Browse Topic: Batteries

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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
Analysis of Energy Consumption for Heating City Electric Buses and Ways to Reduce It2026-26-01561/16/2026
For regions with cold climates, the driving range of electric buses becomes a significant obstacle to the broader adoption of this type of transport. The increased energy consumption affects not only the range of autonomous operation but also the lifespan of battery packs, the scheduling of bus departures, and the load on the charging infrastructure. In this context, finding ways to reduce the energy consumption of the climate control system is an actual issue. The aim of the presented research is to experimentally and computationally determine the energy consumption for heating the driver's cabin and passenger compartment of an electric bus during the autumn-winter operation period, as well as to identify and analyze ways to reduce this energy consumption. To determine the air temperature in the passenger compartment, a mathematical model based on heat balance equations was used. This model was validated using data from real-world tests. The research was conducted at a proving ground
Kozlov, Andrey, Terenchenko, Alexey, Stryapunin, Alexander
Accelerating EV Thermal Controls Development: A Rapid controls prototyping framework using Speedgoat2026-26-06851/16/2026
In the era of software-defined vehicles, the complexity and requirements of automotive systems have increased significantly. Thermal management systems have become more complicated, incorporating multiple functions and strategies within software frameworks. This shift poses substantial challenges, increased development efforts and extending timelines in creating an efficient thermal management system for EVs. Fulfilling them in the early stages of design makes it more challenging due to the unavailability of key components such as fully developed ECU hardware, the battery pack, and the motor. To address this, a novel framework has been designed that combines virtual simulation with physical emulation, enabling the testing and validation of thermal control strategies without fully matured system and ECU hardware. The framework uses the Speedgoat platform as the central controller which hosts the control and thermal models developed in Simulink and Simscape. Speedgoat is physically
Chothave, Abhijeet, S, Bharathan, S, Ananth, Gangwar, Adarsh, Khan, Parvej, Gummadi, Gopakishore, Kumar, Dipesh
Optimization of Inverter Control Strategies for Improved Powertrain Efficiency Using E-Motor Emulation Platforms2026-26-05091/16/2026
The traction inverter is a critical component in electric vehicles (EVs), functioning as the heart and brain of the electric powertrain. It controls the power conversion between the high-voltage battery and the electric motor, enabling efficient propulsion and regenerative braking. As EV adoption grows, especially in emerging markets like India, the need for robust and scalable inverter testing solutions becomes paramount. Traditional testing methods involving real batteries and e-motors pose several challenges in the Indian context, including high safety risks, infrastructure limitations, high battery costs, and limited availability of prototype-grade components. This paper presents a comprehensive approach to inverter validation using the AVL Inverter TS™ system— an advanced Power Hardware-in-the-Loop (PHiL) test system based on e-motor emulation technology.. It enables safe, efficient, and reliable testing without the need for actual batteries or mechanical loads. The system
Mehrotra, Soumya, Chhabra, Rishabh
Electric Vehicle Battery’s Testing Challenges in era of Software Defined Vehicle2026-26-01591/16/2026
In era of Software Defined Vehicle (SDV), the whole ecosystem of automobile will be impacted. So, it is going to through several challenges for testing activities. In electric vehicle, most critical component is traction battery, which is controlled and operated through battery management system (BMS). BMS is an electronic system, where is going to function as per software of BMS. And in SDV, software is a key element, which is continuously keep on updating on regular basis. So, it means some of BMS functionalities, features or performance may be also altered on each time on software update, which may impact battery’s operating condition, if some scenario is not evaluated during earlier testing, then there are it may bring battery out of safe operating area, which may significantly impact battery safety, performance or cycle-life. In this paper, we are exploring that different testing requirements for EV Batteries, which may be part of testing practices under era of SDV. Here we will
BHATESHVAR, YOGESH KRISHAN, Mulay, Abhijit B
Enhancing Range Prediction Accuracy for the BEV: Bridging the Gap Between Simulation and Real-World Testing2026-26-05211/16/2026
