Browse Topic: Batteries

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Fuel Cell Electric Vehicles: Method for Characterization of Onboard Power Management System and Defining Vehicle Level Attributes2026-26-05701/16/2026
Fuel Cell and Battery Pack/Capacitors are two power sources on-board a Fuel Cell Electric Vehicle. Each having it's own set of boundary conditions and ideal operating conditions in order to deliver expected performance over the intended useful life. Such a dual power source architecture poses a challenge of optimally balancing power delivery from Fuel Cell and Battery Pack/Capacitor in order to ensure health of both these important aggregates of vehicle over it's intended useful life. Therefore, a method and tool for characterizing the Power Management System of Fuel Cell Electric Vehicle is required during development and validation. "Aggregate Sizing" and "Calibration of Power Control Strategy" are significant factors for optimum life of Fuel Cell powered vehicle without compromising performance. Although the former is mainly a design decision, the latter is crucial during testing and validation to achieve the design objective and avoid unwanted failures. Distribution of load catered
Deshmukh, Naval, Ganguly, Sutanu, Sindgikar, Pavan, Jain, Sarika
A Comprehensive Analysis of Sealing Methods for EV Battery Packs: Trends and Insights.2026-26-01801/16/2026
The widespread adoption of electric vehicles (EVs) has brought about unique engineering challenges, particularly in the design of battery packs, which are central to vehicle performance, safety, and longevity. One critical requirement is maintaining ingress protection (IP) ratings of IP67 or higher to safeguard against water and dust exposure. These ratings are essential to ensure compliance with homologation standards and to meet the demands of diverse terrains and operating conditions. Achieving effective sealing of EV battery packs is thus a key aspect of their design and engineering. This study presents an in-depth analysis of sealing technologies employed in EV battery packs, focusing on four primary types: Adhesive-based sealants, Cure-In-Place Gaskets (CIPG), Foam Cut seals, and Rubber Gaskets. Benchmarking data gathered from more than 90 vehicle models across 20+ brands provide insights into adoption trends, historical shifts, evolution and interface requirements of different
Varambally, Vishakha, Sithick basha, Abubakker, Chalumuru, Madhu, Yaser, K U Syed, Sasikumar, K
Advancing Sustainable Mobility: Transitioning to Zero-Emission Electric Vehicles with BEVs and FCVs2026-26-01641/16/2026
The transportation and mobility sector is undergoing a profound transformation, with a growing emphasis on sustainability and minimizing the environmental impact of transportation. Among the most significant trends is the transition to electric vehicles (EVs) in the form of Battery and Fuel cell, which produce zero emissions without any harmful gases release in nature. This review highlights several infrastructure-related issues and critical factors that could drive India's transportation sector toward adopting electric vehicles. It also delves into the fundamental understanding of e-mobility, shedding light on the daily challenges and barriers it faces. Furthermore, the study explores research aspects, including the strategies, methods, and tools used for electric vehicles to complete the research on Battery electric vehicles (BEV) and also comparative analysis with Fuel cell vehicles (FCVs). The shift BEVs has been driven by decreasing battery costs and advancements in charging
Kumar, Dr. Vijay Bhooshan
Dynamic Voltage EV System (DVEVS): Achieving Enhanced Electric Vehicle Efficiency and Performance through switchable Series-Parallel Battery Configuration2026-26-02031/16/2026
The study here investigates on the Electric vehicles (EVs), which are often segmented by range or performance, typically offered as distinct entities. Powertrain design also tends to be either settled or performance focused. A significant challenge in the automotive world is the charging time of EVs, a key performance indicator impacting customer convenience. Battery technology is evolving, allowing for potential architectural changes in battery modules over time. Issues such as cell balancing lead to energy wastage in batteries, and thermal management is critical as increased current causes higher I2R power losses and heat generation. Battery weight negatively affects EV efficiency and range. Adapting to new battery cell technologies and architectures can be costly. Addressing these challenges, this paper presents on Dynamic Voltage EV System (DVEVS) as a solution to enhance EV efficiency by dynamically adjusting battery voltage based on driving conditions. Such as Utilizing a smart
Amberkar S, Sunil, Raool, Anuj Rajesh, M G, Shivanag, RAJAPURAM, BHEEMA REDDY
Integrated Side Fairing and Crash Protection System for High Voltage EV Battery Safety2026-26-00281/16/2026
The paper presents a well-engineered and novel structural solution for side impact protection of high-voltage battery packs in electric trucks. While electric vehicles offer benefits like zero emissions and independence from fossil fuels, in turn present challenges in meeting crashworthiness standards and safety regulations. The device addresses the critical need for effective battery protection & styling of battery electric vehicles. The integration of a hybrid corrugated panel system with plastic side fairings is innovative, combining crashworthiness with aerodynamic and aesthetic benefits. The crash protection features two hat-section steel channels at the top and bottom and corrugated steel sheet with alternating ridges is attached to these channels. Corrugated panels are enforced with help of backing strips. This assembly is mounted on shear plates at both ends, secured to the vehicle's frame rail. During a side impact event, the plastic side fairings absorb the initial impact
Badgujar, Prathamesh, Devendra, Awachare, Hansen, Benjamin
Enhancing EV Battery Safety: Progressive Crushing and Energy Absorption Techniques2026-26-01891/16/2026
• The paper presents and provides a crash energy absorption assembly and method for enhancing the safety and structural integrity of battery packs in electric vehicles during collision events adhering to global regulations. • One of our novel analyses is described here, in which the assembly comprises a battery housing designed to mount one or more battery cells, at least one crash member coupled to the side surface of the battery housing, flexural members coupled to the crash member. The flexural members are designed to absorb impact forces, deform, and store potential energy during sudden impacts. This innovative approach ensures that the energy is stored within the flexural elements rather than being transferred to the battery cells, thereby reducing almost cell intrusion for example by 50% under a 100kN which is EC100R requirement. The design effectively delays intrusion, enhances battery safety and minimizes cell-level damage. • Also, the strategic placement of flexural members
Amberkar S, Sunil, Lakshman singh, Meenakumari, Bodaindala, Anil
Analysis of Second-Life electric vehicle batteries value maximizing through repurposing and resale, ways to achieve optimal performance and standardization challenges for testing and certification2026-26-01931/16/2026
