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)

 

 

Birla Carbon To Display Carbon Nanotube Solutions At Nanotech 2026

Birla Carbon To Display Carbon Nanotube Solutions At Nanotech 2026

Birla Carbon is set to showcase its innovative Nanocyl range of multi-walled carbon nanotube solutions at NanoTech 2026 in Tokyo, Japan, held from 28 to 30 January. The company’s presence at Booth 3W-A11 highlights a commitment to providing advanced materials that enhance performance and sustainability for industries including automotive, electronics, energy storage and transportation. Through the Nanocyl brand, a global leader in MWCNTs, Birla Carbon offers formulations that improve material efficiency, enable significant cost optimisation and support energy savings.

A key focus will be the NC7000 MWCNT, recognised for its high electrical conductivity, superior processability and strong mechanical property retention. Its UV resistance and exceptional cleanliness make it suitable for demanding industrial and advanced applications. Beyond the base material, Birla Carbon will showcase specialised engineered formulations that address specific industry challenges. These include thermoplastic concentrates for conductive polymers, elastomer masterbatches for durable static control and epoxy-based systems that improve conductivity with processing flexibility. The portfolio also features eco-friendly aqueous dispersions and specialised solvent dispersions tailored for energy storage applications, responding to the growing demand for sustainable and efficient conductive solutions.

This participation underscores Birla Carbon’s dedication to innovation-led growth and its commitment to developing advanced materials that meet evolving market demands. Visitors are invited to explore how these MWCNT technologies can enable new possibilities and support future growth in their own projects.

Laurent Kosbach, CEO, Nanocyl, said, “Nanotechnology is a powerful enabler of material innovation. Through the Nanocyl range of carbon nanotubes, we are advancing material properties such as electrostatic discharge (ESD), electrical conductivity, mechanical reinforcement and thermal dissipation across a wide range of materials. Nanotech 2026 provides an important platform to engage with global partners and demonstrate how our engineered formulations are already delivering value across demanding industries.”

Sadak Suraksha Abhiyan

Union Minister for Road Transport and Highways Nitin Gadkari has announced the return of the Sadak Suraksha Abhiyan (SSA) 2026. This campaign brings together figures from the film industry to address road safety through a public awareness initiative. The ministry will host a telethon on 25 January in Mumbai to mark the fourth year of the programme.

Notable participants joining the movement include Amitabh Bachchan, Alia Bhatt, Vicky Kaushal, Kay Kay Menon, Shankar Mahadevan and Swanand Kirkire. Data from the ministry shows that India recorded 487,707 road crashes in 2024, leading to 177,175 deaths. Figures indicate that adults between 18 and 45 years old represent over two-thirds of these fatalities.

The theme for SSA 2026 is 'Kartavya' (Duty), which frames road safety as a shared responsibility. The tagline for the initiative is ‘Parvaah Se, Kartavya Tak’. The 2026 edition operates on four pillars: Kartavya (Duty), Kayda (Discipline), Kavach (Shield) and Kranti (Change). These are intended to influence road user behaviour across the country.

Factors contributing to fatalities include overspeeding, rash driving, overtaking, jaywalking and the non-use of helmets and seatbelts. The campaign also highlights the failure to provide assistance during the golden hour. The initiative aims to use conversations and performances to encourage the public to follow road regulations.

The event is designed to move from awareness to action within the road ecosystem. The telethon will be broadcast on CNN-News18 on 25th January from 11:00 am onwards.

Honda Chief Engineer Sue Bai Elected To SAE International Board

Sue Bai, Honda

Sue Bai, Chief Engineer at American Honda Motor Co., Inc., has been elected to the SAE International Board of Directors.

She serves as the Director at Large for the 2026-2027 term, Bai is the second representative from Honda to join the governing body. Her appointment follows a career focused on the research and deployment of mobility technologies.

Bai manages the Sustainability & Business Development unit at American Honda. Her previous experience includes leading data business for the Digital Service Development Division, where she analysed transportation data to assist road infrastructure and traffic environments. Since joining Honda R&D Americas in 2004, she has held leadership positions at the Honda Research Institute USA and the Automobile Technology Division.