Accurate range estimation in battery electric vehicles (BEVs) is essential for optimizing performance, energy efficiency, and customer expectations. This study investigates the discrepancies between physical test data and simulation predictions for the Jeep Wagoneer model. A detailed range delta analysis identifies key contributors to the observed deviations, including regenerative braking inefficiencies, increased propulsion demand, auxiliary loads, and estimated drivetrain losses within the Electric Drive Module (EDM) during traction and regen. Results indicate that the test vehicle exhibits lower regenerative braking efficiency and higher traction and lower regen consumption than predicted by simulations, primarily due to EDM inefficiencies and friction brake usage during regeneration. The study underscores the importance of refining simulation methodologies by integrating real-world, test based EDM loss maps to improve accuracy and better align predictive models with actual vehicle
ali, Shoaib, Mahajan, Prasad
Improve the electric vehicle range by using the climate control setting in economy mode at hot climatic conditions2026-26-01721/16/2026
Electric vehicles (EVs) have surged in popularity in recent years due to their environmental benefits. The influence of range on air conditioning (AC) power consumption is a critical concern for electric vehicle (EV) owners, particularly in warmer climates. Overcoming obstacles such as a limited vehicle range is necessary for the increased use of electric-powered automobiles. Cabin heating and cooling demand for climate control consumes more energy from the main battery and has been revealed to significantly reduce vehicle range. During peak cooling or heating, the overall power consumption of the AC system takes almost 50% of the energy used for traction. The average reduction in driving range caused by air conditioning (heating and cooling) approximates 33%. The energy usage of an electric vehicle can be considerably decreased by switching the climate control setting to economy mode. The AC system will operate more effectively, enabling the vehicle to save energy and extend its range
Mulamalla, Sarveshwar Reddy, Anugu, Anil, E A, Muhammed, ummiti, kumar, M, Nisshok, Choudhary, Ankit
A Method of Precooling of EV Vehicle from Grid connected aux supply/Charger to reduce peak power demand of HVAC system when vehicle is allotted for passenger operation using cloud based infrastructure2026-26-00561/16/2026
This paper explains the method of precooling of electric vehicle from grid connected charger reduce load on HVAC and improve the range. HVAC systems are integral part of a commercial EV bus. With the rise of ambient temperatures during various seasons, the load on HVAC System is increasing. Once an Electric vehicle is released from a depot for service, with an initial soaked up ambient vehicle, the HVAC system demands peak power for cooling the interiors which consumes a lot of battery power thus affecting the range. That cause the additional energy consumption required for precooling, which cannot be estimated as it is highly dependent on ambient temperature and range of the vehicle is also dependent on HVAC consumption during summer and peak loads. This paper is proposing a method that uses a special precooling mode which is activated depending on the selection of the vehicle route based on backend application running on cloud. The Application in the cloud checks if the vehicle is
Ganguly, Sutanu, Shukla, Amisha, Jain, Sarika, Patil, Rohan, Sahu, Pritish, Yadav, Ankit, Marskole, Deepa, Amancharla, Naga Chaithanya
Complex Pulse Width Modulation Generation for Motor Controls Application Using Multichannel Sequencer (MCS) of Generic Timer Module (GTM)2026-26-01531/16/2026
The inverter in electric vehicles (EVs) transforms the battery's DC power into a regulated, variable-frequency AC signal, allowing for exact control over the three phase AC motor's speed and torque. The PWM allows for synchronized regulation of pulse widths of all the three phases, resulting in balanced and controlled power output to the motor windings and improves overall performance. The Advance Routing Unit (ARU)Connected Timer Output modules (ATOM) of Generic Timer Module (GTM) incorporate motor control-specific capabilities including fast triggering mechanisms, synchronization, high-resolution (24-bit resolution) and dead-time generation. Whereas other timer modules may be more generic and not optimized for advanced motor control applications. The objective of this paper is to present the strategy to reduce the CPU load in software by utilizing the submodules of GTM called Multi channel sequencer (MCS). It has a minimal amount of software operating on the chip core, resulting in
Reddy, Kurlapalle Sainath
Comprehensive Insights on Techniques for Managing and Preventing Thermal Runaway in EV Lithium-Ion Batteries.2026-26-01711/16/2026
This paper presents a comprehensive investigation into the mechanisms, risks, and mitigation strategies associated with thermal runaway in lithium-ion batteries used in electric vehicles (EVs). It begins by emphasizing the urgency of the issue, identifying key vulnerabilities within EV battery systems that contribute to runaway events. A multiscale, stage-wise breakdown of thermal runaway progression is provided, illustrating how physical, chemical, and thermal interactions compound during failure scenarios. The study analyzes global incident data from 2000 to 2025, revealing trends in human health impacts, vehicle damage, and public safety concerns. Particular attention is given to how battery aging, manufacturing defects, and external abuse conditions elevate the likelihood and severity of thermal runaway. Current emergency response protocols and state-of-the-art mitigation technologies are critically evaluated to identify best practices and existing gaps in safety management. A