As electric vehicle (EV) adoption accelerates globally, a growing volume of lithium-ion batteries are reaching end-of-life in their primary automotive application—despite retaining 60 to 80% of their original capacity. This presents a significant opportunity to extend battery utility through second-life applications such as stationary energy storage, microgrid support, and commercial backup systems. This paper analyzes the strategies for maximizing the residual value of second-life EV batteries through repurposing and resale, while also addressing the challenges associated with performance optimization and standardization of testing and certification procedures. The study evaluates the techno-economic viability of second-life batteries compared to new systems, emphasizing cost savings, environmental impact, and emerging market demand. Techniques for enhancing second-life performance are examined, including advanced state-of-health (SoH) diagnostics, machine learning models for usage
Agarwal, Pranjal, Penta, Amar
Coupled Thermo-Mechanical Simulation Framework for Structural Evaluation of Battery Pack2026-26-04141/16/2026
With the rapid adoption of electric vehicles (EVs), ensuring the structural integrity and thermal safety of lithium-ion battery pack has become a critical priority. Battery failures resulting from mechanical abuse, thermal stress, internal pressure build up or electrical faults may lead to structural failure. To address these challenges, it is essential to understand the coupled thermal and mechanical responses of battery structure under extreme conditions. Thermo-mechanical simulation serves as a powerful tool for predictive safety assessment and design optimization, particularly in addressing thermal propagation and pressure-induced failure events. This study presents a comprehensive coupled thermo-mechanical simulation framework designed to evaluate the structural performance of EV battery enclosures under worst-case thermal and overpressure conditions. The methodology involves high-fidelity three-dimensional modeling of the battery pack enclosure, incorporating realistic material
BHAT, SADASHIV C, Sugumar, Mohanraj
Steel-based Laminates for Lithium-ion Pouch Cell of Electric Vehicles2026-26-01861/16/2026
Aluminium foils have gained traction with EV battery manufacturers for their pouch cell format. Over the years it has evolved as a material of choice, but it is still plagued by issues of stress concentration, swelling due to lower strength and stiffness of base aluminium layer. Preliminary investigation revealed that laminates using steel foil material (thickness <0.1mm) could be a potential candidate for EV pouch cell casing. Thus, steel-based laminate was developed meeting key functional requirements (e.g. barrier performance, insulation resistance, peel strength, electrolyte resistance, formable without cracking at edges, and heat sealing compliant). This innovative patented steel-based laminate was further used to manufacture pouch cell prototypes (maximum capacity 2.5Ah) for key performance tests (e.g. cell cycling, nail penetration and thermal runaway). The study paves the way for a low cost, sustainable and flexible yet strong steel-based laminate packaging material solution
Singh, Pundan Kumar, Raj, Abhishek, Kumar, Ankit, Chatterjee, Sourabh, Verma, Rahul Kumar, Samantaray, Bikash, Gautam, Vikas, Pandey, Ashwani
Simulation Based Approach to Optimize Electric Vehicle Battery Thermal System2026-26-03761/16/2026
The performance and longevity of Li-ion batteries in electric vehicles are significantly influenced by the cell temperature. Hence, efficient thermal management techniques are essential for battery packs. Simulation based optimization approaches can enhance these techniques during early product development and life cycle. In this work, a method to optimize the battery thermal system comprising of cooling plate and external insulation is described. The first part is to optimize the cell heat extraction by the cooling plate. The heat transfer coefficient of the coolant is a parameter which can indicate the thermal efficiency of a cooling plate. At the same time, it's important to keep the coolant pressure drop within a reasonable limit. A 1D simulation methodology is described to optimize the cooling channel height based on pressure drop and heat transfer coefficient targets. This methodology is based on empirical correlations and multi-objective pareto optimization. The advantage of
U, Reghunath, P S, Shebin
Circularity and LCA: Enhancing Sustainability in the Indian Electric Vehicle Sector2026-26-02391/16/2026
The global shift to electric vehicles (EVs) is vital for reducing greenhouse gas emissions, but their sustainability hinges on effective battery lifecycle management. This review examines the interplay between Life Cycle Assessment (LCA) and circular economy (CE) principles in EVs, with a focus on both international trends and India-specific challenges. We analyze CE strategies such as extending battery lifespan, second-life applications, and recycling integrated with LCA to evaluate environmental impacts from raw material extraction to disposal. Key areas include battery chemistry, LCA methodologies, policy frameworks, and industrial practices, informed by a synthesis of over 50 peer-reviewed articles, technical papers, and sustainability reports. Challenges include inconsistent LCA baselines, low material recovery in informal recycling, and regulatory gaps, particularly in India. Despite these, innovations like solid-state batteries and advanced recycling techniques offer promise
Haregaonkar, Rushikesh Sambhaji, Kumar, Om, Sankar M, Gopi, Kumar, Rajiv
Transforming Battery Management: The Role of Artificial Intelligence and Machine Learning in Digital Twin Technologies2026-26-03821/16/2026
The traditional Battery Management System (BMS) faces certain limitations in fully utilizing battery capacity and performance during the long cycle life operation of Electric Vehicles (EVs). These constraints include limited real-time data collection, low processing speed, lack of predictive maintenance, and very limited accuracy in predicting health and degradation chemistry. A Battery Digital Twin (BDT) can effectively address these limitations of the BMS. Battery Digital Twins (BDT) can be viewed as a cyber-physical system comprising four key elements: virtual representation, bidirectional connection, simulation, and connection across the life cycle phases of an EV battery. The performance of a Li-ion battery largely depends on the cathode chemistry, component design, and operating conditions. The battery should be manufactured in a manner (such as cylindrical or prismatic cell) that prevents explosion, leakage, and gas generation inside the battery. To enhance the performance and
Chaturvedi, Vikash, M, Venkatesan, Lanke, Siddhi, Subramaniam, Anand, Karle, Manish, Pandit, Rugved, Gupta, Drishti, Karle, Ujjwala Shailesh
Driving Thermal Intelligence – Pioneering Digital Twin-Driven Hardware-In-Loop for Smart Climate Control Modules2026-26-03801/16/2026
The automotive industry is undergoing a transformative shift from hardware-driven vehicle development to software-centric, model-based validation practices. At the heart of this evolution is the demand for smarter, more adaptive cabin climate management systems. The Climate Control Module (CCM) a critical embedded ECU—regulates the vehicle’s Heating, Ventilation, and Air Conditioning (HVAC) functionality based on a fusion of passenger inputs and environmental sensor data. Traditionally, validation of such systems relied heavily on manual testing within climatic chambers or through in-vehicle trials using physical interfaces like the Climate Control Head (CCH) and the Infotainment Head Unit (HU). These legacy methods are increasingly inadequate in addressing rapid development cycles, high functional complexity, and stringent safety and quality standards. This paper introduces a Digital Twin-enabled Hardware-in-the-Loop (HiL) testing methodology using advanced real-time controllers to
More, Shweta, Shinde, Vivek, Turankar, Darshana, Patel, Dafiya, Gosavi, Santosh, GHANWAT, HEMANT
Comparative Assessment of Lithium-Ion Battery Recycling Strategies: Unveiling Challenges, Optimizing Benefits, and Exploring Future Potential.2026-26-02011/16/2026
