.
Training teams, ensuring quality control, and integrating design output with other development
stages are crucial. Continuous feedback and process optimization ensure ongoing
improvement.

Now let’s learn how to communicate with the APDM in prioritising key reliability risk items with
the help of this video clip.

In this roleplay we saw how to take support from Production Design Manager in Prioritising Key

Reliability Risk Items, now let's go through a methodical process to estimate and assess the
design reliability of automotive products. The first step is to identify reliability conditions by
defining the product's key features, establishing performance levels, and ensuring safety. Next,
conduct a Failure Modes and Effects Analysis also called FMEA to pinpoint potential failure
modes and assess their severity, likelihood, and detectability. Calculate the Risk Priority
Number to prioritise mitigation efforts, and use fault tree analysis to illustrate how single-
component failures can lead to overall system breakdowns.
After identifying potential failures, collect and analyse data using historical information and
simulations. Predict reliability metrics with models like MIL-HDBK-217 and calculate the Mean
Time Between Failures for key components. Then, enhance the design through root cause
analyses and Design for Reliability principles, validating improvements via testing. Finally,
monitor field performance, document findings, and communicate results to stakeholders to
ensure automotive products meet quality and market expectations.

Once assessing product design reliability is done, the next step is to create Simulations.
Simulation involves imitating real-world systems over time by creating models that reflect their
key characteristics and behaviours. By experimenting with these models, simulations predict
system performance in various scenarios. Tools like CAD, CAM, CAE, CFD, FEA, and PLM are
vital in industries, especially in product design and engineering, as they enable the creation,
execution, and analysis of simulations to enhance design accuracy and efficiency.

The key tools for product design simulations include CAD for creating 2D and 3D models, CAM
for manufacturing instructions, and CAE for tasks like finite element and thermal analysis. CFD
simulation fluid dynamics, while FEA assesses product behaviour under stress. PLM software
manages the entire product lifecycle, and electronics simulation tools optimise electronic circuit
performance. Together, these tools improve the design process by enhancing functionality,
performance, and reliability.

Now that we've discussed simulation tools, let's move on to the process of designing the vehicle
and its components. Designing a vehicle starts by defining requirements like performance,
safety, and customer preferences. Next, conceptual designs are made focusing on looks and
function. Then, detailed designs set material specs and dimensions. The vehicle is tested
through simulations and prototypes, with improvements made based on feedback.

After refining the design, manufacturing planning begins, including sourcing materials and
setting up production processes. Components are made, assembled, and integrated, with
quality checks throughout. Final testing ensures performance and safety, and the vehicle is
delivered to customers, with ongoing support and improvements based on feedback.

So to sum up, with your support to the line manager in defining product specifications and
capturing design outputs, we can ensure a reliable product meets both consumer

expectations and industry standards.

Thanks for watching

MODULE 3 SESSION 3

Hello and welcome to this video on the process of coordinating with co-workers to achieve work
efficiency and today we are going to learn how to check for the reliability and validity of the
created layout design
As an AutoCAD Technician, you should coordinate with the product design team and other
departments to review designs and gather feedback on the accuracy and validity of drawings for
production. Additionally, you will conduct quality inspections of drawings and sketches, ensuring
they meet various tolerance levels.

In the automotive sector, product reliability and accuracy are ensured through thorough testing
and analysis. Endurance tests, simulations, and environmental assessments check for
dependability, while fault tree analysis identifies potential failures.

Prototype testing validates designs against benchmarks and regulations, ensuring that vehicles
meet safety and performance standards.

Reliability testing checks how well a product will last and perform over time. It uses methods like
simulating its lifespan, testing it in different environments, analyzing potential failures, and
predicting when it might break. These techniques help improve the product's design to make it
strong and durable.

Design validity is established through prototype testing to evaluate functionality, CAE

simulations for performance analysis, and virtual prototyping for real-world condition
simulations. Benchmarking compares designs to industry standards, and expert evaluations
assess feasibility, manufacturability, and compliance

Integrated design approaches ensure reliability, performance, and compliance. Design for
Reliability addresses failures early, while validation testing confirms performance and safety.
Customer feedback and field testing validate real-world use, and regulatory compliance ensures
adherence to industry standards.

