Q: What is your contribution to testing new energy vehicles – Battery Electric Vehicles and Hybrids? Please elaborate on the testing equipment you have for these vehicles?

Arora: As a B2B startup that enables its customers to maximize the capacity of the battery pack, and improve battery life and safety, we run elaborate tests on Battery Management Systems on all of our BMS designs. These BMSes have been deployed by ION’s customers on a fleet of batteries that go inside two / three-wheelers, passenger and commercial vehicles, and industrial electric vehicles.  Our cloud analytics platform, Edison, helps our customers visualize the data coming out of these tests and generate insights. In a bid to counter the challenge of costly industrial equipment, we have developed battery emulators, end of line testing equipment and HIL (Hardware-in-the-loop) setup, in house at about a minimal 10 percent cost of the commercial market rate. We have also built a gaming engine based simulation engine called the ‘Ghost Rider’ that runs simultaneously with our battery models. The simulation helps us integrate our BMS algorithms to vehicles models and monitor the performance of those models in life like situations.

Q: Can you tell us briefly about your overall portfolio of BMS testing equipment and a bit about your company?

Arora: Quality Assurance (QA) and Testing are the most important phases in the life cycle of BMS since the success of this phase dictates the level of safety and the management of the battery’s life. As a startup, we have adopted a lean and creative approach with our testing methodologies. We have a number of indigenously developed tools and software for testing of our batteries. Once the hardware design of the BMS is finalized, the prototypes are validated for their basic functionalities. The prototypes are further optimized based on the functionality and additional features that develop the hardware. When all the modifications are completed, the BMS is validated for its functionalities at different environmental conditions. Based on the data collected in the previous step an ‘operating range’ is defined.

Similar to the hardware, the software is also tested on the prototype BMS hardware. Based on the outcomes and new requirements, the iterations are made to tailor the firmware for its optimum performance and management of battery life and safety. Once the desired results are obtained, the firmware is finalized and deployed in the BMS. The prototype is then sent to external independent laboratories for EMI / EMC tests, basis whose clearance, the hardware and the firmware are again validated, and the design is finalized. In the manufacturing stage, ION Energy conducts as Automated Optical Inspection (AOI) testing is more reliable than manual visual inspection. In the final stage of the manufacturing process, the Design for Manufacturing (DFM) files are used for the component assembly process. Testing is necessary to avoid any incorrect component placement issues. Testing during this stage is typically more intensive than during the fabrication phase.

End-of-Line Testing measures and checks the functionality of ION’s battery management systems. The key factors taken into consideration at ION are high test quantity, test completion and low system with upgrade costs. At ION, we have built an automated testing platform called the ION Testmaster, built specifically for performing automated Functional Circuit Test (FCT) on ION’s BMSes. In the latest update, the ION Testmaster is interfaced with Edison Analytics for accurate and real-time inventory management using the MNP/serial number of the DUT, in this case, the BMS.

Q: A lot of players claim that they build technologies to enhance the life and performance of lithium-ion batteries. What is the USP of ION Energy?

Arora: It's worth noting that oftentimes when organizations emphasize on enhancing the life and performance of a battery, reliability takes a backseat. In a market like India that is still in a nascent stage, ION Energy is one of the very few players that offers reliable and tested solutions, making it our USP. ION Energy is an advanced battery management and intelligence platform that was born out of the desire to tackle the threat of climate degradation by enabling a much more environment-friendly mobility solution. Founded in 2016, ION’s mission is to accelerate Earth's transition to an all-electric planet. We are doing this with a focus on building technology that improves the life and performance of lithium-ion batteries, which power electric vehicles and energy storage systems.

ION’s full-stack solution blends advanced electronics and machine learning with deep domain expertise in energy storage. ION’s disruptive battery intelligence platform - Edison Analytics leverages battery data, software analytics, and ML to significantly improve battery performance and extend battery life by up to 40 percent. Battery Makers & OEMs around the world use ION’s platform to optimize their battery management systems (BMS) and build world-class batteries. ION Energy is leaps ahead when it comes to leveraging data. In a bid to enhance life and performance, ION Energy has a fully integrated stack with Battery Design Engineers, BMS Design Engineers and Software Engineers learning from insights captured by our cloud platform - Edison.

Q: In Evs the packaging is key and anything lighter is the most sought after by the OEMs. What are the contributions from your end on these expectations?

Arora: The battery usually comprises 25-30 percent of the weight of electric vehicles. There is always a tradeoff between the weight and size of the battery, vis-a-vis the range it offers. A bigger battery offers a higher range, but it also adds to the weight of the vehicle - reducing its energy efficiency. It is crucial to achieve the right balance in this trade off - and that needs a deep knowledge and understanding of the application, usage and the environment of the battery packs. At ION Energy, we have tools that can help OEMs find the right size for its battery packs.

