Maxwell Spearheads Functionally Safe BMS for India's Top Two-Wheeler OEM.
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About customer
As India's leading two-wheeler manufacturer, the company prioritizes delivering unmatched value to its customers by crafting affordable and modern mobility solutions. Their goal is to empower individuals to progress in life, riding the wave of development and innovation.
Dedication to a sustainable future is a continuous collaborative journey for them. Guided by their vision - to become the Future of Mobility - they forge ahead with a clear focus on sustainable mobility and decarbonization. World-class manufacturing facilities and R&D centers, spread across the globe, stand as renowned Centers of Excellence and beacons of sustainability measures.
Outcome we delivered
100,000+
Units Deployed
85+
Customers
15+
Countries
Challenge for Maxwell
The client had specific objectives to meet, driving their challenge in several key areas. They required the development of prototypes within a strict three-month timeframe, showcasing robust vehicle-centric algorithms like dynamic paralleling, VCU authentication, and vehicle range management. Additionally, ensuring functional safety aligned with ISO26262 standards was a top priority, leading to the necessity of implementing a dual-core microcontroller. Emphasizing close collaboration with the overall vehicle concept, the client aimed for seamless integration and project advancement.
Despite facing a global semiconductor shortage, our team successfully fulfilled the client's demand by strategically scaling production to manufacture over 10,000 Battery Management Systems (BMS) per month.
Lastly, the client emphasized continuous improvement, driving the implementation of value engineering and value addition programs to optimize Bill of Materials (BOM) costs and enhance supply chain efficiency.
"As the leading two-wheeler manufacturer in India, our company faced critical challenges in battery management while striving for innovation and sustainability. We sought a solution that could enhance our mobility offerings, providing precise battery management crucial for our electric scooter models while meeting stringent standards of reliability and efficiency."
Solution - Riding The Electric Transition
Our strategy went beyond delivering a well-engineered product; it aimed to provide comprehensive support to the customer. This included assistance with vehicle systems design and testing, as well as aiding in the establishment of their in-house battery assembly line. We ensured that the correct processes were in place for BMS<>Battery assembly and End of Line testing. To achieve this, we implemented CT-Safe, a custom development program housed within Maxwell. This initiative involved a dedicated team of over 20 engineers specializing in hardware (HW), firmware (FW), systems, validation, and certification.
The Product:
The resulting product was a Monolithic BMS featuring an integrated MOSFET-based PDU capable of High-side switching, supporting peak currents of up to 120A. Both hardware (HW) and firmware (FW) designs were meticulously crafted to adhere to functional safety standards as per ISO26262.
The impact of our efforts was multifaceted:
• We facilitated the establishment of a versatile battery platform for the customer, poised to serve various applications beyond just 2-wheelers in the future.
• Through our collaboration, a vehicle with a Functionally Safe powertrain design was developed, integrating components such as the VCU, MCU, and other subsystems seamlessly.
• Our solution expanded the scope of multiple battery paralleling, eliminating the need to create massive battery packs while enhancing efficiency and flexibility.
Our BMS helped with:
Precisely estimating the State of Charge (SOC), State of Health (SOH), State of Energy (SOE), and State of Power (SOP) of the battery, ensuring accurate monitoring and management.
Optimizing battery usage while adhering to the constraints of the Safe Operating Area, maximizing efficiency and lifespan.
Offering configurability of over 300 parameters, allowing fine-tuning of the BMS to suit specific application requirements perfectly.
Providing extensive diagnostics via Unified Diagnostic Services (UDS) for over 100 errors and events, enabling comprehensive fault detection and troubleshooting.
E-SCOOTER
Application
NMC
Cell Chemistry
1.8 kWh / 3.6 kWh
Energy
14S7P/8P/9P
Battery Configuration
120 A
Peak Discharge Current
Product deployed
BMS: CT-Safe
A functionally safe, hot-swappable, monolithic BMS built for on road and battery safety.
Companion applications
Trace
ION Trace is a supply chainapplication that can be usedto add a new component inyour inventory, test, assem-ble, ship, and associate with a BMS. IONTrace lets the user scan and view thefollowing component details:
What they say about us
"Maxwell played a vital role in overcoming challenges and achieving our objectives efficiently. Their expertise in developing the Monolithic BMS ensured precise battery management crucial for our electric scooter. They navigated challenges like the global semiconductor shortage, delivering exceptional results within a tight three-month timeframe. We highly commend Maxwell for their dedication and innovative approach to crafting advanced mobility solutions."
Customer Testimonial
Unmatched Quality and Reliability in Battery Management Systems
Trusted by the World’s
Largest OEM’s
Dedicated Engineering
Support across each step
Unparalleled Product
Configurability
Safe, Certified and
Reliable Systems
Commitment to
Quality
Software Ecosystem that integrates
with seamlessly with the Hardware
Trusted by the World’s
Largest OEM’s
Dedicated Engineering
Support across each step
Unparalleled Product
Configurability
Safe, Certified and
Reliable Systems
Commitment to
Quality
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