Within SAE International, Bai has chaired technical committees for Vehicle-to-Everything (V2X) standards. These protocols aim to coordinate safety for vehicles, pedestrians and cyclists. She has also acted as the technical lead for industry-government projects, including the Ohio Smart Mobility Corridor, a test bed for connected safety systems.

SAE International is a global network that develops consensus standards and provides career development for engineers. Bai has been a member for nearly 20 years and has received honours including the SAE Top Contributor of the Year in 2021 and 2022, as well as the James M. Crawford Executive Standards Committee Outstanding Achievement Award.

Bai holds a Ph.D. in Industrial Engineering and a Master of Science in Electrical and Electronics Engineering from the University of Michigan. Her work has spanned Intelligent Transportation Systems (ITS) and automated vehicle research.

Sue Bai, said, “I’m honoured to be elected to the SAE International Board of Directors. SAE plays a vital role in bringing engineers together to solve complex mobility challenges, and I look forward to further contributing to work that advances knowledge and solutions for the benefit of society.”

The SAE Board of Directors oversees the organisation’s mission to connect members through standards and learning opportunities. Bai’s term will focus on the application of engineering knowledge to address mobility issues.

Greencell Mobility

GreenCell Mobility (GCM), the electric bus platform backed by Eversource Capital, has completed a USD 89 million mezzanine funding round. The investment was provided by the International Finance Corporation (IFC), British International Investment (BII) and Tata Capital. The capital is designated to support the expansion of GCM’s electric vehicle operations across India.

The company currently operates a fleet of more than 1,200 electric buses and 270 charging stations. This funding will facilitate the growth of the fleet to 3,700 units. The expansion includes buses secured through the National E-Bus Programme and the PM Seva E-Mobility initiative. These vehicles will serve routes in Delhi, Madhya Pradesh, Andhra Pradesh, Bihar and Puducherry.

The mezzanine financing structure is intended to catalyse private and institutional capital for the transport sector. By increasing the number of electric buses on intra-city and intercity corridors, GCM aims to address air quality and carbon emission targets. The project also focuses on establishing payment-security models and financing structures that can be replicated in urban transport markets.

GCM functions as an OEM-agnostic platform, allowing it to integrate various bus models into its network. The investment will also fund the development of charging infrastructure required to support the larger fleet, specifically targeting connectivity in tier-2 and tier-3 cities.

Dhanpal Jhaveri, Vice-Chairman of Everstone Group and CEO of Eversource Capital, said, "Through this funding round for GreenCell Mobility, we are deepening our partnership with IFC, BII and Tata Capital (leaders in sustainable investments). The transaction exemplifies the catalytic role that private, development and institutional capital can play in accelerating India’s clean transport revolution. GCM’s expanded operations will drive transformation efficient transportation to cities and commuters while delivering returns."

Devndra Chawla, Managing Director & CEO, GreenCell Mobility, said, "This fundraise marks a significant milestone in GreenCell Mobility’s journey to build electric mobility as a mainstream, scalable public transport solution for India. The participation of IFC, BII and Tata Capital reflects strong conviction in our platform, our operating model, and our ability to execute at scale. As we expand our fleet and charging infrastructure across states under programmes such as PM Seva E-Mobility, our focus remains on delivering reliable, cost-efficient and zero-emission transport for cities and intercity corridors."

Katherine Koh, Regional Industry Manager, IFC, added, “Electrifying buses is central to India’s urban transformation agenda, and our mezzanine investment in GreenCell will accelerate the rollout of sustainable public transport for thousands of people across India’s tier-2 and tier-3 cities. It will create jobs while catalyzing private capital through innovative financing and payment-security models.”

Shilpa Kumar, Managing Director and Head of India, BII, said, “Climate action is a key priority for BII in India, with electric mobility as a key pillar of our climate investment strategy. Electric buses are a critical lever for decarbonising public transport at scale. Our investment in GreenCell Mobility reflects our commitment to supporting proven platforms that accelerate clean mobility.”

Manish Chourasia, Chief Operating Officer, Tata Capital, noted, "Tata Capital is pleased to participate in this strategic investment that accelerates India’s transition to cleaner, more efficient transport. GCM’s innovative approach aligns with our vision for sustainable urban development and inclusive growth.”