Force Motors Junior Engineering Manager Interview Questions, Process, and Tips

Electrification of an ICE vehicle requires significant changes to the powertrain and supporting systems.

• Removal of the internal combustion engine and installation of an electric motor

• Addition of a battery pack and associated electronics

• Modification of the transmission or installation of a new one

• Upgrades to the cooling and heating systems

• Changes to the braking system to enable regenerative braking

• Installation of chargi...read more

Weight distribution & GVW can be targeted by analyzing the vehicle's design, load capacity, and distribution of weight.

• Analyze the vehicle's design and load capacity to determine the maximum GVW

• Distribute the weight evenly across the vehicle to maintain stability

• Consider the type of cargo being transported and adjust weight distribution accordingly

• Ensure that the vehicle is not overloaded and is within legal weight lim...read more

Parameters for vehicle integration job

• Compatibility of different vehicle systems

• Electrical and mechanical integration

• Safety regulations compliance

• Testing and validation

• Cost and time constraints

The electric motor is mounted differently for front-wheel and rear-wheel drive vehicles.

• In front-wheel drive vehicles, the electric motor is mounted transversely, usually between the engine and the transmission.

• In rear-wheel drive vehicles, the electric motor is mounted longitudinally, usually behind the transmission.

• In some cases, electric motors can also be mounted directly on the wheels, known as in-wheel motors.

• The...read more

EV battery pack mounting requires proper placement, securing, and cooling to ensure safety and performance.

• Consider the weight and size of the battery pack and ensure it is mounted securely to prevent movement or damage during operation.

• Choose a location that allows for proper cooling and ventilation to prevent overheating.

• Use appropriate mounting hardware and techniques to ensure the battery pack is securely fastened ...read more

An electric vehicle requires several components or aggregates to function. These include the battery, motor, controller, charger, and more.

• Battery - stores energy to power the vehicle

• Motor - converts electrical energy into mechanical energy to propel the vehicle

• Controller - manages the flow of electricity between the battery and motor

• Charger - recharges the battery when needed

• Power electronics - converts DC power from ...read more

Vehicles are categorised as per AIS based on their type and usage. The standard to be referred is AIS-052.

• AIS categorises vehicles into various types such as M1, N1, L5, etc.

• The categorisation is based on factors such as weight, seating capacity, and usage.

• AIS-052 is the standard that specifies the requirements for the categorisation of vehicles.

• This standard also provides guidelines for the testing and certification o...read more

Factors to consider for selecting an EV motor

• Power and torque requirements

• Efficiency and energy consumption

• Size and weight constraints

• Cost and availability

• Compatibility with battery and controller

• Regenerative braking capability

• Maintenance and reliability

• Environmental impact

Battery capacity can be determined by calculating the product of current and time.

• Calculate the current drawn by the device

• Determine the time for which the device will be used

• Multiply the current and time to get the battery capacity

• Consider the efficiency of the battery and the device while calculating capacity

FAW & RAW can be calculated by dividing the total number of hours worked by the number of units produced.

• FAW stands for Full-time equivalent adjusted workload and RAW stands for Regular adjusted workload.

• To calculate FAW, divide the total number of hours worked by the number of hours in a full-time workweek.

• To calculate RAW, divide the total number of hours worked by the number of units produced.

• For example, if an empl...read more

Different suspension types include rigid, spring, hydraulic, and air suspension. Travel conditions refer to the range of motion of the suspension.

• Rigid suspension has no movement and is commonly found in bicycles

• Spring suspension uses metal coils to absorb shock and is commonly found in cars

• Hydraulic suspension uses fluid to absorb shock and is commonly found in heavy-duty vehicles

• Air suspension uses compressed air to ...read more

Crash and rollover requirements for EVs are determined by various standards such as FMVSS, ECE, and GB.

• Crash and rollover requirements for EVs are determined by various standards such as FMVSS, ECE, and GB.

• FMVSS 305 is the standard for electric-powered vehicles, which includes requirements for post-crash safety, electrical isolation, and thermal management.

• ECE R100 is the European standard for electric vehicles, which...read more

Gradability is the measure of a road's slope. It is calculated as a percentage or ratio of rise to run.

• Gradability is important in road design and construction.