This research paper offers a comprehensive evaluation of lithium-ion battery recycling methods, tracing the entire journey from global demand to the practical challenges and solutions for sustainable battery recycling. It starts with the analysis of worldwide LIB demand growth alongside the exponential growth in volumes of spent batteries and recycling rates. The study focuses on the imbalance in production and recovery of critical battery components and its environmental and economic effects. The paper then systematically examines six major recycling methodologies: mechanical, pyrometallurgical, hydrometallurgical, biotechnological, direct, and ion-exchange recycling. It goes into detail about their advantages, limitations, and roles in maximizing the recovery of valuable metals such as lithium, cobalt, and nickel. Traditional techniques like hydrometallurgical and pyrometallurgical methods, and emerging approaches including bioleaching and ion-exchange, are evaluated for their
Jain, Gaurav, PREMLAL, P, Pathak, Rahul, Gore, Pandurang
Optimizing Busbar Design by Investigating Critical Parameters and Their Influence on Electrical and Thermal Behaviors for Reliable Electric Vehicle Battery Packs.2026-26-04741/16/2026
With the rise of EVs, researchers are focusing on optimizing busbar design to meet the demands of high energy density, fast charging, and compact battery packs. The busbar design starts with selecting the cross-sectional area based on current-carrying capacity and material type. The width matches or exceeds the battery cell terminal size, while the length is optimized based on space constraints. The research also highlights the risk of busbars to oxidation and corrosion, which increases resistance and decreases thermal conductivity for which Plating and coating techniques are applied to improve surface hardness, durability, and thermal conductivity while minimizing heat loss. Using simulations and experimental validation, the study examines three key design parameters: weld diameter, electrical resistance, and contact resistance. A detailed analysis investigates how weld diameter influences electrical resistance and temperature rise, as well as the impact of contact resistance between
Nogdhe, Yogesh, Singh, Shobit Kumar, Paul, Jibin, Mishra, Mukesh, MENON, Praveen
Innovative Friction Locking Mechanism for High Voltage Busbar Connections in EV Batteries2026-26-01551/16/2026
In the development of high-voltage (HV) batteries, ensuring secure connections between HV conductors and maintaining the safety and performance of the battery pack is paramount. Therefore, In the pursuit of enhancing efficiency and reliability in electrical connections, this paper explores the innovative alternate for a traditional screwing method with a friction locking mechanism for connecting busbars. The novel design reimagines the busbar as a Friction clamp (Female part) that securely holds the male part of the Busbar, significantly increasing the contact surface area up to 50%. This enhanced surface area not only improves electrical conductivity but also reduces heat generation, addressing common issues associated with traditional screw-based connections. By eliminating the need for screws, the new design streamlines the assembly process, resulting in reduced cycle times and improved overall assembly line efficiency. This study presents the design methodology, performance
Venkatesh, Murali, Raghu, Arun, Bhramanna, Amol
Enhanced Integrated Cooling-Protection Plate for Battery pack Underbody Impact Resistance in Electric Vehicles2026-26-01691/16/2026
In the quest for enhancing electric vehicle performance and safety, this paper presents a comprehensive investigation into the design and performance of high-voltage (HV) battery cooling plates featuring dedicated cooling channels, integrated with structural bottom protection members positioned at the bottom. The study aims to address the dual challenges of effective thermal management and enhanced crash protection in electric vehicles. Through a combination of Design iterations, Thermal performance evaluation and Crash simulations, the research evaluates the cooling efficiency and structural resilience of the proposed design. Findings reveal that the integrated cooling plates not only maintain optimal battery temperatures under various operating conditions but also significantly improve the vehicle's crashworthiness. The paper concludes with the results of numerical simulations, rigorously validated against the robust design requirement globally accepted for series components to
DUSAD, SAGAR, Kummuru, Srikanth, Joshi, Amarja
Performance Evaluation of Battery Pack With E-Rickshaw on Chassis Dynamometer by Using In-House Developed Driving Cycle2026-26-01481/16/2026
The present work highlights a case-study that aims to determine the performance (power input/output) and battery temperature on in-house developed e-rickshaw battery pack. With the rise of e-rickshaws in Indian market, the demand for the batteries have also increased and being the largest state-run energy company of India, R&D Centre of Indian Oil Corporation Limited (IOCL) has developed a chemically modified nanomaterial-based lead acid battery. The lab scale experiments, which are not presented in the study due to confidentiality and intellectual property obligations, indicated that the nanomaterial doped lead acid battery pack performs better than the control (reference) and leading commercial batteries in terms of lifecycle, capacity etc. Subsequently, this paper highlights the performance with IOC R&D Centre manufactured 12V/100AH chemically modified (nanomaterial) lead acid battery pack for e-rickshaw on duty cycle developed indigenously based on the city driving experiences. The
Saroj, Shyamsher, Sithananthan, M, Kumar, Prashant, Arora, Ajay, Sundaram, P, Kalita, Mrinmoy
Integrated Simulation of Electric Vehicle Model Using the ROM Approach2026-26-03691/16/2026
The growing demand for Electric Vehicles (EVs) has highlighted the importance of efficient and accurate simulation tools for design and performance optimization. The architecture of electric vehicles is distinct from that of internal combustion engine vehicles. It consists of on-board charger, DC-DC converter, Lithium ion battery pack, Inverter, electric motor, controllers and transmission. The battery pack supplies electric current to the traction motor, which then converts this electrical energy into mechanical energy, resulting in the rotational motion needed to drive the vehicle. Wide range of Multiphysics is involved in the simulation which involves Power electronics, Electromagnetics, Fluid Mechanics, Thermal engineering. This paper presents an integrated simulation and range prediction methodology for Electric Vehicles (EVs) using the Reduced Order Model (ROM) approach. The methodology includes simulation in both 3D and 1D domain. Computational fluid dynamics (CFD) simulation is
Shandilya, Anand, Kumar, Vivek
Structural design and simulation of Composite Metal Hybrid based battery enclosure for an electric vehicle2026-26-03001/16/2026
Addressing the critical need for lightweight and safe energy storage solutions in electric vehicles, this paper presents the design and optimization of a novel Composite Metal Hybrid (CMH) battery pack structure. A computer aided simulation using Abaqus software was done to optimize the weight of battery pack. The structural integrity and crash worthiness of the optimized lightweight design were rigorously evaluated under various load cases like side impact (crush), shock loading and underfloor impact. Manufacturing aspects were discussed to ensure feasibility and integration. Modal analysis and load tests addressed demonstrate the CMH battery pack as a viable and promising lightweight solution for electric vehicle applications.
