In current scenario, demand for alternate energy is increasing due to depletion of fossil fuels and countries working to achieve carbon neutrality by 2050. Hydrogen being a cleaner fuel, many OEMs across the world started to work on various strategies like hydrogen combustion engine and fuel cell. Passenger vehicles like buses are at the lookout for fuel cell technology at faster rate than other commercial vehicles. In fuel cell vehicles, cooling system design is critical & complex since it includes fuel cell cooling, Power electronics cooling & battery cooling. In this paper, cooling system design of a Fuel cell electric bus for inter-city application is demonstrated. Radiators and Fans are designed considering overall heat rejection and Coolant inlet temperature requirements of components. Cooling system circuit and pump is decided to meet the coolant flow rate targets. Flow simulation and thermal simulation done with the help of simulation models built using software KULI to predict

M S, Vignesh, Kiran, Nalavadath

Simplified Simulation of Electric Vehicle Battery Packs Using Deep Learning Based Reduced Order Models

2026-26-0403

To be published on 01/16/2026

The increasing adoption of electric vehicles (EVs), efficient and accurate battery modeling has become crucial for reliable performance evaluation and control system design. However, maintaining high accuracy in simulations generally requires complex computations, which can limit real-time applicability and scalability. High-fidelity battery models often require significant computational time, making them unsuitable for real-time simulations and large-scale system integration. This paper presents the application of Simulink Reduced Order Models (ROM) to simplify the simulation of EV batteries while maintaining acceptable levels of accuracy. The EV simulation environment has been developed in MATLAB/Simulink to analyze Battery Management System (BMS) control system design and assess EV system level performance. This simulation platform consists of BMS and other important EV controller models and high-fidelity plant models for battery and powertrain systems. While these high-fidelity

Vernekar, Kiran

Simulation of EV Range Estimation for Different Payload of Vehicle

2026-26-0389

To be published on 01/16/2026

The electrification of transportation is revolutionizing the automotive and logistics sectors, with electric vehicles (EVs) assuming an increasingly pivotal role in both passenger mobility and commercial activities. As the adoption of EVs rises, the necessity for precise range estimation becomes essential, especially under diverse operational circumstances, including vehicle and battery characteristics, driving conditions, environmental influences, vehicle configurations, and user-specific behaviors. Among the varying factors, a key fluctuating one is user behavior—most notably, increased payload, which significantly affects EV range. A key business challenge lies in the significant variability of EV range due to changes in vehicle load, which can affect performance, operational efficiency, and cost-effectiveness—especially for fleet-based services. This research aims to tackle the technical deficiency in forecasting electric vehicle (EV) range under various payload conditions

Khatal, Swaraj, Gupta, Anjali, Krishna, Thallapaka

Predictive Modelling of Battery Behaviour for Enhanced Energy Management in Electric Vehicles

2026-26-0385

To be published on 01/16/2026

The transition to electric vehicles is a significant change as the world moves toward sustainable objectives, and thus the effective usage of energy and batter functioning. However, accurate battery modelling and monitoring is still challenging due to its highly nonlinear behaviour because of its dependencies with temperature variations, aging effects, and variable load conditions. To address these complexities, there are smart battery management systems that monitor the key parameters like voltage, current, temperature, and State of Charge, ensuring safe and efficient battery operation. At the same time, this may not completely capture the battery's dynamic aging behaviour. Here, digital twin emerges as the powerful solution, which replicates the complete physical system into a virtual platform where we can monitor, predict and control. This research paper shows the digital twin solution framework developed for the real-time monitoring and prediction of key battery parameters and

G, Ayana, Gumma, Muralidhar

Thermal Management of High-Voltage Connectors Using Double-Layered Phase-Change Materials (PCM)

2026-26-0279

To be published on 01/16/2026

High Voltage cables and terminals are prone to high temperatures and rapid heat generation due to high current ratings, especially in electric vehicles (EVs). If the temperature exceeds a critical limit, danger may be posed to the components which are connected and the overall safety of the passengers. Traditionally, cooling methods are often energy-intensive and rely on active systems, which may not always be practical for high-power applications. Thus, a localized, fast, and reliable passive thermal management methodology that can be retrofitted into existing connector designs through modifications (e.g., enlargement and PCM integration) would provide significant safety enhancement. The material property of phase change materials, which possess high latent heat, has been used to maintain a steady temperature for a period of time. A dual PCM-layer has been incorporated into the design of the high-voltage connector to serve two purposes:1. The first PCM layer (PCM-1), with good

Neogi, Angshuman, Shinde, Shardul

Electric Vehicle Battery’s Testing Challenges in Era of Software Defined Vehicle

2026-26-0159

To be published on 01/16/2026

In era of Software Defined Vehicle (SDV), the whole ecosystem of automobile will be impacted. So, it is going to through several challenges for testing activities. In electric vehicle, most critical component is traction battery, which is controlled and operated through battery management system (BMS). BMS is an electronic system, where is going to function as per software of BMS. And in SDV, software is a key element, which is continuously keep on updating on regular basis. So, it means some of BMS functionalities, features or performance may be also altered on each time on software update, which may impact battery’s operating condition, if some scenario is not evaluated during earlier testing then there are it may bring battery out of safe operating area, which may significant impact battery safety, performance or cycle-life. In this paper, we are exploring that different testing requirements for EV Batteries, which may be part of testing practices under era of SDV. Here we will

