Safety innovations in battery packs
The importance of robust battery management systems (BMS) and thermal management in ensuring the safety and efficiency of electric vehicle (EV) batteries.
Read Article
Electric Vehicle Battery Aging Prediction Methods
This whitepaper discusses types of batteries, its aging phenomena, performance prediction models, and the future scope of batteries in the automotive industry.
Read Whitepaper
Accelerating Power Electronics Design for xEVs
Tata Elxsi, in collaboration with Ansys, explores advanced simulation techniques to enhance the reliability and efficiency of electronic components in electric and autonomous vehicles.
Watch WebinarEngineering Excellence in Battery Pack Development
As electric vehicles (EVs) revolutionize mobility, battery pack development stands at the forefront of this transition. Original Equipment Manufacturers (OEMs) now strive for deeper control over the value chain, from Battery Management Systems (BMS) to fundamental design capabilities. This shift underscores the rising need for in-house innovation and advanced collaborations.
By partnering with Tata Elxsi, companies gain access to holistic battery engineering support, from concept to validation. Our expertise transcends traditional boundaries, seamlessly integrating mechanical, software, and electronic capabilities. Together, we can accelerate time-to-market and enable a new era of sustainable, cost-effective solutions. With a global footprint, we empower OEMs to excel.
Here's How We Help
Holistic Battery Engineering
- System engineering, hardware-software co-development, and mechanical design to manage the entire battery lifecycle effectively
- Robust integration with Tier 1 and 2 suppliers for faster development and manufacturing support
- This approach ensures consistent quality across every stage of development
Advanced Simulations and Accelerators
- Sophisticated thermal, CFD, and structural simulations to predict and mitigate potential issues, including nail penetration or thermal runaway
- Pre-built accelerators like BMS software/hardware references and battery twins to shorten development cycles
- These tools significantly lower risk and accelerate time-to-market
Comprehensive Validation & Testing
- Functional testing and system validation using specialized HILs for BMS, ensuring compliance with automotive standards
- Packaging and vehicle-level integration, supported by robust physical testing ecosystems for reliability and safety
- Our global labs reinforce unwavering excellence at scale
Solution Framework
Our methodology is designed to ensure efficient and effective creation of innovative products through four key stages:Cell Development, Module & Pack Design, System Development & Integration, and Validation & Build. Each stage includes detailed tasks such as cell testing, thermal management, BMS development, pack integration, and homologation to ensure efficient and effective product creation.
Framework Features
Integrated Powertrain Efficiency
Optimize vehicle performance and cost-effectiveness by leveraging Tata Elxsi’s integrated powertrain approach. We combine battery pack design, motor control, and software optimization into one seamless ecosystem. This holistic perspective yields improved thermal management, reduced energy losses, and enhanced regenerative braking, helping OEMs achieve higher mileage and sustainability. Every step counts.
Functional Safety and Compliance
Elevate product reliability with robust functional safety (FuSa) solutions aligned to industry standards. Our experts integrate rigorous hazard analysis, fault tree assessments, and automotive SPICE compliance within BMS and other battery systems. This ensures resilience against catastrophic failures, safeguarding users, assets, and brand reputation at every stage of battery deployment.
Scalable Global Delivery
Tap into our worldwide network of labs, testing facilities, and engineering teams to expedite large-scale battery programs. We tailor cost and delivery models to OEM-specific needs, ensuring optimal resource utilization. This global footprint fosters rapid iteration, local compliance adherence, and faster market entry, driving enduring success in EV manufacturing globally.
Why Tata Elxsi?
- Dedicated cross-disciplinary teams ensuring truly seamless transitions from concept to production for swift market impact.
- Holistic approach aligning mechanical, electrical, and software domains, truly optimizing cost, quality, and performance simultaneously.
- Extensive battery ecosystem partnerships offering cutting-edge accelerators, comprehensive reference designs, and proven supply chain excellence.
- Adherence to stringent global standards and regulations, ensuring regulatory compliance at every step of development.
- Flexible engagement models suited for diverse OEM needs, enhancing ROI and accelerating commercialization of EVs.
In Focus
Information Hub
-
How does battery pack development influence overall EV performance and longevity?
Battery pack development is central to an EV’s performance, impacting range, charging efficiency, and long-term reliability. Well-designed packs maintain stable thermal conditions, preventing degradation and extending battery life. Integrating advanced BMS ensures balanced cell usage and optimized charging profiles, reducing overall stress on individual cells. Furthermore, robust mechanical design safeguards against physical damage and environmental factors. By focusing on these elements, OEMs can significantly enhance battery longevity, reduce maintenance costs, and deliver a superior driving experience.
-
What role does functional safety play in battery pack engineering?
Functional safety ensures that battery systems operate reliably under various conditions, minimizing risks such as thermal runaway or electrical hazards. By integrating safety mechanisms like fault detection, isolation, and system redundancy, OEMs can protect both users and critical components. Comprehensive hazard analysis, automotive SPICE compliance, and continuous monitoring of parameters help maintain safe operating conditions. This not only prevents catastrophic failures but also bolsters consumer trust and meets global regulatory standards. Overall, a robust functional safety strategy is an essential pillar in guaranteeing effective, worry-free battery pack performance.
-
How can OEMs optimize cost without compromising on battery quality or safety?
OEMs can leverage modular designs and scalable reference architectures to streamline production and reduce manufacturing overheads. Employing advanced simulations early in the design phase helps identify potential issues, minimizing costly reworks. Additionally, robust supplier partnerships and negotiated volume pricing can lower material costs. By integrating best-in-class software, hardware, and mechanical capabilities, OEMs maximize efficiency throughout the lifecycle, from concept to end-of-life management. Ultimately, a balanced approach—one that fosters innovation while mitigating unnecessary expenditures—enables OEMs to achieve cost targets without sacrificing performance or safety benchmarks.
-
What emerging trends are shaping the future of EV battery pack design?
Solid-state batteries, greater energy density, and faster charging capabilities are among the most disruptive trends driving EV battery innovation. Additionally, AI-driven predictive analytics is playing a significant role in optimizing thermal management and cycle life. Manufacturers also explore more sustainable production processes, including recycling and second-life usage for battery modules. With intensified R&D in new materials and chemical formulations, the market anticipates safer, more efficient, and longer-lasting packs. As regulations tighten and consumer expectations rise, future designs will increasingly emphasize environmental stewardship, functional safety, and adaptive intelligence within the battery ecosystem.
-
How does Tata Elxsi support long-term innovation in battery technologies?
Tata Elxsi invests in continuous R&D, collaborating closely with industry leaders, academia, and technology partners to stay ahead of evolving battery trends. Our integrated approach—encompassing system design, hardware-software co-creation, and advanced simulations—facilitates iterative improvements that enhance energy density, reduce charge times, and maintain safety. Through accelerators, reference designs, and thorough validation frameworks, we enable OEMs to adopt emerging chemistries, architectures, and manufacturing processes. By focusing on holistic lifecycle solutions and scalable partnerships, Tata Elxsi drives sustainable innovation, ensuring clients remain competitive in the rapidly evolving EV landscape.