In automotive product design, failure risk analysis starts with Failure Modes and Effects Analysis
or the FMEA, identifying and prioritizing potential failures. Root Cause Analysis follows,
pinpointing the causes and implementing fixes. Computational tools like Finite Element Analysis
simulate component behavior for strength and durability, while physical tests—such as
durability, environmental, and crash tests—validate the designs, ensuring they meet safety and
performance standards

Continuous improvement in automotive design is driven by data from testing, failures, and
customer feedback, refining future designs. Cross-functional collaboration between engineers,
designers, and manufacturing teams ensures holistic improvements, enabling automakers to
produce reliable, durable vehicles that meet safety standards and stay competitive

Life Data Analysis uses statistical methods to assess product reliability and lifespan in
engineering. Key techniques include Weibull Analysis for failure modeling, Reliability Growth
Analysis for tracking improvements, Accelerated Life Testing (ALT) for simulating long-term
stress, and Bayesian Reliability Analysis for updating estimates. FMEA identifies failure modes,
while Fault Tree Analysis helps understand causes and preventive measures. Together, these
methods improve product and system reliability

Reliability Growth testing seeks to improve product reliability by identifying and fixing defects
through structured testing. It begins with setting goals, such as target reliability levels, and
developing a detailed test plan. The testing phase includes identifying potential failure modes,
creating test cases, and recording failures. Results are analyzed to prioritize and address
defects, with fixes verified through re-testing. This cycle continues until desired reliability is
reached, with all findings documented and design changes implemented to enhance reliability
further.

Improving automobile design during or after testing involves identifying weaknesses through
data analysis and using advanced simulations for virtual testing. Iterating on prototypes based
on feedback and collaborating with engineers, designers, and end-users enhances safety,
efficiency, and functionality. Compliance with regulations, benchmarking, and rigorous quality
control maintain reliability, while considering environmental impact and future technologies
ensures vehicles meet evolving needs.

Maintaining accurate records is essential in vehicle design and reliability studies. This includes
documenting design specifications, engineering drawings, and prototypes, as well as recording
iterative modifications, test results, and validation procedures. Comprehensive logs of
component sourcing, supplier qualifications, and manufacturing processes ensure adherence to
SOPs and support effective decision-making and quality control.

Key documents in vehicle design and reliability management include the Design Requirements
Document, Design Verification Plan and Report (DVP&R), and Failure Mode and Effects
Analysis (FMEA). Important records also include test protocols, reliability plans, supplier quality,
compliance records, and customer feedback, ensuring quality, safety, and continuous
improvement.

To sum it up, as an AutoCAD technician, you will now be able to evaluate product design
reliability and validity, analyze failure risks, and use Life Data Analysis techniques.

Thank you for watching

MODULE 4 SESSION 1

Hello and welcome to this video on performing Product Designing and Validation. In this session
we are going to learn how to transform the functional architecture of vehicle design to physical
architecture

As an AutoCAD Technician, you should coordinate with the product design team and other
departments to review designs and gather feedback on the accuracy and validity of drawings for
production. Additionally, you will conduct quality inspections of drawings and sketches, ensuring
they meet various tolerance levels.

Advanced design engineering techniques are essential in automotive development. Simulation

tools replicate real-world conditions, enabling engineers to tackle safety and regulatory issues
early. CAD software facilitates the creation and testing of 2D and 3D designs, accelerating
development and resulting in safer, more advanced vehicles.

Talking about simulation tools, here are some tools used in product designing.

Autodesk

ANSYS
Bevy wise IoT simulator

MATLAB/Simulink

COMSOL Multiphysics

CATIA

SOLIDWORKS Simulation

Siemens NX

These tools are essential in product design for testing and optimising performance without the
need for physical prototypes.

With optimised designs from simulation tools, the next step is transforming the functional vehicle
architecture into a practical physical structure for production. Transforming a vehicle's functional
architecture into physical design involves several steps.

First, create detailed specifications based on functional needs.

Select sub-systems and components, then use CAD software to design 3D models.

Build and test prototypes to ensure standards are met, optimising for manufacturing efficiency.

Choose materials for performance and cost, integrate electrical systems, and collaborate with
suppliers for quality.

Finally, perform thorough testing to validate the design. This process ensures a practical, high-
performing vehicle design aligned with functional goals.

With the physical architecture established, the focus now shifts to integrating innovative
technologies specific to electric vehicles for enhanced performance and sustainability. Since
2010, electric vehicles have surged in popularity, with global sales reaching 10 million by 2020.
In India, the e-mobility market is expected to boost GDP by 25% by 2022 through reduced crude
oil imports, while EVs save about 20,000 rupees on fuel for every 5,000 km.

There are three types of EVs: fully battery-powered, solar-powered, and hybrid.