Bhateshvar, Yogesh Krishan, Mulay, Abhijit B

Review of Conducted EMI by Different PWM Schemes in the EV Inverters

2026-26-0181

To be published on 01/16/2026

The advent of wide-bandgap (WBG) switching MOSFET devices enables high-frequency operation, allowing for significant reductions in the size of passive components such as inductors and capacitors, and improving the overall efficiency of inverter systems. However, these benefits come with the trade-off of increased electromagnetic interference (EMI), which imposes stringent requirements on filter design. The complexity of designing EMI filters, which depends heavily on switching frequency and applicable EMI standards, presents a significant challenge and can impact development timelines. Carrier wave modulation technique is considered as an effective method for minimizing conducted EMI in traction inverters. This article presents various carrier wave modulation schemes that successfully reduce conducted EMI. The evaluated strategies aim to eliminate noise fluctuations and simplify the design of demanding EMI filters. Additionally, the impact on output voltage, output current, total

R, Kodeeswaran, Kuncham, Sateesh Kumar, Kolhatkar, Yashomani

State of Health Estimation in Lithium-Ion Batteries: Methods, Comparisons, and Future Directions

2026-26-0208

To be published on 01/16/2026

As the world is moving towards electric vehicles, we are observing a wide use of Lithium-Ion batteries in modern transportation. Lithium-Ion Batteries offer several advantages over conventional battery systems, including higher energy density that is energy stored per unit mass, longer Cycle Life, faster Charging rates, low Self-Discharge, lighter weight, and ease of maintenance as the memory effect present in other batteries is absent. However, despite these advantages, the system faces significant technical challenges arising from inaccurate battery State of Health (SOH) estimation techniques. These inaccuracies can lead to unexpected vehicle failures and a degraded end-user experience, especially due to incorrect “distance to empty” predictions. In this paper, different SOH estimation techniques are reviewed and compared in detail. The SOH estimation approaches are broadly classified into three main categories: Model based estimation techniques, data driven estimation techniques

Patel, Parvez, Bhagat, Ayush

State of Health Estimation Based on Dynamic Cell Behaviour in EVs

2026-26-0183

To be published on 01/16/2026

In electric vehicle (EV) applications, accurate estimation of State of Health (SOH) of lithium ion battery pack is critical for ensuring its performance, reliability, operational safety and user confidence. SOH is a key parameter monitored by Battery Management System (BMS) to check the remaining usable life of the battery and to make informed decisions regarding charging, discharging, power delivery, and maintenance scheduling. In traditional SOH estimation techniques commonly rely on simplistic full-cycle charge-discharge data or single-parameter tracking (such as voltage or internal resistance) and other method like coulomb counting. Kalman filter, model based method such as equivalent circuit modelling, data driven models etc. This methods not consider variable field conditions such as partial and full state of-charge usage condition, dynamic load profiles, and non-uniform aging. As a result, these methods can produce significant deviations in SOH estimation, potentially causing

Nikam, Ashish, Tiwari, Awanish Shankar, Sodha, Nirav, Hariyani, Ganesh, Ambhore, Yogesh Gajanan

Analysis of Energy Consumption for Heating City Electric Buses and Ways to Reduce It

2026-26-0156

To be published on 01/16/2026

For regions with cold climate, the range of an electric bus becomes a serious restriction to expanding the use of this type of transport. Increased energy consumption affects not only the autonomous driving range, but also the service life of the batteries, the schedule delays and the load on the charging infrastructure. The aim of the presented research is to experimentally and computationally determine the energy consumption for heating the driver's cabin and passenger compartment of an electric bus during the autumn-winter operation period, as well as to identify and analyze ways to reduce this energy consumption. To determine the air temperature in the passenger compartment, a mathematical model based on heat balance equations was used. This model was validated using data from real-world tests. The research was conducted at a proving ground under two conditions: driving at a constant speed and simulating urban bus operation with stops and door openings. The causes of heat loss in

Kozlov, Andrey, Terenchenko, Alexey, Stryapunin, Alexander

Thermal Management Control Strategy for Primary & Secondary Drive Cooling Hybrid Electric Tractor

2026-26-0069

To be published on 01/16/2026

Global emission norms are getting very strict due to combat the harmful pollutants from internal combustion engine. Hence internal combustion engine (ICE)-based agricultural tractors need to introduce complex after-treatment systems and fuel optimization to provide same or higher value to farmers as cost of these systems drive the overall cost of the product. Engineers around the world are building Electric vehicles to combat the problem and has range issues due to design constraints & Hybrid tractors have emerged as a promising intermittent solution. It helps in combining the advantages of respective ICE and electrification solutions while reducing overall vehicle emissions and enhances operational flexibility. This paper presents a modular thermal modes system developed for a hybrid electric tractor platform where a downsized diesel engine operates at optimal efficiency DC generator used to charge the battery & DC converter is used to charge the auxiliary battery. Battery which is

