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HomeAnimal NewsWhy Do EVs Catch Fireplace? Startup Makes Batteries to Battle the Threat

Why Do EVs Catch Fireplace? Startup Makes Batteries to Battle the Threat


Pratik Kamdar has lengthy advocated for utilizing fire-resistant grade battery supplies together with superior BMS (Battery Administration System) and best-quality cells to cease autos from catching fires.

“For those who make use of the precise high quality of cells and the right kind of BMS, the chance of an EV catching fireplace reduces considerably,” says Pratik, the co-founder of Neuron Power, in a dialog with The Higher India.

Neuron Power is a Mumbai-based startup which manufactures lithium-ion and lead acid batteries for electrical car (EV) makers. Pratik co-founded this enterprise with fellow entrepreneur Raj Shah in 2018.

At Neuron, they minimise the chance of their batteries catching fireplace by using A-grade EV cells and a wise microprocessor-based BMS. Moreover, Pratik claims that Neuron was the primary enterprise in India to introduce a microprocessor-based BMS in two and three-wheeler EVs.

“We’ve got been proactively selling this ideology that we must always use a wise microprocessor-based BMS as a result of it has a better present carrying capability and accuracy. Utilizing this sensible BMS, if the temperature lower off of the battery is about at 60 or 65 levels Celsius, it should robotically shut down at that temperature. That’s not the case with different forms of BMS, leading to a poorer response to variations in temperature,” explains Pratik.

“Additionally different forms of BMS, notably of the MOSFET (metal-oxide-semiconductor field-effect transistor) selection, don’t actually management the functioning of the battery pack. However a wise microprocessor-based BMS actually controls the battery again. A number of algorithms and settings are put in play to manage the efficiency of the battery pack,” he provides.

A battery pack manufactured by Neuron has 4 core temperature sensors. “Within the final two years, now we have been promoting battery packs with core temperature sensors whereby as soon as the battery cell temperature touches 60 levels Celsius, the BMS robotically cuts off energy to the battery. As soon as it reduces to 55 levels Celsius, the BMS can kickstart it,” he notes.

As well as, the startup additionally emphasises applicable cell spacing for thermal administration and runs a Neuron App for distant help.

Now, the federal government has additionally come out with Automotive Business Requirements (AIS)-156 (Section 1, Modification 3) norms, which they’ve made obligatory.

“As per this norm, every battery pack in India should have core temperature sensors and likewise a microprocessor-based BMS similar to those we manufacture. As well as, the federal government has additionally mandated an extruded IP67-rated aluminium enclosure for any EV battery pack,” he says.

Assembling and manufacturing battery packs

Like all producers of EV battery packs in India, Neuron additionally imports cells. As soon as these cells are imported, they’re sorted as per their inside resistance (IR). Cells having related IRs are batched collectively and utilized in a single battery pack. As soon as sorting is finished, they’re taken by a grading course of and put in cyclers, the place one cost and discharge cycle is run.

“In complete, we run 5 such cycles earlier than we use a cell in our battery pack. In different phrases, a battery cell is charged and discharged 5 instances simply to weed out any points with it. Following this, the correct cells which were taken from the grader in-house are utilized in a battery pack, the place a cell holder and different gadgets are put in place as effectively. As soon as the cells are stacked collectively in a battery module and the busbar (stable steel bar used to hold present) is created as per the output we require of the battery pack, we carry out the welding course of,” explains Pratik.

“After this, these modules go into the meeting and we assemble the pack — modules are put right into a steel field or aluminium extrusion with padding on the aspect. We then assemble an extruded IP67-rated aluminium enclosure for the battery pack, after which we go into testing and ageing. We do a full cost and discharge cycle of the battery pack,” he provides.

They run a cycle to examine whether or not the pack is working usually or not. It goes by an ageing take a look at whereby they see whether or not there isn’t any cell imbalance, all cells are correctly functioning, and so forth. Aside from importing the cell, every part else is finished in-house. It takes about 15–20 days from the second they purchase cells to transform them right into a battery pack.

It’s crucial to notice that almost all fires are resulting from brief circuits resulting in uncontrolled currents. These brief circuits occur due to poor cell high quality, shoddy battery design (how say 12 cells are packaged and related to construct a battery pack with a capability of 3kWh), and poor BMS whereby cells aren’t adequately managed with the precise sensing and software program intelligence.