Q: How do you see the increasing electronics and vehicles becoming more connected in EV space too? What sort of solutions do you give? Please elaborate.

Arora: The global automobile industry is on the brink of a major transformation. The Global Connected Car Market size is projected to reach USD 212.7 billion by 2027, from an estimated value of USD 42.6 billion in 2019, at a CAGR of 22.3 percent - as predicted by Markets and Markets. Technology is driving this shift, shaped by demographic, regulatory, and environmental pressures. Other factors include - consumer tech companies entering the automotive world, as software and other technologies, are taking a pivotal position in the future of automobiles. These businesses want to focus on design, ease of use, better service and extended battery life to bring new kinds of innovation to the field

Shared Asset Utilization requires companies to leverage advanced IoT, Battery Management & Driver Profiling to improve asset sweating, protect the lifetime of the asset, and ensure financial viability. This will have powerful effects beyond the auto industry. Insurers, for example, will have new ways to monitor driver behavior, reward good drivers, and distribute costs to bad ones. Companies can better connect idle cars with customers that need them. Continuously improving UX is becoming a norm, not only in mobile phones but also EVs. OTA updates that extend range, improve charging time and boost speed are a reality today. Companies with the technical capability to package world-class technology, UX and affordable pricing will win in the future of mobility. The growing battery swapping ecosystem for two / three-wheelers in Asia is one of the best examples of the shift in the transport sector brought about by EVs and connected electronics. It gives end-users the option to lease batteries and pay per km, instead of paying all the battery costs upfront. This is only possible because of connectivity between the batteries, the vehicles, the users and the swapping station.

Shared utilisation of batteries is possible only because of integrated battery management and telematics functions. It is important to track the location, usage and the state of the battery - all at the same time - to be able to charge users accordingly. ION has a lot of experience in building integrated Battery Management and Telematics Units for batteries and swapping stations. Our BMSes have GPS sensors and LTE modems integrated with battery management functions. We are able to send real time data to our cloud that enables monitoring and optimization of asset utilization.

Our BMSes - FS-CT, FS-LT, and FS-XT - are equipped with on-board memory storage to log every data point of the battery pack collected by the BMS, up to 20 years of historical battery data. Normally this would lead to an enormous amount of data, but we've developed compression algorithms tailored for battery data acquisition. The BMS records all physical parameters, events, errors relating to the performance of the battery pack. Our cloud-connected battery intelligence platform, Edison Analytics, allows engineers to access this data and gain insights into the life and performance of the battery. (MT)

Tata Motors, India’s largest auto and mobility solutions company, displayed its range of ultra-modern vehicles, cutting-edge concepts advanced aggregates and intelligent digital solutions at the Bharat Mobility Global Expo 2025, setting new benchmarks in innovation, connectivity and sustainability. These exhibits are on display up to 22 January 2025, in Hall No 1 at the Bharat Mandapam (Pragati Maidan), New Delhi.

Tata Motors presented its ambition for revolutionising every aspect of personal mobility and business transportation with the largest exhibition of more than 50 displays, which included 32 aspirational, future-ready passenger and commercial vehicles. Tata Motors unveiled its next-generation green mobility solutions, which range from small cars and strong SUVs to agile micro trucks and tough heavy-duty carriers. These solutions are intended to improve safety, provide outstanding performance and completely transform the customer experience. In addition to providing visitors with 18 immersive experiences and interactive displays, the organisation showcased 20 intelligent, cutting-edge solutions to improve safety, productivity and customer experience. The company also unveiled 'Better Always' as a new motto for Tata Motors Commercial Vehicles, signifying the company's dedication to ongoing development and enhancement.

N Chandrasekaran, Executive Chairman, Tata Sons and Chairman, Tata Motors said, “For eight decades, Tata Motors has been at the forefront of shaping the future of mobility, pioneering advancements in safety, design, connectivity and sustainability. Our relentless pursuit of excellence is fuelled by a deep commitment to creating value for customers, communities and our nation. The rapid shift toward green energy and mobility, an irreversible global megatrend, has made the need for clean, zero-emission vehicles more urgent than ever. We are leading this revolution in India with smart, holistic solutions delivering exceptional performance, reliability and convenience. Our customers have ready access to an expansive range of cleaner, greener mobility options for both personal and commercial use. At the Bharat Mobility Global Expo 2025, we are proud to unveil more than 50 next-generation vehicles, visionary concepts and intelligent solutions that redefine the future of mobility across segments and applications. Rooted in our legacy of trust, innovation and responsibility, we will continue to lead the way – creating value for customers, driving the automotive industry and advancing our nation's progress with purpose and determination." 