Jain, Gaurav, PREMLAL, P, Pathak, Rahul, Gore, Pandurang
Eliminating High-Voltage Pre-Charge Circuits in Electric Vehicles Using Bidirectional DC-DC Converters2026-26-00751/16/2026
Pre-charge circuit ensure the safety of the electric vehicle. During start up, the pre-charge circuits are critical for managing the initial connection between the high voltage battery and the power electronic system in all electric vehicles. Pre-charge circuits typically consist of resistors and contactors that gradually charge the input capacitors of inverters and DC-link systems to prevent sudden inrush currents that could damage components or trigger faults. However, traditional pre-charge solutions present several limitations like increased component count and system complexity, thermal losses due to resistor dissipation, mechanical wear of contactors over time, Slower start-up response, added cost and potential failure points. This paper introduces a novel method to eliminate conventional pre-charge circuits by utilizing bidirectional DC-DC converters to manage the pre-charge function. Through controlled ramp-up of voltage from the low-voltage system to the high-voltage bus, the
S, Aswathy, R O, Raghi
Early prediction of relaxation voltage & detection of state of battery for functional safety2026-26-01661/16/2026
During parking condition of vehicle, state of the battery is uncertain as it goes through the relaxation process. In such scenarios the battery voltage may exceed the functional safety limits. If we cross the functional safety limits it is hazardous to the driver as well as the occupant. In this case relaxed voltage plays a crucial role in identifying the safe state of the battery. To estimate the relaxed cell voltage there are methods such as RC filter time constat modeling and relaxation voltage error method. The problem with these solutions is the waiting time and accuracy to determine the relaxation voltage. In this manuscript a solution is proposed which ensures the above problem gets reduced. To achieve the reduction of relaxation voltage estimation time, a python sparse identification of nonlinear dynamics (PySindy) is used which identifies and fits an equation model based on observing the battery characteristics at different SOC and temperatures. The implementation is done and
Pandey, Priyanshu, Nilajkar, Ankur, Panda, Abinash
Lithium-ion Battery’s State of Health Prediction: A Deep Learning Framework2026-26-01621/16/2026
The growing adoption of electric vehicles (EVs) has increased the need for reliable and efficient battery health monitoring systems. Lithium-ion batteries, widely used in EVs, undergo performance degradation over time, making the prediction of their health status a crucial task for ensuring safety, longevity, and operational efficiency. Traditional model-based approaches often face challenges due to their reliance on complex physical models and sensitivity to varying operational conditions. To overcome these limitations, data-driven methods are increasingly preferred for predictive maintenance. In this study, a data-driven framework is proposed for estimating the State of Health (SoH) of lithium-ion batteries. The framework is developed using data collected from multiple battery cells under diverse operating scenarios. Key steps such as data preprocessing, feature engineering, and model development are carried out to build robust machine learning and deep learning models. A focus is
Suryawanshi, Chaitanya Balasaheb, Nangare, Kapilraj, Gaikwad, Pooja
Driving performance impact analysis on EV components for efficient, safe, and intelligent mobility2026-26-06551/16/2026
Electric vehicles (EVs) are the cornerstone of sustainable transportation, but their performance and component longevity are heavily influenced by driving behaviors. This study proposes a comprehensive analytical framework to assess how different driving styles affect the operational health of key EV components such as the battery pack, motor, and DC-DC converter. Various driving styles such as aggressive, moderate, and economical are discriminated against using dynamic vehicle operation signatures including acceleration and braking intensity, turning profiles, and load variations. These behavioral patterns are reflected in the electrical responses, namely current and voltage waveforms across power electronic systems. By analyzing these electrical signatures, a range of KPIs can be estimated for each component, offering insights into their operational stress and degradation trends. Experimental analysis using real-time EV datasets validates the framework’s ability to predict and
Deole, Kaushik, Kumar, Pankaj, Hivarkar, Umesh
EV Battery Evolution in India: Challenges, Innovation, and Policy Synergy2026-26-01741/16/2026
