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Battery Associated Engineering

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Battery Associated Engineering 

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Some of the other performance factors that also come into play considering the current technological advancements in batteries

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Hinduja Tech boasts over a decade of expertise in successfully executing 14 electric vehicle (EV) programs, with more in progress. We have a proven track record in developing modular Low and High-voltage battery packs for diverse mobility applications. 

[Hinduja Tech](https://hindujatech.com/) boasts over a decade of expertise in successfully executing 14 electric vehicle (EV) programs, with more in progress. We have a proven track record in developing modular Low and High-voltage battery packs for diverse mobility applications. Our proficiency extends to the comprehensive design of battery packs, requiring a deep understanding of various cell types, including cylindrical, polymer (pouch), and prismatic cells.

Our dedicated team possesses in-depth knowledge of these cell types, enabling us to craft sustainable batteries tailored for OEMs and battery suppliers. What sets us apart is the wealth of experience our battery engineering SMEs bring from their previous roles in automotive and industrial OEMs. Their strategic insights play a pivotal role in assisting our customers in selecting the right battery pack for specific applications, ensuring optimal performance and efficiency.




We encompass the entire Product Development Cycle for both Low and High-voltage battery packs. 

Our comprehensive approach includes Concept Modelling, Detailed Engineering (CAD), Rigorous Safety-Critical Testing utilizing various CAE (FEA/CFD methods), Electrical Systems development, BMS Development, and Value-added services such as BOM Cost Reduction, Strategic Sourcing, Bench/Vehicle Level Tests, Prototyping, UN/ULC Certification including Low Volume Manufacturing Support.   


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Battery Associated Engineering Services

- Benchmarking
- System Requirements & Architecture Development
- Schematics & PCB Layout
- Real-Time Circuit Simulation
- SoC, SoH Control Algorithms 
- Cell Balancing (Passive)
- BMS Fault Monitoring
- CAN Communication to Vehicle Network
- Prototype Veriﬁcation & Validation/ A, B and C Sample/ SoP

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Battery Management System Development

Battery Management System Development (48V to 1250V System)

Battery Management System Development 

- Design Audit of Battery Packs 
- Material Selection
- Technical 2D Drawings 
- Part/Component Design
- Battery Pack Enclosure Design adhering to Centre of Gravity
- Stack-up Calculations & Fastener Analysis
- Core Pack Module Development
- Electrical Bus-bar Design
- Electrical Component Packaging
- Battery Pack Chassis Integration

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Mechanical Enclosure Design

- High-Level Architecture
- Battery Pack Electrical Schematics
- Wiring Harness Design (LV/HV)
- Hardware, Software Design & Development
- Load Calculation and System Sizing
- Design Interface, DMU, Clash Analysis, and Virtual Integration
- Veriﬁcation and Validation
- Functional Safety Compliance
- ASPICE Compliance

Electrical and Electronics

- Low Voltage Battery Pack - Passive cooling
- High Voltage Battery Pack - Active Cooling
- High Voltage Battery Pack - Warmup
- Coolant flow optimization - Single Module - Battery Cooling Plate level, Battery Pack level
- High Voltage Busbars – Joule Heating Analysis
- BMS Components Cooling
- Thermal Run Away and Propagation
- Battery Compartment Cooling




HindujaTech_Thermal Management Simulation

Thermal Management Simulation

- Shock Loading as per UN 38.3
- Random Vibration SAE J2380
- Battery Module Crush & Drop Test
- Thermal Fatigue
- Safety Enhancement on Impact




HindujaTech_VV_Battery casing crush test

HindujaTech_VV_Vibrational Analysis

HindujaTech_VV_Shock Simulation

HindujaTech_VV_Drop Test

HindujaTech_VV_Crash Impact

Structural Simulations

- Strategic Sourcing
- BoM Cost Reduction up to 50% 
- Bench Test
- LABCAR Test 
- Vehicle Level Testing 
- UN 2580 Certiﬁcation and UN Testing
- Prototyping



Value Added Services

Our Battery Associated Engineering Offerings

Li-Ion battery pack enclosure design, bus bar design and electrical packaging

Battery pack Enclosure Design, Bus Bar Design and Electrical Packaging

thumbnail_Battery pack Enclosure Design, Bus Bar Design and Electrical Packaging

Battery Enclosure Design

48V BMS development from Concept to Proto release including custom test bench validation

