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)

 

 

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    Two-wheeler Sales Performance In November 2024

    Two-wheeler Sales Performance In November 2024

    Honda Motorcycle & Scooter India (HMSI) dispatched 4,72,749 units in November 2024. Of these, 4,32,888 units accounted for domestic sales, an increase of three percent when compared to the sale of 4,20,677 vehicles in November 2023. The company exported 39,861 units in the respective month. 
    Royal Enfield sold 72,236 units in the domestic market in India in November 2024 marking a decrease of four percent when compared to the sale of 75,137 vehicles in November 2023. The two-wheeler major exported 10,021 units in November, up 96 percent as compared to the export of 5,114 vehicles in November 2023. 
    Hero MotoCorp sold 459,805 units in November 2024 marking a 6.36 percent decrease when compared to the sale of 491,050 vehicles in November 2023. Domestic sales in November 2024 were 439,777 vehicles, down 7.66 percent when compared to the sale of 476, 286 units in November 2023. Exports saw a growth of 35.65 percent increase with 20,028 units dispatched in comparison to 14,764 units dispatched in November 2023. 
    At 4,21,640 units in November 2024, Bajaj Auto has announced a five percent increase in total sales year-on-year. In the domestic market, the company saw a sales decline of seven percent at 2,40,854 units. In November 2023, it sold 2,57,744 vehicles. 
    At 1,80,786 units, the two-wheeler major witnessed a 24 percent rise in exports in November 2024. In November 2023, it exported 1,45,259 vehicles. 
    Suzuki Motorcycle India Pvt Ltd achieved a total sale of 94,370 vehicles in November 2024, up eight percent when compared to the sale of 87,096 units in November 2023. 
    The domestic sale in November 2024 stood at 78,333 units, up seven percent when compared to the sale of 73,135 units in November 2023. Exports grew 15 percent at 16,037 units in November 2024 as compared to 13,961 units in November 2023. 
    TVS Motor Company registered a total sale of 401,250 units in November 2024, an increase of 10 percent when compared to the sale of 364,231 units in November 2023. Of these, 392,473 two-wheelers were sold in November 2024 respectively, marking a 12 percent increase in two-wheelers with the sale of 352,103 units in November 2023. In November 2024, 8,777 three-wheelers were sold marking a modest decline when compared to the sale of 12,128 units in November 2023. 
    In the domestic market, the two-wheeler business of TVS Motor Company witnessed a four percent growth with the sale of 305,323 units. In November 2023, the company sold 287,017 units.  The motorcycle category saw a growth of four percent with the sale of 189,247 vehicles as compared to the sale of 172,836 units in November 2023. Scooter witnessed a growth of 22 percent with the sale of 165,535 units in November 2024 as compared to the sale of 135,749 vehicles in November 2023. 
    The company recorded a 57 percent growth in electric vehicles with a sale of 26,292 units in November 2024 as compared to the sale of 16,782 vehicles in November 2023. The iQube e-scooter has been a big success, steadily closing the gap with e-scooter market leader Ola Electric’s offerings in the same category.
    TVS Motor Company exported 93,755 units in November, clocking a growth of 25 percent year on year when compared with the sale of 75,204 units in November 2023. 
     

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      Stellantis CEO Carlos Tavares Has Stepped Down

      Stellantis CEO Carlos Tavares Has Stepped Down

      Stellantis CEO Carlos Tavares has stepped down due to differences with the board, a news report in the CNN.com (Business) has mentioned. It has also mentioned that Tavares faced criticism for the lack lustre performance of the Group brands – formed with the coming together of FCA and PSA Groups – during the nine months of the current calendar year in the US. 
      The announcement of Tavares’ departure comes at a time when popular group brands such as Jeep, Chrysler and Dodge have seen sales drop as the ‘affordable’ models are discontinued under the wake of a ‘lean’ strategy and in what looks like an attempt to elevate the brands to offer premium luxury vehicles. 
      In India too, the Jeep vehicles are priced much higher than they may be worthy of. It is no surprise therefore that they are being undercut by Jeep-like vehicles from brands like Mahindra, which costs many million Rupees less. 
      Beginning its journey in Mumbai after Independence by assembling Willys CJ3 Jeep under license from Willys Corporation, Mahindra has grown to be a leading utility and SUV vehicles manufacture in India. It has also found a strong footing in export markets of US, Australia and South Africa with its 4x4 vehicles. 
      Also failing to extensively refresh or introduce next generation models such as the Compass in India, Jeep is not doing great in India either, the figures indicate. The other brand, Citroen seems to be better positioned and more agile in its ability to learn and adapt to the market requirements in the country. It too is yet to show its prowess to set the sales charts on fire in India.   
      Criticised to have taken the lean strategy a bit too far to come back and bite the group where it hurts the most, Tavares’ stepping down comes at a time when dealers across many parts of the world struggle to move the inventory on their lots. 
      Several workers laid off at several plants of the group – particularly in the US – have also criticised Tavares for the situation Stellantis got into in that market. 
      The situation in other markets is claimed to be not very different either. 
      The process to appoint the new permanent CEO is underway with a Special Committee of the Board expected to announce one in the first half of 2025 calendar year, as per the report. A new Interim Executive Committee, chaired by John Elkann, will be established, the report further mentions. 
      Global sales volume for the first half of this year fell 10 percent in the case of Stellantis. In the third quarter, it plunged 20 percent. 
      With many loyal buyers of Dodge and Jeep vehicles keeping away as the prices have risen way beyond, sales in US have been down by 17 percent in the first nine months of the year. 