• It is calculated by dividing the rise (vertical distance) by the run (horizontal distance) and multiplying by 100 to get a percentage.

• A road with a 10% grade means that for every 100 feet of horizontal distance, the road rises 10 feet.

• Steep grades can be dangero...read more

Factors affecting range of an EV

• Battery capacity and chemistry

• Vehicle weight and aerodynamics

• Driving behavior and terrain

• Temperature and climate

• Efficiency of regenerative braking

• Accessories and load on the battery

• Charging infrastructure and speed

• Tire pressure and maintenance

There are three types of EV chargers: Level 1, Level 2, and DC fast chargers.

• Level 1 chargers use a standard 120-volt outlet and provide up to 4 miles of range per hour of charging.

• Level 2 chargers require a 240-volt outlet and provide up to 25 miles of range per hour of charging.

• DC fast chargers provide the fastest charging speeds, with up to 80% charge in 30 minutes.

• Examples of Level 1 chargers include the standard c...read more

ADR angles are the angles between the axes of a vehicle's suspension system. They can be calculated using trigonometry and referred to industry standards.

• ADR stands for Australian Design Rules.

• The angles are important for ensuring proper handling and stability of the vehicle.

• Calculations involve measuring the angles of the suspension components and using trigonometry to determine the ADR angles.

• Industry standards such ...read more

Regenerative braking is a system that converts kinetic energy into electrical energy to recharge a vehicle's battery.

• It is commonly used in electric and hybrid vehicles.

• During braking, the electric motor acts as a generator, converting the kinetic energy into electrical energy.

• The electrical energy is then stored in the battery for later use.

• Regenerative braking helps to improve the overall efficiency of the vehicle an...read more

Minimum mandatory clearances between one aggregate and other dynamic aggregates.

• The minimum clearance depends on the size and speed of the aggregates.

• Clearances should be maintained to avoid collisions and damage to the aggregates.

• Clearances can be calculated using mathematical formulas and simulations.

• Examples of dynamic aggregates include vehicles, robots, and drones.

• Clearances should also take into account any obsta

There are three types of electric vehicles: Battery Electric Vehicles, Plug-in Hybrid Electric Vehicles, and Hybrid Electric Vehicles.

• Battery Electric Vehicles (BEVs) run solely on electricity stored in batteries.

• Plug-in Hybrid Electric Vehicles (PHEVs) have both an electric motor and a gasoline engine, and can run on either power source.

• Hybrid Electric Vehicles (HEVs) have an electric motor and a gasoline engine, but ...read more

Uneven weight distribution affects suspension by causing imbalance and uneven wear on tires and suspension components.

• Uneven weight distribution can cause the vehicle to pull to one side or the other

• It can also cause uneven wear on tires and suspension components

• This can lead to premature failure of suspension components and decreased handling and stability

• Proper weight distribution is important for optimal performance

H-Point is the hip point of a vehicle seat. It determines the seating position and ergonomics of the driver.

• H-Point is the pivot point of the human body where the thighs and torso meet.

• It is used to determine the position of the driver's seat in a vehicle.

• The H-Point is important for ensuring proper ergonomics and comfort for the driver.

• It is also used in crash testing to determine the position of the test dummy in the...read more

Five failure modes for an EV and their resolutions

• Battery failure - replace battery or repair

• Motor failure - replace motor or repair

• Charging failure - check charging port and cable, replace if necessary

• Brake failure - check brake system, replace brake pads or repair

• Software failure - update software or replace faulty components

DFMEA stands for Design Failure Mode and Effects Analysis. It is a systematic approach to identify and prevent potential failures in a product or process.

• DFMEA is a proactive risk assessment tool used during the design phase of a product or process.

• It involves identifying potential failure modes, their effects, and the likelihood of occurrence.

• The responsibility of creating DFMEA lies with the design team, but it requi...read more

Occupant packaging refers to the arrangement of occupants in a vehicle to ensure safety and comfort.

• Parameters to be considered include body size and shape, seating position, seatbelt usage, and airbag deployment.

• Occupant packaging is important for crash safety and can also affect passenger comfort and ergonomics.

• Examples of occupant packaging solutions include adjustable seats and headrests, seatbelt pre-tensioners, a...read more