Shah, Bijay Kumar, Singh, Pundan Kumar, G., Manikandan
Design and Validation of UDS Application Software for Fuel Cell Electric Vehicle within AUTOSAR Framework2026-26-02531/16/2026
Affordable and clean energy has been one of the major objectives adopted by United Nations under the 2030 Agenda for Sustainable Development. In this direction, fuel cell electric vehicles have gained popularity in recent times due their efficiency and environmental friendliness. Fundamentally, it uses compressed hydrogen from the vehicle-mounted tank and combines with ambient air to generate DC electricity. Water is created as a by-product and expelled through the tailpipe. The technology being integrated on powertrain architecture, along with battery pack can prove to be an efficacious approach for zero emission automotive system. However, hydrogen being the primary fuel, and being stored at high pressure, the system involves handling and potential hazards of hydrogen, and possibility of explosions due to hydrogen leaks. Hence, safety is the key issue in handling fuel cell vehicles. This paper discusses about role of Unified Diagnostic Services (UDS) in providing safety and
PRASAD, Dr. P SHAMBHU, Jacob, Joe, Hadke, Tanmay, Wagh, Priyanka, Achanur, Mallappa
Preventing thermal run-away using shape memory alloy2026-26-00091/16/2026
Title: Preventing thermal run-away using shape memory alloy Rini Reginald, Ashish Chauhan, Saswat Rout, Venkatesh Muthukrishnan Mercedes-Benz Research and Development, India Key words: Thermal Runaway, Active and Passive Safety, Shape Memory Alloy, Nitinol, Literature Survey, Structural Simulation Abstract The present disclosure pertains to advancements in battery modules for electric vehicles (EVs). Addressing the critical issue of thermal runaway in high-voltage battery packs, this invention introduces a novel battery module designed to enhance safety of the vehicle. The battery module comprises a plurality of battery cells housed within an enclosure, electrically connected to the vehicle's circuit via busbars and innovative connectors made of Shape Memory Alloy (SMA). These connectors are engineered to transition between two states: a first state where they facilitate electrical coupling and a second state where they isolate the battery cells upon detecting temperatures exceeding a
Reginald, Rini, Rout, Saswat, VENKATESH, Muthukrishnan, Chauhan, Ashish Jitendra, Selvaraj, Elayanila
A strategic approach to the selection of switchgear and busbars for EV battery packs2026-26-01651/16/2026
With the rising adoption of electric vehicles (EVs), the need for robust and efficient power distribution systems has become increasingly important. This paper outlines a strategic method for selecting switchgear and busbars in EV battery packs, emphasizing key factors such as safety, energy efficiency, thermal control, and future scalability. Proper optimization of these components can significantly improve performance, minimize power losses, and ensure durability under demanding operating conditions. The design and selection of battery conducting components, such as switchgears and busbars, are typically based on the maximum continuous and peak current capabilities of the EV battery pack. While this approach ensures that the components can withstand extreme conditions, it often leads to over-engineering, resulting in unnecessary costs and added weight. However, this method overlooks the dynamic power demands of the vehicle, which fluctuate based on driving conditions and usage. Real
Soman, Anu, satheesh, Goutham, K, Mathankumar
Drive Cycle Based Energy Audit & Range Estimation for 4X2 Electric Truck2026-26-01631/16/2026
Transportation sector in India accounts for 18% of total energy consumption. Demand of energy consumption is being met by the imported crude oil, which makes transportation sector more vulnerable to fluctuating international crude oil prices. India is mindful of its commitment in 2016 Paris climate agreement to reduce GHG emissions by 35% by 2030 as compared to 2005 levels. To fast track the decarbonization of transportation sector, commercial vehicle manufacturers have been exploring other viable options such as battery electric vehicles (BEVs) as a part of their fleet. As on today, BEV has its own challenges such as range anxiety & high total cost of ownership. Range anxiety can be certainly addressed by optimum sizing of electric powertrain, reduction in specific energy consumption (SEC) & use of effective regeneration strategies. Higher SEC can be more effectively addressed by doing vehicle energy audit thereby estimating the energy losses occurring at each powertrain component of
Gijare, Sumant, Karthick, K., Juttu, Simhachalam, Thipse, Sukrut S., A, Jothikumar, J, Frederick Royston, SR, Subasree, G, Harini, M, Senthil Kumar
Correlation of Power Rating for Battery Electric Vehicles Simulation vs. Test Validation in Accordance with regulatory compliance2026-26-05751/16/2026
Accurate power and energy assessment in Battery Electric Vehicles (BEVs) requires high-fidelity simulation models that reflect real-world performance. This study presents a power rating correlation of the Stellantis Dodge model in compliance with the GTR 21 standard, validating the simulation’s accuracy against physical test data. Simulations conducted using STLAsim, Stellantis’ proprietary tool, estimate EDM power at the inverter input and axle output under standardized conditions. The operating parameters were shared with the testing team to ensure consistency; however, the initial test results deviated by approximately 18 kW from the simulation target. To address this delta, EDM speed and vehicle speed were optimized, achieving a close alignment with the simulation and meeting the GTR 21 power rating criteria. The results demonstrate a strong correlation between the simulation and test data, confirming the model’s accuracy and reliability. This study underscores the effectiveness of
Mahajan, Prasad, ali, Shoaib
Design of the BIW structure for battery pack protection in case of side pole impact.2026-26-00251/16/2026
Electric vehicles (EVs) are becoming more popular than Internal Combustion Engine (ICE) powered vehicles, but their battery and motor components elevate their Gross Vehicle Weight (GVW), posing unique collision risks. Manufacturers strategically mount the high voltage (HV) battery packs under the passenger compartment to lower the Centre of Gravity and shield them from the front impacts. However, side impacts remain a concern, as the battery deformation in such instances could trigger fires or explosions, endangering occupants. To address this, crashworthiness designs adhere to New Car Assessment Program (NCAP) standards, particularly against side pole impact and side mobile barrier impact. Unlike the frontal section of BIW, which typically has larger crush space to absorb the crash energy, extensive design attention is required to the vehicle's side structure to absorb pole impacts without transmitting excessive force to the battery pack. Utilizing aluminium extrusions and sheet
Nivesh, Dharun, NAMANI, Prasad, Ramaraj, Rajasekar