Girish Wagh, Executive Director, Tata Motors, said, “Today marks a defining moment in Tata Motors Commercial Vehicles' journey as we introduce our new mantra, 'Better Always’, embodying our unwavering dedication to driving growth and success, for our customers and for our nation. At the Expo, we are unveiling a bold new era in mobility, showcasing 14 smart vehicles, all integrated with ADAS, alongside six cutting-edge intelligent solutions that provide real-time performance insights, and four advanced aggregates. Accelerating our aspiration towards a greener future, we are presenting four zero-emission electric vehicles, ranging from mini trucks and pickups to intermediate and heavy trucks, alongside buses designed for comfortable, long-distance travel. We are redefining last-mile mobility with the launch of the all-new Tata Ace Pro, available in multiple powertrain options, and the Intra EV, India’s most advanced electric pickup, setting new benchmarks for performance and sustainability. Our next-generation hydrogen-powered Prima Truck is set to revolutionise long-haul trucking. We’re showcasing the Prima deep mining tipper with state-of-the-art technologies. In addition, on display are an array of green mobility solutions powered by a variety of decarbonising technologies – Hydrogen, Electric, Natural gas and Flex-fuel. With relentless innovation and agility, we will continue to redefine the future of mobility with sustainable, intelligent and cutting-edge solutions – setting new industry standards and creating a lasting, positive impact on the environment.”

Shailesh Chandra, Managing Director, Tata Motors Passenger Vehicles and Tata Passenger Electric Mobility, said, "We are honoured to spearhead India’s journey toward zero-emission mobility. With over 200,000 Tata EVs already covering more than 5 billion kilometres on Indian roads, we’ve cut down 700,000 tonnes of CO2 emission. Tata Motors has also crossed the remarkable milestone of 6 million car sales, a testament to the success of our customer centric, multi-powertrain strategy. But this is just the beginning. With relentless innovation and a deep commitment to sustainability, Tata Motors is determined to accelerate the transformation towards a future that is greener, safer and full of boundless opportunities for all. At the Bharat Mobility Global Expo 2025, we are proud to unveil our ‘Future of Mobility’ portfolio, showcasing the greenest, smartest and most advanced suite of mobility solutions. Our display embodies a holistic approach blending innovative design and smart engineering, with a profound understanding of customer needs. Today, we are thrilled to announce the return of a legend – the All-New Tata Sierra – reimagined for a new era, ready to inspire and lead once again. Alongside, in a nation first gesture, we ‘summoned remotely’ the Harrier.ev, the most powerful and technologically advanced SUV from the Tata Motors stable. Furthermore, we presented the next chapter of automotive excellence with the Avinya X concept— a bold leap into the future of luxury mobility that expands on Avinya’s commitment to sustainability, innovation and well-being. These reveals mark not just milestones, but the beginning of a boundless journey towards a future driven by lifestyle, safety, sustainability and cutting-edge technology.”

The Automotive Research Association of India (ARAI) launched the project on development of ‘Motor Vehicle Energy Consumption Calculation Tool (Bharat VECTO) for Real Drive Fuel Consumption/CO2 Emissions’, a landmark project in India’s homologation process, at the ongoing Bharat Mobility Global Expo 2025. ARAI is showcasing its technology and services at stall no H11-04, Bharat Mandapam; stall no H2-02, Yashobhoomi and stall no H1-A14, India Expo Centre & Mart from 17 to 22 January 2025.

Minister of Road, Transport and Highway Shri Nitin Gadkari; Dr Reji Mathai, Director, ARAI; P K Banerjee, Chief Executive Director, Society of Indian Automobile Manufacturers (SIAM) and Dr Sukrut S. Thipse, Senior Deputy Director – ARAI and Bharat VECTO Project Leader graced the event.

In accordance with Europe, the United States, Japan, China and other countries, the developed Bharat VECTO will be used to compute the realistic fuel consumption and CO2 emissions from Heavy Duty Vehicles (HDVs) (GVW > 3.5 tonnes) on a driving cycle basis. The BS-VII regulation will include it. Various mission profiles will be created under the Bharat VECTO project to address all HDV classifications, driving styles, road topography etc. Before being finalised for usage, the created tool will be tested on a few vehicle classifications. Along with project partners, ARAI will make every effort to create Bharat VECTO. It will be made available in Bharat Stage-VII and will serve cars powered by internal combustion engines, electric vehicles (EVs), fuel cell EVs and flex fuel vehicles (FFVs) in a phased way.