In the pursuit of sustainable transportation and energy security, India is placing increased focus on addressing the multifaceted challenges associated with electric vehicle (EV) battery technology. As a cornerstone of EV performance and adoption, battery systems in India face critical issues such as high import dependency, limited local manufacturing capabilities, cost inefficiencies, safety concerns, and lack of standardized design frameworks. This paper presents a comprehensive analysis of India's evolving battery ecosystem, emphasizing indigenous design, development, and scalable in-house manufacturing under the "Make in India" initiative. It examines supportive government policies, strategic public-private partnerships, and the pivotal role of research institutions in fostering innovation and overcoming original equipment manufacturers' (OEMs) and end-users' concerns. It also focus on prototype product development challenges. Through detailed case studies, technological reviews
Thorat, Jalindar Sukhadev, Sandhu, Jivraj Singh, Kumar, Dharmendra
Developments in 2-Wheeler electric vehicle architecture2026-26-01991/16/2026
Electric vehicles are becoming more popular due to the low-cost investment for individual daily usage, such as traveling to nearby places, offices, and schools. There are environmental benefits that make them green and produce less pollution compared to traditional vehicles. Two-wheeler electric vehicles (EVs) have more electronic components compared to two-wheeler internal combustion engine (ICE) vehicles. The major components in two-wheeler EVs are the motor and battery. The traction motor is driven by the battery, Battery is a primary energy source in 2Wheeler electric vehicle. An electric vehicle comprises different major electronic components such as the battery management system (BMS), motor control unit (MCU), human-machine interface (HMI), and, in some cases, a vehicle control unit (VCU) as well. Considering a 48V architecture or less than 60V provides advantages of low system cost as it requires less effort for safety measures. Furthermore, this paper explores diverse
Karunakar, Praveen, K R, Amogh
Simplified Simulation of Electric Vehicle Battery packs Using deep learning based Reduced Order Models2026-26-04031/16/2026
Accurate yet computationally efficient simulation of electric vehicle (EV) batteries is essential for system design, performance evaluation, and real-time control applications. This paper presents a simplified simulation framework for lithium-ion EV battery systems using reduced order models (ROMs) that balance fidelity and computational speed. The EV system simulation environment has been developed in MATLAB/Simulink environment to analyze Battery Management System (BMS) control system design and EV system performance. This simulation platform consists of BMS and other important EV controller models and high-fidelity plant models for battery and powertrain systems, which are modelled using Simulink and Simscape library blocks. Performing virtual testing, control design and system-level analysis with such high-fidelity plant models poses significant computational challenges and poor simulation performance. The focus of this paper is to enhance system level simulation performance by
Vernekar, Kiran
Mathematical Modeling and Genetic Algorithm-Based Energy Management in Hydrogen PEM Fuel Cell Electric Vehicles2026-26-02571/16/2026
Hydrogen fuel cell electric vehicles (FCEVs) present a promising solution to environmental challenges such as emissions, global warming, and fossil fuel depletion. By utilizing hydrogen as a clean energy source, FCEVs achieve zero tailpipe emissions while maintaining high efficiency and extended driving ranges. Their development focuses on optimizing fuel cell architecture, hydrogen storage systems, and advanced power management strategies to enhance energy conversion under varying operational conditions. This requires precise design, simulation, analysis, and system integration to improve performance, durability, and sustainability. This study develops a high-fidelity mathematical model of a hydrogen Proton Exchange Membrane (PEM) fuel cell vehicle and implements advanced Energy Management Strategies (EMS). Using the forward approach method, the model accounts for the physical constraints of the powerplant. Detailed fuel cell system modeling accurately represents voltage loss
Mulik, Rakesh Vilasrao, E, Porpatham, Senthilkumar, Arumugam
To study and compare communication protocol for fast charging in electric two-wheeler with respect to CCS 2.0: An Indian Perspective2026-26-01981/16/2026
India, as the world’s largest two-wheeler market, is witnessing an aggressive transition towards electric mobility, driven by urban air quality concerns, fuel cost sensitivity, and government incentives. Among the critical enablers of this shift is the availability of robust and efficient fast charging infrastructure tailored to electric two-wheelers. This paper proposes a systematic testing framework for fast charging of electric two-wheelers, addressing key parameters such as battery thermal management, charging communication protocols, safety interlocks, and State of Charge (SOC) estimation accuracy. The study evaluates current and emerging standards, including AIS-156, IS 17017, and IEC 61851, and identifies gaps specific to two-wheeler applications such as compact form factor constraints, lower energy storage, and high operational turnover in fleet usage. A special focus is placed on interoperability, user safety, and infrastructure scalability for dense urban environments. The
Uthaman, Sreekumar, Mulay, Abhijit B
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
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