Tuesday, February 25, 2025

“Many Companies Avoid Pack Testing And Validation Because It Is Time-Consuming” – Akshay Kashyap, Greenfuel Energy

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Battery pack reliability goes beyond cell quality—it relies on precise engineering, thorough testing, and tailored thermal management. In a conversation with EFY’s Nitisha Dubey, Akshay Kashyap of Greenfuel Energy discusses whether the industry will prioritise safety and innovation or compromise quality for cost.


Akshay Kashyap Managing Director, Greenfuel Energy

Q. How does proper engineering impact battery pack performance and cycle life compared to cell ratings?

A. A battery pack’s performance heavily depends on its engineering, even if the cell is rated for 1000 cycles. Poorly designed packs fail to deliver the promised cycle life. Despite this, 90% of Indian manufacturers report cycle life based solely on cell data, avoiding time-intensive pack testing and validation, which can take five to six months and incur high costs. As a result, reported figures often neglect the reduction in cycle life during the cell-to-pack transition. Depending on design and integration, cycle life varies widely, from 800 to 4000 cycles, with lifespans ranging between two and seven years.

Q. How does an engineering-driven approach differ from basic assembly in battery pack manufacturing?

A. An engineering-driven approach prioritises detailed analysis, such as computational fluid dynamics (CFD), to assess heat generation during charge and discharge cycles. This ensures the selection of optimal thermal materials, boosting safety and performance. In contrast, assemblers typically lack such in-depth analysis, resulting in substandard and potentially hazardous battery packs.

Q. What technologies are available for thermal management, and how do they compare?

A. Thermal management technologies include liquid immersion cooling, which uses dielectric coolant to stabilise cell temperatures, and thermal foam for effective heat dissipation. However, many manufacturers still rely on potting materials without exploring broader options. Tailoring the thermal solution to a pack’s specific needs is essential for optimal safety and performance.

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Q. Why are thermal materials particularly important in Indian two-wheelers and three-wheelers?

A. Given India’s reliance on air cooling for two- and three-wheelers, selecting appropriate thermal materials is vital for safety. Detailed engineering analysis of cell type, heat generation, and usage profiles ensures that temperature rise (delta T) remains within 4°C, a standard upheld in our battery packs.

Q. What steps are necessary to ensure the correct selection of materials?

A. To ensure optimal performance, a detailed cell profile under various charge and discharge conditions is essential. When integrating it into the battery pack, a comprehensive CFD (computational fluid dynamics) analysis must be conducted to evaluate heat generation under different scenarios. By analysing extreme charge and discharge conditions, the required heat dissipation can be determined to maintain safety and efficiency.

Q. What type of battery management system ensures effective cell balancing while adhering to safety protocols?

A. Choosing the right battery management system (BMS) involves ensuring safety protocols align with operational needs. For high discharge rates (above 100 to 120 amps), contactor-based mechanisms are suitable, while MOSFET-based safety suffices for lower rates. AISIL compliance is critical for automotive-grade BMS, yet cost constraints limit adoption among tier-two manufacturers. This disparity highlights the prioritisation of safety by tier-one OEMs versus the cost-driven compromises of others. Globally, generation 3 BMS systems—standard in Europe—outperform domestic options with superior safety features, enhanced balancing currents, and precise state of charge measurement, underscoring the gap in standards.


Nitisha Dubey
Nitisha Dubey
Nitisha Dubey is a journalist at EFY. She focuses on startups and innovations with a deep interest in new technologies and business models.

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