At Bharat Mandapam, a concept demo of the Over-Head Automated Charging Device (OH-ACD), one of ARAI's projects in collaboration with IIT-Madras, is on exhibit. Fast charging is possible with the 600-kW charging power, 1000V voltage and 600A current, which is made to satisfy the needs of the changing transportation environment. In addition to OH-ACD, the company is showcasing its in-house ADAS Validation Platform, a Light Commercial Vehicle with a 117 HP engine and an E-Axle for European customers and a Training Kit for the Battery Management System.

Stall number H2-02, Yashobhoomi, lists ARAI's specialised service portfolio for certification and support in developmental validation for components, systems and sub-systems. Along with engine models and lightweight components from the ARAI Fatigue Material Centre of Excellence, ARAI is also exhibiting the Acoustic Vehicle Alert System (AVAS) Bike and Battery Management System Kit, which was constructed by ARAI engineers.

Dr Reji Mathai, Director, ARAI, said, “It is a great pleasure to host Hon’ble Minister Shri Nitin Gadkari and have his presence for the launch of Bharat VECTO project. Ministry of Road Transport and Highway has played a significant role in enabling ARAI guide the auto industry towards one direction. Hence, ‘Motor Vehicle Energy Consumption Calculation Tool for Real Drive Fuel Consumption/CO2 Emissions’ will be instrumental in accelerating the momentum for industry-wide adoption of green mobility. ARAI, while being a major stakeholder in homologation and developmental testing and standardisation has also been fundamental in innovating technologies for sustainable mobility like Over-Head Automated Charging Device, Hydrogen Fuel Cell Electric Powertrain, which are at display at Bharat Mobility Global Expo. We are thrilled to showcase these technologies and drive conversations for greener tomorrow.”

Automotive customisation brand DC2, together with Mercury EV-Tech, unveiled two futuristic products – e-TANQ, a futuristic off-roader, and Europa, an ultra-luxurious showroom on wheels – at the ongoing Bharat Mobility Global Expo 2025.

The e-TANQ, an all-electric commercial vehicle developed in-house by DC2 in a partnership with Mercury EV-Tech Ltd, is intended to transform commercial and urban transportation. With a huge 180 kWh battery that produces 650 BHP, the off-roader blends sustainability and performance. DC2 also launched Europa, a custom-built, unique mobile showroom in partnership with Goldmedal Electricals. The cost of designing the opulent, cutting-edge mobile store was INR 180 million.

DC2 also displayed four other innovative items at the event. These include the Empyrean, a family-oriented luxury car that blends comfort and style; the Lex Lounge, which offers first-class luxury on daily commutes; the e-Rover, a sleek and contemporary take on the urban rickshaw; and the Vellfire Quad Luxe, a modified Toyota Vellfire that offers the luxury of a private jet on wheels.

Dilip Chhabria, Founder, DC2, said, “Bharat Mobility Global Expo 2025 has been an opportunity to reconnect with automotive enthusiasts and showcase our vision for the future of mobility. The Expo offered the perfect stage to present our innovations to a passionate audience, and we are thrilled to have been a part of it. Our collaboration with Mercury EV-Tech has been an incredible journey. Together, we’ve created a vehicle that combines the boldness of a rugged off-roader with cutting-edge electric technology, making a strong statement about our commitment to sustainability and innovation. This is just the beginning of a new chapter for DC2."

Jayesh Thakkar, Chairman, Mercury EV-Tech Ltd, said, "We believe in Dilip Chhabria's legacy of futuristic design and engineering excellence, which made his brand the perfect partner for the e-TANQ. DC2’s commitment to transforming futuristic ideas into reality is well-aligned with our vision. With the e-TANQ, both our brands aim to redefine the future of mobility by focusing on cutting-edge design and sustainability. This collaboration is a step toward creating vehicles that cater to the expectations of the modern consumer.”

Axalta Coating Systems, a leading global coatings company, has announced Evergreen Sprint as its Global Automotive Color of the Year for 2025.

Axalta has been introducing its automotive colour of the year for 11 years, and this is the second time that a green hue has been highlighted. Evergreen Sprint honours the renowned British racing green, a hue that has adorned the best racing vehicles and represents performance and speed. It is a deep, rich forest green. Axalta's newest hue is ideal for all car types because it combines the excitement of motorsport with a hint of refinement for sedans and SUVs.

Dan Benton, Global Color Marketing Director, Axalta, said, “This striking hue revs up our global automotive colour of the year. Evergreen Sprint stands out on the road and evokes the spirit of competition and adventure. The dynamic colour is sure to attract the hearts of passionate drivers.”