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)

 

 

Stellantis - Antonio Filosa

European auto major Stellantis has unveiled its FaSTLAne 2030 strategy, which will see it invest around EUR 60 billion over the course of the next five years.

The aim is to accelerate growth and profit, prioritising customer centrality and capital allocation across its global regions and brands.

Antonio Filosa, CEO, Stellantis, said, “FaSTLAne 2030 is the result of months of disciplined work across the Company and is designed to drive long-term profitable growth. With the customer at the centre of everything we do, the plan will deliver our purpose – ‘to move people with brands and products they love and trust’ – powered by our unique combination of strengths.”

The strategy focuses on an overhaul of the brand portfolio to improve capital efficiency, leading to more than 60 vehicle launches and 50 refreshes by 2030. The company will direct 70 percent of its product investments towards its four global brands – Jeep, Ram, Peugeot and FIAT – and its commercial vehicle unit, Pro One.

Its regional brands, including Chrysler, Dodge, Citroen, Opel and Alfa Romeo, will share global assets, while DS and Lancia will be managed as specialty brands. Maserati will add two vehicles to its lineup.

Filosa noted, “Every brand in Stellantis will play a clear role in delivering our FaSTLAne 2030 commitments.”

Stellantis will allocate over EUR 24 billion to global platforms, powertrains and technologies, including the new STLA One architecture. By 2030, half of its annual volumes will be produced on three global platforms. The company will also deploy its software and autonomous driving architectures – STLA Brain, STLA SmartCockpit, and STLA AutoDrive – starting in 2027.

The plan incorporates new and expanded corporate partnerships to access markets and share manufacturing capacity.

Through Leapmotor International, Stellantis will share capacity at its Madrid and Zaragoza plants in Spain. A joint venture with Dongfeng will produce Peugeot and Jeep models for China, while a European joint venture with Dongfeng will handle distribution and capacity sharing at the Rennes plant in France.

Stellantis is also working with Tata Motors to improve supply chain synergies in the Asia-Pacific, Middle East, Africa and South America regions, and will explore technology collaboration with Jaguar Land Rover in the United States.

Manufacturing capacity utilisation will be adjusted across regions, with European capacity expected to decrease by more than 800,000 units to raise utilisation from 60 percent to 80 percent by 2030. US capacity utilisation is also projected to reach 80 percent by 2030.

To improve execution, Stellantis aims to reduce vehicle development cycles to 24 months and implement a Value Creation Program to cut annual costs by EUR 6 billion by 2028.

“The success of FaSTLAne 2030 is built upon the great talent and strong commitment of our Stellantis team. We will execute as one team, hands-on, to deliver incremental, profitable growth for the benefit of all our stakeholders,” added Filosa.

Regional targets under the plan include 25 percent revenue growth in North America, supported by 11 vehicles. Enlarged Europe targets 15 percent revenue growth, featuring a new generation of electric vehicles built at the Pomigliano d'Arco plant in Italy. South America aims for 10 percent revenue growth via a pickup offensive, while the Middle East and Africa targets 40 percent revenue growth through local manufacturing. The Asia-Pacific region will focus on asset-light growth to support export requirements.

Volvo Financial Services India

Eicher Motors (EML) and the Volvo Group have announced their intent to form a new 50:50 joint venture to provide financing, leasing and other financial services in India.

The partnership will be established through EML acquiring a 50 percent stake in Volvo Financial Services (VFS) India. Eicher Motors' board has approved an investment of up to INR 7.5 billion to subscribe to the equity stake. The exact investment amount will be finalised upon the closing of the transaction, which is subject to regulatory approvals.

The new joint venture will serve as the captive financing arm for products from Volvo Eicher Commercial Vehicles (VECV), Eicher Motors, Volvo Group and Royal Enfield. By combining VFS’s global financial services expertise with Eicher’s local market knowledge, extensive dealer network and product portfolio, the venture aims to offer more accessible and streamlined financing solutions to customers.