The driving cycle, influenced by geography and vehicle type, varies and is continuously
monitored to optimise EV components, enhancing performance and user experience.

Designing an electric vehicle involves key parameters such as vehicle dynamics, weight, motor
torque, speed, range, battery type, and power converter. These factors influence performance,
energy consumption, and overall efficiency. The power converter is essential for converting DC
to AC and regulating speed during regenerative braking, impacting range and cost.

Having outlined the key design parameters of an electric vehicle, we can now explore the steps
to create a virtual representation of the design process. Building a simulated model of an
electric vehicle involves several key steps. First, define simulation objectives and gather data on
components like the battery and motor, using tools such as MATLAB/Simulink. Develop and
integrate models which are validated against real-world data, and then optimise it for accuracy.
Finally, document the process and results to facilitate informed decision-making, ensuring the
development of efficient and reliable electric vehicles.

Now that we have an understanding about the steps to create a virtual representation of the
design process, we will now discuss how to build a simulated model of the electric vehicle
design. Creating a virtual model of an electric vehicle utilises software and hardware simulation,
particularly in early design stages without physical prototypes. Tools like Simscape simulate
components to analyse power flow, torque, and battery efficiency, enabling engineers to
optimise key elements for improved performance and drivability through real-time validation.

Let us now explore the process of developing a virtual electric vehicle model.

Creating a virtual electric vehicle model involves defining simulation goals, gathering
specifications, selecting appropriate tools, and developing component models. Then integrating
these components into a cohesive system model, verifying accuracy with real-world data, and
evaluating performance. At last offer valuable insights for improving energy efficiency and
overall reliability.

After developing the electric vehicle model, the next step is to focus on integrating and
calibrating the vehicle to ensure optimal performance and accuracy. Automotive testing involves
various assessments to ensure vehicle components are reliable, safe, and perform well while
meeting legal standards. Modern vehicles rely on electronic sensors, with the powertrain control
module coordinating data for the engine and gearbox. Before calibration, vehicles undergo tests
for performance, safety, durability, emissions, and electrical systems.

Calibration in the automotive sector is essential for optimising performance and reliability. It
involves adjusting the engine, gearbox, brakes, suspension, and electronic systems to improve
efficiency, safety, and features like automated parking.

Let’s now turn our attention to the critical role of the Battery Management System in optimising
performance and safety. A battery pack is made up of cells that deliver specific voltage and
current, managed by a Battery Management System. In electric vehicles, Electromagnetic
Compatibility or EMC is vital to prevent electrical interference. The BMS monitors charge,
health, and temperature, ensuring optimal performance and safety through a microcontroller
that coordinates data management.

With the BMS ensuring optimal battery performance and safety, let’s discuss the organisational
procedures involved in creating effective EV product designs. Creating EV product designs
follows a structured process to ensure safety, compliance, and customer satisfaction. It begins
with concept development and gathering requirements based on market needs and regulations.
Preliminary designs are created and evaluated for feasibility. Detailed designs are developed
using CAD software and simulated for performance. Finally, prototypes are built and tested to
verify they meet design specifications.

Following prototype testing, design reviews and iterative improvements are conducted with
cross-functional teams to refine the design based on feedback. Comprehensive documentation
is maintained to ensure regulatory compliance and track design changes. The manufacturing
process is prepared and production is ramped up gradually, addressing any quality control
issues. Finally, a launch plan is developed for market introduction, and ongoing support is
provided to address customer needs and gather feedback for future enhancements.
To sum it up, designing and validating electric vehicles involves transforming functional
architecture into practical designs using advanced simulation tools and CAD software. Key
parameters like vehicle dynamics and battery management are crucial for optimising
performance and reliability. The structured development process—from concept to prototype
testing—ensures compliance with market needs. Continuous support and feedback drive
ongoing improvements, ultimately advancing the future of sustainable and efficient electric
mobility in the automotive industry.

Thank you for watching

MODULE 4 SESSION 2

Hello and welcome to this video on Performing Product Designing and Validation. In this
session, we are going to learn how to carry out simulation models and detect possible failures.

As an AutoCAD technician, you must coordinate with the product design team and other
departments to review designs and incorporate feedback for production accuracy. You will
conduct quality inspections of drawings and sketches, making adjustments based on feedback
from the design team. Additionally, you are responsible for tagging and storing drawings with
appropriate numbers and codes according to organisational guidelines.

