Force Motors Interview Questions, Process, and Tips

Q1. What are the changes required for electrification of an ICE vehicle ?
Ans. 
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
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Q2. How would you target the Weight distribution & GVW considering the above query ?
Ans. 
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
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Q3. What are parameters to be considered for vehicle Integration job?
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Parameters for vehicle integration job
• Compatibility of different vehicle systems

• Electrical and mechanical integration

• Safety regulations compliance

• Testing and validation

• Cost and time constraints
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Q4. How is an Electric Motor mounted for Front wheel drive & rear wheel drive?
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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
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Q5. How to mount EV Battery pack & what other things are to be considered?
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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
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Q6. Name the components or aggregates required in an Electric vehicle? Define the functions of the same ?
Ans. 
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
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Q7. How are the vehicles categorised as per AIS? And which standard to be referred ?
Ans. 
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
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Q8. What factors are to be considered for selection of an EV motor?
Ans. 
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
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Q9. How to determine the battery capacity ?
Ans. 
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
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Q10. How to calculate FAW & RAW?
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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
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Q11. What are the different suspension types & travel conditions?
Ans. 
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
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Q12. What are the crash & rollover requirements for an EV? Which standard to be referred?
Ans. 
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
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Q13. What is gradability ? How to calculate ?
Ans. 
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
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Q14. What are the factors to be considered for calculating range of an EV?
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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
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Q15. What are the types of EV chargers?
Ans. 
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
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Q16. What are ADR angles & how to calculate? Which standard to be referred?
Ans. 
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
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Q17. What is regenerative braking? How does it function ?
Ans. 
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
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Q18. What are the minimum mandatory clearances to be maintained with one aggregate w.r.to other dynamic aggregates?
Ans. 
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
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Q19. What are the different types of Electric Vehicles?
Ans. 
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
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Q20. What are the effects of uneven weight distribution on front & rear and LH & RH of vehicle on suspension ?
Ans. 
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
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Q21. What is an H-Point ? What is its significance?
Ans. 
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
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Q22. Name minimum 5 failure modes for an EV and how to resolve them ?
Ans. 
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
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Q23. What is DFMEA ? Who is responsible to make it ?
Ans. 
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
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Q24. What are the roles and responsibilities of an Vehicle Integration Engineer?
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Q25. What is Occupant packaging? What are the paramenters to be considered ?
Ans. 
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
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Everything should be accomplished collaboratively within a group.

Regardless of the task, it must be completed.

It is a comprehensive and detailed investigation of an individual, group, organization, event, or situation, carried out in a real-world context to derive generalizations and new insights.

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Q1. How do is Engine testing
Ans. 
Engine testing evaluates performance, efficiency, and emissions to ensure reliability and compliance with standards.
• Conduct bench tests to measure power output and torque under various conditions.

• Perform durability testing by running the engine for extended periods to assess wear and tear.

• Use dynamometers to simulate real-world driving conditions and gather performance data.

• Evaluate emissions using specialized equipmen...read more
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Q2. How do yo PDF finally
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Q1. Force all vehicle working
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Q2. Eny complete the vehicle ok
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Q1. Timing chain, gear box, grown setting
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Q2. Driving wheel greaseing
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