Siddhartha Lal, Chairman, Eicher Motors, said, "Expanding our highly successful 18-year partnership with Volvo Group, Eicher is now entering the vehicle financing business in India through a new joint-venture. This JV combines Volvo’s global financial services expertise and Eicher’s local knowledge and network. The JV will serve Eicher, Volvo, and Royal Enfield customers in India and presents an opportunity for EML to operate in an important segment of the value chain, using financing as a lever for a superior customer experience."

Marcio Pedroso, President, Volvo Financial Services, added, "We believe now is the time to sharpen our focus on the Eicher brand as well, with our intended partnership serving as a springboard for bringing innovative financial services and solutions to both current and new customers and dealers, positioning us well to create long-term value in the growing Indian market."

This joint venture builds upon the long-standing collaboration between Eicher Motors and Volvo Group, which has successfully operated Volvo Eicher Commercial Vehicles (VECV) for the past 18 years. VFS India has been operational in the market for over a decade and reported assets under management (AUM) of approximately INR 18.25 billion as of 31 March 2026.

MANN+HUMMEL Opens Global Technology & Innovation Center In Karnataka, Plots INR 1 Billion Investment Too

MANN + HUMMEL

MANN+HUMMEL has inaugurated its new Global Technology & Innovation Center in Tumkur, Karnataka. This facility serves as the company's largest development hub outside of Germany and is designed to accelerate global product development for mobility, industrial and purification applications.

The centre integrates research laboratories, testing infrastructure, digital engineering and data analytics. The company intends for this site to function as an innovation engine, leveraging India's engineering talent to shorten development timelines.

Additionally, MANN+HUMMEL announced plans for a new manufacturing facility in Pune. The company expects total investments across these initiatives to exceed INR 1 billion. Currently, the company employs approximately 1,250 people in India, with plans to add 300 to 400 more positions over the next year.

With existing operations in Tumkur and Bawal, and the upcoming site in Pune, the company is establishing a manufacturing footprint across Southern, Northern, and Western India to improve proximity to customers. Interestingly, India currently hosts over one-third of the company’s global R&D workforce.

Hasmeet Kaur, President of the Transportation Division, MANN+HUMMEL Group, said, “The new Global Technology & Innovation Center in India marks a significant milestone in MANN+HUMMEL’s global innovation journey. India stands at the forefront of engineering talent and technological advancement, making it a natural choice for our largest development hub outside Germany. This centre will not only accelerate our innovation capabilities but also enable us to deliver scalable, sustainable filtration solutions to customers worldwide.”

Sudeesh Karimbingal, Managing Director, MANN+HUMMEL India, added, “The new facility in Tumkur is a testament to India’s growing role as a strategic growth and engineering powerhouse for MANN+HUMMEL globally. For over 20 years, our Indian engineering team has been deeply embedded in our global product development. This centre transitions India from a support hub to a strategic engineering powerhouse, driving innovation that meets both local and global market needs.”

The Tumkur facility will prioritise – energy-efficient filtration systems, reduction of lifecycle emissions and circular economy solutions, including the use of recycled materials.

Stellantis And JLR Announce US Product Development Collaboration

Stellantis - JLR

European auto major Stellantis and British luxury brand Jaguar Land Rover (JLR) have signed a non-binding Memorandum of Understanding (MoU) to explore collaborative opportunities in the United States.

The partnership intends to create synergies in product and technology development by utilising the complementary strengths of both organisations.

The companies aim to leverage this collaboration to create value and support their long-term growth objectives within the US market.

Antonio Filosa, Chief Executive Officer, Stellantis, said, “By working with partners to explore synergies in areas such as product and technology development, we can create meaningful benefits for both sides while remaining focused on delivering the products and experiences our customers love.”

PB Balaji, Chief Executive Officer, Jaguar Land Rover, added, “As we continue to evolve JLR for the future, collaboration will play an important role in unlocking new opportunities. Working with Stellantis allows us to explore complementary capabilities in product and technology development that support our long‑term growth plans for the US market.”

Any potential transactions resulting from these discussions remain subject to standard closing conditions, including the execution of definitive agreements.

Stellantis, Dongfeng Group Ink MoU For Europe-Based Joint Venture