Developing modern cars is complicated because of the mix of electronics, software, and
mechanical parts. Designers must adapt their processes to manage this complexity. Failures
can come from mechanical issues, like tyre blowouts or faulty brakes, or from user misuse.
Addressing design flaws, such as poor airbag performance or stability issues, is key to
improving safety and preventing accidents.

Creating failure modes in a simulation involves setting up scenarios where key parts, like the
battery or motor, fail under certain conditions. First, identify important components, then define
failure types like sensor issues, communication problems, or wear and tear. Modify models to
simulate these failures and integrate them into simulation tools like MATLAB/Simulink or
specialised EV software.

After adding failure models, set conditions like temperature limits or current overloads to trigger
failures during simulations. Run the simulations to see how these failures affect performance
and safety. Compare the results with real data for accuracy, then document the findings and
suggest design improvements. This helps engineers catch issues early and make systems
stronger before physical testing.

Let us now understand the ways to formulate an EV simulation model.

It involves setting clear goals, defining the scope, and gathering data on key components like
the battery, motor, and drivetrain. Input parameters such as temperature, driving cycles, and
load conditions are identified. Suitable software like MATLAB/Simulink or Dymola is selected to
simulate systems like powertrains, battery behaviour, thermal management, and vehicle
dynamics.
The next steps include creating mathematical models for each component, integrating them into
a cohesive system-level simulation, and validating the model against real data. Sensitivity
analysis and control algorithms help optimise performance by testing various scenarios in
simulations. These runs assess key metrics like range and energy consumption. The results are
used to refine the model, improve the design, and document findings, guiding stakeholders in
making informed decisions and driving design improvements

Failure analysis in simulation involves studying how components, like battery packs or electric
motors, fail under certain conditions to evaluate their impact on performance and safety.
Engineers identify critical parts and define failure modes, such as short circuits or overheating,
then create models to simulate these failures. Tools like MATLAB/Simulink or Dymola are used
to set up and test these failure scenarios by adjusting parameters to reflect reduced efficiency or
other failure effects.

Engineers run simulations with failure models to see how they affect vehicle range and thermal
management. They use Failure Mode Effects Analysis to prioritise fixes, such as design
improvements or better diagnostics. Comparing simulation results with real data ensures
accuracy, and refining models improves realism. Documenting the process helps inform design
changes for better reliability and performance before actual testing.

The Battery Management System (BMS) monitors and balances battery cell voltages and
temperatures to ensure safety and extend battery life. It estimates the battery's charge and
health, prevents overcharging or overheating, and communicates battery status to vehicle
systems.

To ensure effective electromagnetic compatibility (EMC) in Battery Management System (BMS)

design, it's essential to minimise emissions, enhance immunity to interference, and comply with
standards like CISPR 25 and ISO 11452. Key design factors include PCB layout, grounding,
component selection, and enclosure design. Thorough testing during development is vital for
verifying compliance and identifying issues early.

Detection Rating (DR) for a Failure Cause

Experts use Failure Mode and Effect Analysis (FMEA) to identify risk factors in potential failures.
FMEA evaluates risks in designs, systems, and processes. A key part is the Risk Priority
Number (RPN), which measures risk by multiplying three factors: occurrence (how often failures
happen), detectability (the chance of finding the failure before it affects customers), and severity
(the impact of the failure).

In Failure Modes and Effects Analysis (FMEA), the "Detection" rating shows how well controls
can spot potential failures. It measures the likelihood of finding a failure before it impacts
production. For Design FMEAs, this looks at design controls, while Process FMEAs focus on
process controls before products leave the factory. The detection rating indicates effectiveness
but doesn't consider how likely or serious the failure is.

In the automotive industry, simulation models are becoming more common, but more programs
mean more potential faults in the software. During the design phase, features are developed
and tested using tools like MATLAB/Simulink. This includes Model in the Loop (MIL) testing,
where real-world scenarios are simulated to find and fix issues. Once the testing is successful,
the model is passed to the Automotive CAD technician team for further development.
Creating failure modes starts by pinpointing the key parts of a product, like electrical,
mechanical, and software components that are crucial for its function and safety. After that, you
identify different ways these components might fail. This includes mechanical issues like broken
parts, electrical problems such as short circuits, software bugs, and failures caused by extreme
conditions or misuse.

To sum up, Simulation plays a crucial role in modern automotive design, enabling engineers to
test and improve complex systems like electronics, software, and mechanical components. By
integrating failure modes and running simulations, potential issues are identified early, helping
enhance safety, reliability, and overall vehicle performance before physical testing.

Thank you for watching