Conceptual Framework for Real-Time Battery Health Estimation in Automotive Digital Twins Using Reinforcement Learning2026-26-06581/16/2026
The explosive growth of electric vehicles (EVs) calls forth the need for smart battery management systems that can perform health monitoring and predictive diagnostics in real-time. The conventional battery modeling methods mostly do not cover the complicated, dynamic behaviors coming from different usage patterns. The study outlines a structure that would use Reinforcement Learning (RL)-based AI agent as a part of the Battery Electrical Analogy (BEA) simulation platform. With the help of the AI agent, different health parameters such as State of Health (SOH), State of Charge (SOC), and the signs of early thermal runaway can be predicted in real-time. The suggested design takes advantage of the simulation-based approach to have the agent learn and utilizes a decentralized cloud architecture suitable for scaling and reducing the response time. The RL agent performs an essential role in the process by tagging along with the continuous learning and the adjustment of the battery conditions
Pardeshi, Rutuja Rahul, KONDHARE, MANISH, Sasi Kiran, Talabhaktula
Influence of Solar insolation load over the battery pack of a 3-Wheeler Vehicle2026-26-01911/16/2026
Battery is one of the advancing topics in the current automotive industry, it is necessary to understand in detail every possible design scenario to make the operation safe. This research investigates the influence of solar radiation on a battery pack located beneath the driver’s seat in a three-wheeled vehicle. Solar rays can strike the battery pack’s surface at varying incident angles, particularly during sunrise and sunset. This study focuses on understanding how angular variations affect the intensity and distribution of solar load on the battery enclosure. Using three-dimensional Computational Fluid Dynamics (CFD) simulations, the study quantifies the temperature rise within the battery pack caused by solar exposure. Elevated temperatures can impair battery performance and accelerate its degradation over time. Additionally, the research examines the impact of the surface finish of the battery enclosure, highlighting how it influences heat absorption and dissipation. The findings
P, Selvandran, Kolla, Kalyan
Establishing a High-Pressure Direct Injection Hydrogen Engine Test Facility with Integrated Ammonia Fuel Capability: Technical Considerations, Safety Framework, and Best Practices2026-26-02671/16/2026
The transition toward zero-carbon propulsion technologies has highlighted the urgent need for specialized test infrastructure to support hydrogen and alternative fuel research. This paper presents the conceptualization, design, and operation of a High-Pressure Direct Injection (HPDI) Hydrogen Internal Combustion Engine (H2 ICE) test facility with integrated ammonia fuel testing capability, marking a significant advancement in India’s sustainable automotive research efforts. Drawing from practical experience, it outlines crucial technical specifications, safety protocols, and best practices for establishing robust, adaptable, and secure testing environments. Addressing the industry’s need for dedicated infrastructure, it is engineered for adaptability across various engine types—including heavy-duty, light-duty, and multi-utility vehicles—while aligning with global technical standards. Key technical considerations include the use of a transient dynamometer that features an advanced
Dhyani, Vipin, Kurien, Caneon, Subramanian, Balaji, Khandai, Chinmayananda, Muralidharan, M
Battery Thermal Management Approach for 2-Wheeler Electric Vehicles – An Indian Case Study2026-26-01511/16/2026
India's electric 2-wheeler (E2W) market has witnessed fast growth, driven by lucrative government policies. Two-wheeler market captures 73% volume of total Indian automotive market, representing the largest segment (Greaves Electric Mobility Limited report 2024). Consequently, all manufacturers of 2-wheelers are developing new electric vehicles (EV) tailored for the Indian market. However, the Indian EV market has witnessed multiple fire accidents in recent years, raising safety concerns among consumers and industry stakeholders. These incidents highlight key weakness in battery thermal management systems (BTMS), particularly during charging. Most existing E2W BTMS relies on passive air cooling, which has been associated with fire incidents due to its inefficiency in heat dissipation, particularly charging in India's high-temperature environment. Therefore, it is imperative to build thermally viable and economical BTMS for the growing E2W vehicles with fast charging capability. The
Emran, Ashraf, Sankhla, Harsh, Garg, Shivam, Raut PhD, Ankit, Hiremath, Vinodkumar, Berry, Sushil
Real-time range optimization for selected destinations by Dynamic Energy Management Strategy (DEMS) in BEV’s2026-26-01681/16/2026
The automotive industry has undergone significant transformation with the adoption of electric vehicles (EVs). However, to tackle range anxiety, the focus has shifted to energy management strategies for optimal range under different driving conditions. Developing an optimal energy management algorithm is crucial for overcoming optimal range and gaining a competitive edge in the market. This paper introduces a Dynamic Energy Management Strategy (DEMS) for electric vehicles (EVs), designed to optimize battery usage and extend driving range. Utilizing vehicle digital twin model, DEMS estimates energy consumption across Eco, Normal, and Sports driving modes by analyzing vehicle velocity profiles and pedal inputs. By calculating actual battery consumption and pinpointing excess power usage, DEMS operates in a closed loop to periodically assess the power gap based on real-time vehicle conditions, including HV components like the Electric Drive system, DCDC, E-compressor and E-Heater; and
Dey, Supriyo, Venugopal, Karthick Babu, Penta, Amar, KUMAR, Rohit, Arya, Harshita
State-of-the-Art Battery Thermal Management Technologies for SCV EV: An Integrated Approach to Enhance Energy Utilization, Boost Battery Efficiency, and Reduce Expenses2026-26-00761/16/2026
The Effective battery thermal management is fundamental to ensuring both the performance and durability of small commercial electric vehicles. This study investigates advanced methods for maximizing energy efficiency, extending driving range, shortening charging durations, and lowering costs by employing insulation and thermoelectric cooling technologies. India's diverse and often extreme climatic conditions-ranging from intense summer heat to cold winters-significantly affect the thermal management of electric vehicle (EV) batteries. Also in small commercial vehicle segment uncontrolled operation condition (loading & off-road driving) of vehicle is common in India which leads to higher average C rate from battery implies need active battery cooling. Keeping batteries within their optimal temperature range is vital for maintaining their efficiency, safety, and service life. Advanced thermal insulating materials stabilize battery temperatures by minimizing heat gain and external