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        Nissan Fears Collapse As Renault Announces A Stake Sale?

        Nissan Fears Collapse As Renault Announces A Stake Sale?

        After its longtime partner Renault revealed plans to sell off its interests in Nissan, which recently made news as one of the partners in a three-company alliance involving Honda and Mitsubishi as the other two to capitalise each’s strengths, Nissan is trying to save itself from collapse as per a recent report in news.com.au. 
        Offering just one compact SUV model in India, the Magnite, Nissan, as per the report, has between 12 to 14 months to survive as it works to fill up the gaping hole Renault’s departure will leave in its finances. 
        Searching for a new investor to ensure its survival beyond 2025, Nissan –finalising the terms of its new electric vehicle partnership with Honda that has been its arch rival – is evaluating ‘all options’ including getting Honda to purchase a stake in it, claim industry sources. 
        The development coincides with a major restructuring that the Japanese automaker has undertaken amid declining sales in China and USA. With the 25-year partnership – which began in 1999 with Renault saving Nissan from going belly up – nearing an end, the company is at a juncture where it would have to team up with other organisations, including automakers, to counter situations that could be an outcome of intense geopolitical shifts and the rising clout of Chinese players across continents in areas such as EVs. 
         

        Image for representative purpose only

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          United Nations Alliance Of Civilisations And BMW Group Honour India’s Grassroots Initiative

          United Nations Alliance Of Civilisations And BMW Group Honour India’s Grassroots Initiative

          United Nations Alliance of Civilisations and BMW Group has honoured India’s grassroots Initiative ‘Football and Beyond’ during the 10th UNAOC Global Forum. ‘Football and Beyond’ is the initiative of India-based organisation ‘Shreeja India’, which is one of the ten grassroots initiatives that were honoured recently under the Intercultural Innovation Hub (IIH), a joint initiative of the United Nations of Civilizations (UNAOC) and the BMW Group. The joint initiative was implemented with the support of Accenture.

          The ‘Football and Beyond’ initiative was honoured at a ceremony held in Cascais, Portugal, under the theme ‘United in Peace: Restoring Trust, Reshaping the Future – Reflecting on Two Decades of Dialogue for Humanity’.
          The Forum convened prominent figures, political leaders, UN officials including the United Nations Secretary-General, António Guterres, as well as representatives from civil society, academia, and the private sector, to share insights and reflect on the 20 years of the United Nations Alliance of Civilizations’ impactful work.

          The ’Football and Beyond’ initiative leverages the unifying power of football to bridge divides across diverse backgrounds while promoting inclusivity and empowerment. By using football as a development tool, the initiative integrates sports with education, mental wellness, social awareness, and skills development. This holistic approach empowers girls and uplifts communities that lack access to essential services such as basic education, nutrition, healthcare, and livelihood opportunities, paving the way for sustainable growth and social cohesion.

          "Shreeja India’s inclusive tactic to empower underprivileged girls and children with a sports-based endeavour is producing powerful narratives in the grassroots of rural India. With the recognition of the Intercultural Innovation Hub, we feel more driven to connect, collaborate and contribute towards breaking barriers and building cohesive societies," said Somasree Basu, Program Manager at Shreeja India.

          “With the Intercultural Innovation Hub, we celebrate outstanding initiatives implemented by extraordinary individuals working to bridge intercultural divisions in innovative and impactful ways,” said Ilka Horstmeier, Member of the Board of Management of BMW AG People and Real Estate, Labour Relations Director. “At the BMW Group, we believe that diversity not only enhances our company but is crucial for social unity and global progress. That is why we are deeply thankful for our strong partnership with the UNAOC. This collaboration allows us to support remarkable initiatives like Shreeja India’s work in empowering underprivileged children, making a tangible difference in their communities and contributing to a better and more inclusive Indian society,” she added.

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