We Run Elaborate Tests On BMS In Design Stage: Puneet Arora

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  • June 17, 2020
We Run Elaborate Tests On BMS In Design Stage: Puneet Arora
Puneet Arora

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.

Bed of Nails - a component of the test bench

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)

 

 

Sustainable Mobility Conclave 2025: Driving India’s Green Automotive Revolution

Sustainability Conclave

The automotive industry world over faces significant sustainability challenges, including high carbon and other particulate emissions, depleting resources, supply chain complexities and slower pace of transition to cleaner and greener mobility. Indian automotive industry over and above has additional challenges, where gaps in recycling infrastructure, hazardous waste disposal and end-of-life vehicles (ELVs) management further obstructs sustainability in the sector. The balance between cost and greener technologies is much trickier to handle.

To bring national attention to this burning topic, a Sustainable Mobility Conclave 2025, is planned at NATRAX, Indore, which isn’t just another conference but a movement to reimagine, redesign and reinvent how Indian automotive carve out its sustainable future path.

The mission: A circular, sustainable and low-emission future

With its core theme, ‘Recycling, Circularity and Sustainability in Mobility’, the conclave seeks to align the Indian automotive ecosystem with global best practices on environmental responsibility. The event aims to be a catalyst for change – putting focus on how vehicles and its associated components are designed, manufactured, consumed and, ultimately, responsibly retired.

In view of the End-of-Life Vehicle (ELV) Management Rules and a rising need for compliance under Extended Producer Responsibility (EPR), the conclave arrives at a critical juncture.

Why this conclave?

India is poised to witness 80 million EVs on the road by 2030. But without parallel efforts in circular economy practices, recycling infrastructure and emission reduction, green mobility may not be truly green. The European Union already recovers 95 percent of vehicle materials from scrapped vehicles, a benchmark India must realistically chase.

Switching to recycled materials, embracing bio-based alternatives and integrating green energy into manufacturing are not just environmental mandates anymore – they are strategic business moves. Reduction in import dependency and a stable supply chain is the need of the hour.

What to expect?

This two-day summit is designed to bring together a powerful mix of automotive manufacturers, recyclers, government leaders, startups and academic minds. And the agenda? Packed with purpose.

Day 1 highlights:

  • Session 1: Circular economy lessons – Tapping into waste as a resource, with a strong focus on e-waste, industrial scrap and auto components.
  • Session 2: Nature’s waste into products – How bamboo, fruit pulp, seaweed and more are being transformed into auto-grade materials.
  • Session 3: From policy to practice – Bridging gaps between regulation and action; featuring deep dives into ESG, green data centres and the Right to Repair.
  • Session 4: Industry success stories – Real-world case studies from top OEMs on implementing sustainable systems.

Day 2 focus areas:

  • Session 5: Beyond metals – Innovation in plastic, rubber and fibre reuse.
  • Session 6: Sustainability education – Building a green-ready workforce.
  • Session 7: Organisational sustainability – How automotive companies are embedding sustainability into their DNA.
  • Session 8: Leadership reflections – A unique dialogue on the societal impact of green mobility transitions.

Join the movement

The Sustainable Mobility Conclave 2025 isn’t just about talks. It’s about transformation. Whether you’re an OEM, policymaker, recycling expert, student or sustainability advocate, this is where the narrative of Indian future mobility is getting actively debated and jointly co-created.

Because sustainability isn’t a choice anymore. It’s the only road ahead!

Honda To Establish New Retail Financing Arm In India

Honda

Japanese auto major Honda Motor Co recently established a new retail finance company in India, christened ‘Honda Finance India’. The new company will provide customers with retail sales financing services, including loans and lease sales options for Honda products in India.

The automaker states that with demand for two-wheelers and four-wheelers set to grow in India, there will be a significant growth opportunity for retail finance too. Till now, retail sales financing services has been primarily done by local financial institutions in India.

However, Honda aims to further strengthen its business in India by offering its own sales financing services through a local subsidiary in India. For this, Honda Finance India is applying for a Non-Banking Financial Company (NBFC) license to conduct financial services business in India.

The Japanese company states that for it financial services business has been one of the main business areas and it has established local subsidiaries specialising in retail sales financing services in Japan and various countries in key regions such as North America and Europe. With the establishment of the new company, India became the ninth country where Honda has a local subsidiary to offer financial services.

Going forward, in anticipation of the global expansion of software-defined vehicle (SDV) sales in the future, Honda is looking into opportunities to offer new financial services designed to increase customer satisfaction and the value of the customer experience using various data from Honda SDVs.

Automotive Veteran Rakesh Srivastava Joins Helyxa Consulting Group As Partner

Rakesh Srivastava

Rakesh Srivastava, the former Managing Director of Nissan Motor India, has been appointed as a Partner at Helyxa Consulting Group, a newly launched firm of senior professionals. Srivastava joins a team with over 150 years of collective experience from top-tier companies across various industries.

Helyxa Consulting Group, which was established on India's Independence Day, is focused on enabling India's growth journey and building a ‘Viksit Bharat’ in line with the vision of a USD 30 trillion economy by 2047. The firm aims to accelerate the growth of Indian companies by providing services in key areas including – AI Transformation, Board Advisory, Deals & Partnerships, Innovation in Entrepreneurship, Leadership & Culture Transformation and Planning & Process Transformation.

Srivastava will work alongside other key partners, including Managing Partner Bhanu Sharma, former President and Global Head of HR and IT at Tega Industries, and Partner Raman Madhok, a board member at Johnson Controls Hitachi and former Joint Managing Director and CEO of JSW Steel. The leadership team also includes Bindu Bhatia and Harish Bhatia.

BMW India Announces Price Hike Starting September 1

BMW India

German luxury automotive brand BMW India is set to increase prices across its entire model range by up to 3 percent beginning 1 September. The company cites continued foreign exchange impacts and rising material and logistics costs as the primary reasons for the price adjustment.

Vikram Pawah, President and CEO, BMW Group India, said the company has seen significant sales growth in the first half of the year.

“BMW India’s growth and sales momentum in the first half of the year has been remarkable. However, factors like continued forex impact and global supply chain dynamics have been leading to increased material and logistics costs. Our commitment to offer best value and experience throughout customer journey is steadfast. In the festive season, we are geared to introduce several new power-packed profiles of our cars. As the strong demand for BMW’s luxurious, pioneering cars continues, we will deliver exceptional performance and innovation to our valued customers,” he said.

At present, BMW sells the locally produced the BMW 2 Series Gran Coupe, BMW 3 Series Long Wheelbase, BMW 5 Series Long Wheelbase, BMW 7 Series, BMW X1, BMW X3, BMW X5, BMW X7, BMW M340i and BMW iX1 Long Wheelbase.

in India. The company also offers a wide selection of imported models, including the BMW i4, BMW i5, BMW i7, BMW i7 M70, BMW iX, BMW Z4 M40i, BMW M2 Coupe, BMW M4 Competition, BMW M4 CS, BMW M5, BMW M8 Competition Coupe and BMW XM (Plug-in-Hybrid) as completely built-up units (CBU).