Chormule, Suhas Rangrao, Warule, Prasad, Nagpure, Rahul, Jadhav, Vaibhav
Integrated Quality Assurance Frameworks for Testing Advanced Automotive Systems in the Era of ADAS and E-Mobility2026-26-05681/16/2026
As the automotive industry rapidly transitions toward intelligent, electrified, and connected mobility, ensuring the safety and performance of advanced vehicle systems has become increasingly complex. Technologies such as Advanced Driver Assistance Systems (ADAS), electric powertrains, and software-defined architectures demand robust quality assurance (QA) frameworks capable of addressing the multi-domain nature of modern vehicle platforms. This paper presents an integrated QA methodology that combines traditional testing protocols with model-based validation, digital twin environments, and real-time system monitoring to comprehensively evaluate the reliability and functionality of next-generation automotive systems. The proposed framework focuses on end-to-end traceability from requirements to validation, encompassing hardware-in-the-loop (HIL), software-in-the-loop (SIL), and over-the-air (OTA) testing strategies. Emphasis is placed on simulating complex scenarios for ADAS, battery
KOMANDURI, ARUN SRINIVAS, Srivastava, Anuj
Thermal Management Control strategy for Primary & Secondary Drive Cooling Hybrid Electric Tractor2026-26-00691/16/2026
Global emission norms are getting very strict due to combat the harmful pollutants from internal combustion engine. Hence internal combustion engine (ICE)-based agricultural tractors need to introduce complex after-treatment systems and fuel optimization to provide same or higher value to farmers as cost of these systems drive the overall cost of the product. Engineers around the world are building Electric vehicles to combat the problem and has range issues due to design constraints & Hybrid tractors have emerged as a promising intermittent solution. It helps in combining the advantages of respective ICE and electrification solutions while reducing overall vehicle emissions and enhances operational flexibility. This paper presents a modular thermal modes system developed for a hybrid electric tractor platform where a downsized diesel engine operates at optimal efficiency DC generator used to charge the battery & DC converter is used to charge the auxiliary battery. Battery which is
K, Sunil, Makana, Mohan, Natarajan, Saravanan, K, MALA
The selection of a two-speed gearbox for small commercial electric vehicles aims to optimize powertrain efficiency2026-26-04171/16/2026
In response to the significant environmental challenges posed by climate change driven by global warming, the automotive industry is accelerating the transition toward electrification. While electric vehicles offer considerable potential for mitigating CO₂ emissions, their elevated upfront costs pose a notable challenge to large-scale market penetration. Energy efficiency improvement of electric vehicles is emerging field of research to reduce total cost of ownership. Electric vehicle powertrain component selection in small commercial vehicles including three and four wheelers is a complex process which has to fulfil multiple requirements Range, performance, drivability, packaging, total cost of ownership of vehicle and comfort. In addition, powertrain configuration including battery, motor and transmission ratio selection plays a fundamental role in cost of electric vehicle. Hence, The task of selecting the right powertrain configuration, encompassing architecture, motor selection
Wani, Kalpesh, Jadhav, Vaibhav, Shendge, Raman, Warule, Prasad
Applicability of EMC Validation for EV powertrain components2026-26-01971/16/2026
The technology in the automotive industry is evolving rapidly in recent times. An electric vehicle is a complex and dynamic system consisting of numerous components interacting with each other. With increase in number of EVs on Indian roads, EV makers to produce innovative and pragmatic concept of electric vehicle features. Considering all these, EMC Testing of all power train components with real case scenarios is utmost important. This paper will put a light on applicability of various EMC tests for EV components like Traction Battery, Traction Motor and Inverter, DC to DC Converter, 3 in 1 Unit, 4 in Unit, BTMS unit, HVAC system, On Board Charger etc. With ICE vehicles, all components were connected to only 12/24V battery but with the EV era, Components are getting connected to HV battery or LV battery or sometimes both. With this change, all ISO and CISPR standards were undergone with major revisions. It is important to consider these changes while performing EMC test. This paper
Yeola, Mayur, Murumkar, Aditya, Mulay, Abhijit B
Impact of Electric Exhaust Heater Power Electronics unit (EHPE) and Energy Storage Systems on Economy and Performance of Heavy-Duty Mild Hybrid Vehicles2026-26-01841/16/2026
With stringent emission norms enforced by governments and public authorities, advancements in internal combustion (IC) engine-based vehicles have become crucial. Cold starts and low-temperature combustion contribute significantly to vehicle emissions and need to be addressed to comply with upcoming stringent emission norms. An electric exhaust heater is known to reduce emissions by maintaining optimal exhaust temperature. For efficient energy management, exhaust heaters are typically powered by an onboard Energy Storage System (ESS), charged by electric machines. These electric machines in hybrid architecture provide efficient energy management by utilizing the recuperated braking energy of vehicles. However, the addition of a 48V hybrid system increases overall vehicle weight, and the vehicle effectiveness depends significantly on the vehicle application and ESS type used. The focus of this study is to investigate the impact of mild hybrids on fuel economy and performance for
Sadaraboina, Vidyasagar, Mehta, Kavish, Patil, Lalit Murlidhar, Busdiecker, Matthew, Karrer, Ben
Simulation of EV range Estimation for different payload of vehicle.2026-26-03891/16/2026
The electrification of transportation is reshaping the automotive and logistics industries, with electric vehicles (EVs) playing an increasingly central role in passenger mobility and commercial operations. As EV adoption grows, the need for accurate range estimation becomes critical, particularly under varying operational conditions such as increased payload. A key business challenge lies in the significant variability of EV range due to changes in vehicle load, which can affect performance, operational efficiency, and cost-effectiveness—especially for fleet-based services. This study focuses on addressing the technical gap in predicting EV range with respect to different payload conditions. Traditional range estimation methods often fail to account for real-world variables like additional cargo weight, leading to suboptimal route planning, increased energy consumption, and unanticipated charging requirements. Payload-induced range degradation can result in up to some deviation in