BMS Development covering Software, Hardware, Prototyping and Verification & Validation

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BMS Development

Thermal validation of battery pack enclosure, mounting bracket and internal electronic components

Efficient Thermal Management development using CFD Simulation tools

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Thermal Validation

Battery pack integration on vehicle chassis/body structure

Battery Pack Integration on Vehicle Chassis-Body Structure

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Battery Pack Integration

Battery pack safety enhancement during frontal Impact 

Simulation studies to meet ULC and SAE Safety Compliance requirements

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Safety Enhancement

Projects Delivered

Why Us? 

Experienced to Handle Various Battery Cell Types


Experienced to Handle Various Battery Associated Engineering

Proficient in both Low & High Voltage Battery Development

Proficient in both Low & High Voltage Battery Associated Engineering

Modular and Scalable Design Concepts for Different Battery Variants

Modular and Scalable Design Concepts Battery Associated Engineering

Advanced Battery Performance Simulation Studies

Advanced Battery Performance Simulation Studies Battery Associated Engineering

Extended Capabilities to Design & Develop BMS and BDU for High Voltage Applications

Extended Capabilities to Design & Develop

AI Model Driven Data Analytics for Battery Associated Engineering

Proven Cost Reduction Methods Battery Associated Engineering

Familiar with Global Battery Safety Regulatory Standards

Familiar with Global Battery Safety Regulatory Standards Battery Associated Engineering

<h3>Business Challenges</h3>
<p>When designing a Thermal Management System, heat-generation factors should be considered</p>
<p>Requires a robust external temperature variation and thermal shock to resist the climate changes</p>


HindujaTech_Battery_Thermal_Management_System _Casestudy.pdf

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 Battery thermal management

Hinduja Tech helped an automotive giant in analyzing the transient for flow distribution in the coolant pipe, comparison of max temperature in the battery module with and without liquid cooling and analysis on the cooling performance


Battery Thermal Management System  

<h3>Business Challenges</h3>
<p>Designing the battery posed a challenge as it required modularity to prevent interference between internal mechanical and electronic components</p>
<p>Ensuring sufficient creepage in the enclosure design emerged as a critical challenge, with the potential consequences being short circuits between electronic components</p>

Hinduja Tech_EV Battery Pack Design

Hinduja Tech has worked with leading US-based battery manufacturer to optimize their current battery enclosure design as well as achieved significant product cost reduction by conducting various packaging studies, suggestions for material alternatives, and modular concepts for its upcoming products.

EV Battery Pack Design & Cost Reduction

<h3>Business Challenges</h3>
<p>To design the pack according to ULC & SAE Standards which will help in maintaining the maximum permissible vibration at the battery enclosure area</p>
<p>Identifying the root cause and implementing necessary design changes in the enclosure assembly was necessary to prevent mechanical failure</p>

Hinduja Tech_Battery Enclosure Random Vibration

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battery enclosure random vibration

Hinduja Tech evaluated a battery enclosure's durability under random vibration according to ULC 2580 and SAE J 2380 standards using advanced CAE tools.

Battery Enclosure Random Vibration

<h3>Business Challenges</h3>
<p>Weak vehicle mountings presented a challenge, leading to imbalanced weight distribution on the chassis and increased vibrations, impacting battery performance</p>
<p>Proper sizing of electrical routings was essential to support high-voltage battery operations effectively</p>

Hinduja Tech_Battery Pack Integration

Hinduja Tech played a pivotal role in assisting an autonomous vehicle OEM with the seamless integration of a high-voltage battery pack onto the vehicle chassis. The team conducted comprehensive weight distribution studies, explored various mounting techniques, and meticulously ensured the proper routing of electrical wirings to meet stringent safety requirements.

Battery Associated Engineering

Battery Associated Engineering Services

Our Battery Associated Engineering Offerings

Projects Delivered

Battery Enclosure Design

Projects Delivered

BMS Development

Projects Delivered

Thermal Validation

Projects Delivered

Battery Pack Integration

Projects Delivered

Safety Enhancement

Why Us?

Case Studies

Battery Thermal Management System

EV Battery Pack Design & Cost Reduction

Battery Enclosure Random Vibration

Battery Pack Integration Studies

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