Neuron Energy's EV Battery Packs
Neuron Power’s EV Battery Packs

For 2 and three-wheelers

In an announcement made yesterday, Neuron Power acknowledged that they plan to take a position Rs 50 crore within the Li-Ion battery pack phase. Underneath their Li-ion phase, they manufacture LFP (lithium ferro-phosphate)-chemistry and NMC (nickel, manganese, cobalt)-chemistry battery packs.

“We provide a whole vary of batteries for 2 and three-wheelers. For two-wheelers, now we have battery packs for passenger, industrial and loader segments, which embody e-scooters, high-speed bikes and loaders. Within the e-rickshaw phase, now we have loader and passenger autos. Within the loader phase, we make 10 kWh and 15 kWh lead acid battery packs,” says Pratik.

Specs of battery packs manufactured by Neuron Power embody 60.8V 30Ah (2 kWh battery pack), 73.6V 42Ah (3 kWh battery pack), 73.6V 60Ah (5 kWh battery pack for an e-motorcycle), 51.2V 200Ah (10 kWh battery pack for loader, e-rickshaw) and 51.2V 100Ah (5 kWh battery pack for passenger three-wheelers), amongst others.

“We’re contract-manufacturing all of the batteries. Our contract producer’s amenities are based mostly out of Pune and Noida. Neuron owns and purchases the uncooked supplies. Your entire sourcing and provide chain is dealt with by us. We’ve got a contract manufacturing companion who converts that to the battery pack as per our design. We oversee the standard examine and PDI, and all the technique of meeting has been put in place by our group. As soon as that’s finished, we push out our merchandise,” says Raj.

“The rationale why we haven’t invested in a plant or numerous equipment but is that the business is altering very quickly. Given the numerous uncertainties out there by way of whether or not NCM or LFP is in demand or whether or not OEMs require 1.5 kWh or 2 kWh battery packs, we determined to tie up with a producer who has an empty meeting and further capability. We lease that area out and if we require any further equipment, we’ll set up it ourselves. We stay asset-light however management all the course of of producing and provide chain. We’re cautious about utilizing solely A-grade cells and sensible BMS in order that we don’t go down on high quality,” he provides.

Neuron Energy's Battery Packs for Electric Vehicles
Neuron Power’s Battery Packs for Electrical Automobiles

Trying forward

For 2-wheelers, Pratik claims that Neuron Power manufactures 60,000 battery packs. Subsequent yr, they’re planning to scale this as much as 1,20,000.

“Within the final monetary yr, our income was Rs 18.6 crore from the EV lithium battery phase. On account of the pandemic, we shut down our manufacturing unit manufacturing lead acid batteries for EVs and tied up with one other producer in Haryana. This yr our goal is to cross Rs 100 crore in income, and the yr after that, we’re eyeing Rs 200–250 crore. Final yr, we misplaced the primary three months to the second wave of COVID-19 which additionally shut down our lead acid battery assembling manufacturing unit. In complete, now we have round 120 distributors to feed throughout Delhi, UP, Bihar, Jharkhand and West Bengal, moreover OEMs who’re shopping for from us,” claims Pratik.

Immediately, India has about 14 crore two-wheelers on the highway, of which EVs quantity to 10–12 lakhs. Earlier than the pandemic, the NITI Aayog proposed that the federal government ought to cease the registration of inside combustion engine (ICE)-driven three-wheelers by 2023 and two-wheelers below 150cc by 2025. “If that occurs, the scope for enterprise development is immense,” he notes.

“We’re at present bootstrapped, however are planning to boost Rs 50 crore in funding and now we have a transparent roadmap to the touch a topline of Rs 1,000 crore within the subsequent 5 years. We’re supplying batteries to OEMs like Komaki, 3EV (one of many largest gamers within the loader phase for three-wheelers doing last-mile supply for firms like Amazon, Flipkart, and so forth.), YC Electrical (key passenger phase participant for three-wheelers), Kinetic and different high gamers,” he provides.                                

(Edited by Pranita Bhat)

(All photos courtesy Neuron Power)



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