Khatal, Swaraj, Gupta, Anjali, Krishna, Thallapaka
Development of a HIL Based Methodology for Over-The-Air Updates Validation2026-26-04801/16/2026
Over-the-Air (OTA) update technology has come forth as a transformative aider in the domain of automotive technology, allowing Original Equipment Manufacturers (OEMs) and Tier-1 suppliers of Electric vehicles (EVs) to frequently make software modifications, enhancements, and bug fixes that are essential to optimize the performance of powertrain components such as the motor controller unit (MCU), Battery Management System (BMS), and Vehicle Control Unit (VCU). This facilitates them to remotely supply updates to the vehicle firmware and software by giving inputs of calibration data without requiring physical access to the vehicle. However, as OTA updates have a direct impact on vehicle’s performance, safety and cybersecurity, a stringent e integration of Hardware-in-the-Loop (HIL) simulation into the OTA validation pipeline as a means to ensure reliability, safety, and functional correctness of updates before they are applied in the field. We present a structured approach of combining
Khare, Shivani, Karle, Ujjwala, Subramaniam, Anand
Methodology to Accelerate BEV Range Testing Using Shortened Cycle Maintaining High Testing Reliability and Accuracy.2026-26-04441/16/2026
In the era of Electric Vehicles (EVs), range is a critical factor for market success. To mitigate range anxiety, Original Equipment Manufacturers (OEMs) are equipping vehicles with larger battery packs. Unlike internal combustion engine (ICE) vehicles, where fuel economy can be determined with a single legislative cycle run, EVs require a full battery discharge to calculate their range. These tests typically take around 10 hours, and this time increases as battery pack sizes grow. A shortened testing cycle has been developed that reduces the testing time to approximately 4-5 hours, leading to significant savings in time, effort, and cost. The shortened cycle consists of three phases: Dynamic Segment1, Constant Speed, and Dynamic Segment2. Despite variations in battery size and powertrain configurations, the testing duration remains consistent. A key challenge in actual testing is accurately determining the start and end points of Dynamic Segment 2 (DS2), which is an iterative process
T, LAKSHMI PRASAD BEKAL, Krishnan, Karthikeyan N., S, VIVEK
A Comprehensive Comparative Study of Battery Swapping Technology vs. Traditional Charging Systems: Evaluating Efficiency, Scalability, and Future Implications for E-Mobility.2026-26-01941/16/2026
As the Electric Vehicle market accelerates at an unprecedented pace, the demand for efficient, scalable, and user-centric charging solutions has become critical. This paper delivers a comprehensive comparative analysis of the two transformative charging paradigms, conventional charging & the innovative Battery swapping technology. While traditional charging methods remains the industry backbone but they grapple with inherent challenges like prolonged charging durations, high infrastructure requirements and substantial energy consumptions. In contrast, the Battery swapping emerging as a disruptive solution which offering near-instantaneous battery replacement that drastically reduces the downtime and mitigates range anxiety, thereby redefining the parameters of EV usability. The paper embarks on a structured exploration of electric vehicle recharging systems, & beginning with a historical review & Evolution of both types technologies to better understanding of their foundational
Jain, Gaurav, PREMLAL, P, Pathak, Rahul, Gore, Pandurang
System Level Temperature Distribution and Balancing in battery swapping stations2026-26-03611/16/2026
Battery charging systems generate heat during operation, which affects battery efficiency, discharge time, and overall lifespan. Effective thermal management is essential to prevent overheating, optimize heat dissipation, and ensure consistent performance. This study investigates testing methodologies to analyse thermal temperature distribution, detect imbalances, and implement effective balancings techniques. Testing was conducted in a controlled environmental chamber to evaluate heat dissipation behavior under varying conditions. Different dock-level temperatures were measured and optimized using multiple design configurations to assess their impact on thermal performance. The analysis identified thermal imbalances that contribute to uneven heat distribution and increased thermal stress, which can degrade battery performance over time. By refining system designs and incorporating optimized balancing strategies, the research demonstrated significant improvements in heat management
Kulkarni, Mukund, P, Hari Prasad Reddy, H, Manjunatha, Dash, Soumya
Predictive Modelling of Battery Behavior for Enhanced Energy Management in Electric Vehicles2026-26-03851/16/2026
As electric vehicles (EVs) and smart energy systems continue to evolve, optimizing energy usage and ensuring system reliability has become critical. However, battery pack modelling remains challenging due to its highly dynamic and nonlinear behavior due to the temperature variations, aging, and variable load conditions. This paper presents a 1D digital twin framework designed for predictive monitoring of the battery parameters, including State of Charge (SoC), terminal voltage, temperature, and an indicative assessment of State of Health (SoH). The battery is modelled using a Thevenin equivalent circuit that covers both steady-state and dynamic electrical characteristics. Key parameters such as open-circuit voltage (OCV), internal resistance, and dynamic characteristics were derived through pulse testing conducted in our laboratory. A thermal modelling is done to capture the heat generation and cell temperature. SoC estimation is carried out using the Coulomb counting method and
G, Ayana, Gumma, Muralidhar
Predictive SoC Management for Enhanced Recuperation Efficiency in Electric Vehicles2026-26-01541/16/2026
In recent years, the automotive industry has been looking into alternatives for conventional vehicles to promote a sustainable transportation future having a lesser carbon footprint. Electric Vehicles (EV) are a promising choice as they produce zero tail pipe emissions. However, even with the demand for EVs increasing, the charging infrastructure is still a concern, which leads to range anxiety. This necessitates the judicious use of battery charge and reduce the energy wastage occurring at any point. In EVs, regenerative braking is an additional option which helps in recuperating the battery energy during vehicle deceleration. The amount of energy recuperated mainly depends on the current State of Charge (SoC) of the battery and the battery temperature. Typically, the amount of recuperable energy reduces as the current SoC moves closer to 100%. Once this limit is reached, the excess energy available for recuperation is discharged through the brake resistor/pads. This paper proposes a
Barik, Madhusmita, S, Sethuraman, Aruljothi, Sathishkumar
State of Health correction based on dynamic cell behaviour in EVs.2026-26-01831/16/2026
In electric vehicle (EV) applications, accurate estimation of State of Health (SOH) of lithium-ion battery packs is critical for ensuring performance reliability, operational safety and user confidence. SOH is a key parameter monitored by Battery Management System (BMS) to assess the remaining usable life of the battery and to make informed decisions regarding charging, discharging, power delivery, and maintenance scheduling. In traditional SOH estimation techniques often rely on simplistic full-cycle charge-discharge data or single-parameter tracking (such as voltage or internal resistance and other method like coulomb counting and kalman filter ), which do not account for variable field conditions such as partial and full state-of-charge usage condition, dynamic load profiles, and non-uniform aging. As a result, these methods can produce significant deviations in SOH prediction, potentially causing premature system-level shutdowns, inaccurate range estimation, and delayed detection
Nikam, Ashish, Tiwari, Awanish Shankar, Sodha, Nirav, Hariyani, Ganesh, Ambhore, Yogesh Gajanan
State of Health Estimation in Lithium-Ion Batteries: Methods, Comparisons, and Future Directions2026-26-02081/16/2026
As the world is moving towards electric vehicles , we are observing a wide use of Lithium-Ion batteries in modern transportation. Lithium-Ion Batteries offer several advantages over conventional battery systems, including higher energy density that is energy stored per unit mass, longer Cycle Life, faster Charging rates, low Self-Discharge, lighter weight, and ease of maintenance as the memory effect present in other batteries is absent . Of course, challenges remain, e.g. accurate battery State of Health (SOH) estimation which stays as an indispensable parameter for safety and useability. Inaccurate SOH estimation can lead to unexpected vehicle behavior and a degraded end-user experience, especially due to incorrect "distance to empty" predictions. Also, different battery chemistries present various challenges, creating need of tailored models. In this paper, different SOH estimation techniques are reviewed and compared in detail . The SOH estimation approaches are broadly classified
Patel, Parvez, Bhagat, Ayush
Validation of 0D-1D Co-Simulation Strategies in Cold Climate for ‘Full EV Digital Vehicle’2026-26-04481/16/2026
Electric Vehicles is embedded with increased software algorithms coupled with several physical systems. It demands the efficacy of components which are linked together to build a system. The digital models reviewed in this paper are at system-level and full vehicle-level, comprising several components and control design, analysis, and optimization. Systems pertaining to each functionality such as, AC loop, E-Powertrain, HEVC, Cooling system, Battery Management System, Vehicle control system etc. together make an 'Integrated Digital Vehicle'. Fidelity of Intersystem co-simulation [AMESIM + SIMULINK] is key to validate the thermal and energy management strategies. This paper elucidates the correlation of Digital Vehicle compared to Test for Thermal Strategy in different driving scenarios and Energy management. Validation of Digital vehicle with 52kWh, 40kWh High Voltage Battery for Intercity Travel of Customer usage and WLTP for Cold condition of -7degC). Also, to evaluate range
Sarapalli Ramachandran, Raghuveeran, Srinivasan, Rangarajan, Saravanan, Vivek, Dutta, Souham, Pichon, Martin, Leclerc, Cedric, Guemene, Alexis-Scott
CAE driven seam weld optimization for stiffness and fatigue calculations2026-26-04781/16/2026
Structural parts are joined using seam welds, spot welds and bolted connections. The strength and stiffness of any structural part are strongly influenced by the properties of their joints. Seam welds are used extensively in the automotive industry to join panels. The design and the positioning of the seam welds have a significant impact on the technical cost of the project. In the automotive industry, structural optimization and fatigue simulation have become standard applications during any development process. The conventional approach in identifying the position and number of seam welds and its length is time consuming and leads to over design. Current paper highlights developing a simulation process for seam weld optimization in identifying the optimal position and length of seam welds. The optimization workflow is set up in CAE with design objective of minimizing the number of seam welds and finding the optimal length by meeting stiffness targets and fatigue life of seam welds
Gudipati, Raja Shekar Reddy
Optimization and Evaluation of Thermal Interface Material Thickness and Distribution Patterns for Improved Heat Transfer in Liquid-Cooled Battery Pack2026-26-04321/16/2026
Battery Thermal Management Systems (BTMS) play a critical role in ensuring the longevity, safety, and efficient operation of lithium-ion battery packs. These systems are designed to effectively dissipate the heat generated by the cells during vehicle operation, thereby maintaining a uniform temperature distribution across the battery modules, preventing overheating and mitigating the risk of thermal runaway. However, one of the primary challenges in BTMS design lies in achieving effective thermal contact between the battery cells and the cooling plate. Non-uniform or excessive application of Thermal Interface Materials (TIMs) without ensuring robustness and uniformity can increase interfacial thermal resistance, leading to significant temperature variations across the battery modules, which may trigger power limitations via the Battery Management System (BMS) and these thermal gradients can cause inefficient cooling, ultimately affecting battery performance and lifespan. In this study
K, Mathankumar, Jahagirdar, Manasi, Kumbhar, Makarand Shivaji
Thermal System design of Inter-City Fuel Cell Electric Bus2026-26-04271/16/2026
In the current scenario, demand for alternate energy is increasing due to depletion of fossil fuels and countries commitment towards carbon neutrality by 2050. Hydrogen is considered as one of the cleaner fuels and many OEMs across the world started to work on various strategies like hydrogen combustion engine and fuel cell. Passenger vehicles like Buses are at the lookout for fuel cell technology at faster rate than other commercial vehicles. In fuel cell vehicles, cooling system design is critical & complex since it includes fuel cell cooling, Power electronics cooling & battery cooling. In this paper cooling system design of a Fuel cell electric bus for inter-city application is demonstrated. Radiators and Fans are selected based on the overall heat rejection and Coolant inlet temperature requirements of components. Cooling system circuit and pump is decided to meet the coolant flow rate targets. Flow simulation and thermal simulation done using simulation models using software KULI
M S, Vignesh, KIRAN, NALAVADATH
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