K, Sunil, D, Mari, Natarajan, Saravanan, Kumawat, Deepak, rojamanikandan, Arumugham, K, Mala, V, Sridharan, Muniappan, Balakrishnan, Makana, Mohan

Combustion Dynamics and Performance Optimisation Using Higher HCNG Blends for Decarbonising the Gas Genset Sector

2026-26-0251

To be published on 01/16/2026

Air pollution is profligate becoming a serious worldwide problem with the increasing population and its subsequent demands. Diesel, Gasoline, Natural Gas, Propane, etc., are some of the traditional fuels used in the power generation sectors. Diesel fuel, popularly utilized for backup power in critical operations, is valued for its swift activation time. This makes diesel generators a preferred choice for commercial properties and hospitals requiring reliable emergency power. Moreover, natural gas, distributed through local utility grids, provides a convenient and readily available fuel source for generators, eliminating the need for on-site fuel storage. On the other hand, CPCB has instructed to modify the emission regulations for genset engines for decarbonization and development clean fuel. The change from CPCB II to CPCB IV+ standard shows the commitment of the Indian government towards environmental sustainability and COP26. Pondering to the stringent emission norms, researchers

Bandyopadhyay, Debjyoti, Sutar, Prasanna S, Dhar, Rit Prasad, Sonawane, Shailesh Balkrishna, Rairikar, Sandeep D, Thipse, Sukrut S, Singh, Sauhard, Mishra, Sumit Kumar, Bera, Tapan, Badhe, Rajesh, Tule, Shubham, Aghav, Yogesh, Lakshminarasimhan, Krishna

Applicability of EMC Validation for EV Powertrain Components

2026-26-0197

To be published on 01/16/2026

The technology in the automotive industry is evolving rapidly in recent times. An electric vehicle is a complex and dynamic system consisting of numerous components interacting with each other. With increase in number of EVs on Indian roads, EV makers to produce innovative and pragmatic concept of electric vehicle features. This electrification in automobile has brought new dimension to Electro Magnetic Compatibility (EMC). Considering all these, EMC Testing of all power train components with real case scenarios is utmost important. This paper will put a light on applicability of various EMC tests for EV components like Traction Battery, Traction Motor and Inverter, DC to DC Converter, 3 in 1 Unit, 4 in Unit, BTMS unit, HVAC system, On Board Charger etc. With ICE vehicles, all components were connected to only 12V battery but with the EV era, Components are getting connected to HV battery or LV battery or sometimes both. With this change, all ISO and CISPR standards were undergone with

Yeola, Mayur, Mulay, Abhijit B, Swaminathan, Ganeshan

Predictive SoC Management for Enhanced Recuperation Efficiency in Electric Vehicles

2026-26-0154

To be published on 01/16/2026

In recent years, the automotive industry has been looking into alternatives for conventional vehicles to promote a sustainable transportation future having a lesser carbon footprint. Electric Vehicles (EV) are a promising choice as they produce zero tail pipe emissions. However, even with the demand for EVs increasing, the charging infrastructure is still a concern, which leads to range anxiety. This necessitates the judicious use of battery charge and reduce the energy wastage occurring at any point. In EVs, regenerative braking is an additional option which helps in recuperating the battery energy during vehicle deceleration. The amount of energy recuperated mainly depends on the current State of Charge (SoC) of the battery and the battery temperature. Typically, the amount of recuperable energy reduces as the current SoC moves closer to 100%. Once this limit is reached, the excess energy available for recuperation is discharged through the brake resistor/pads. This paper proposes a

Barik, Madhusmita, S, Sethuraman, Aruljothi, Sathishkumar

Improve the Electric Vehicle Range by Using the Climate Control Setting in Economy Mode at Hot Climatic Conditions

2026-26-0172

To be published on 01/16/2026

Electric vehicles (EVs) have surged in popularity in recent years due to their environmental benefits. The influence of range on air conditioning (AC) power consumption is a critical concern for electric vehicle (EV) owners, particularly in warmer climates. Overcoming obstacles such as a limited vehicle range is necessary for the increased use of electric-powered automobiles. Cabin heating and cooling demand for climate control consumes more energy from the main battery and has been revealed to significantly reduce vehicle range. During peak cooling or heating, the overall power consumption of the AC system takes almost 50% of the energy used for traction. The average reduction in driving range caused by air conditioning (heating and cooling) approximates 33%. The energy usage of an electric vehicle can be considerably decreased by switching the climate control setting to economy mode. The AC system will operate more effectively, enabling the vehicle to save energy and extend its range

Mulamalla, Sarveshwar Reddy, Anugu, Anil, E A, Muhammed, Ummiti, Kumar, M, Nisshok, Choudhary, Ankit

Early Prediction of Relaxation Voltage & Detection of State of Battery for Functional Safety

2026-26-0166

To be published on 01/16/2026

During parking conditions of vehicles, the state of the battery is uncertain as it goes through the relaxation process. In such scenarios, the battery voltage may exceed the functional safety limits. If we cross the functional safety limits, it is hazardous to the driver as well as the occupant. In this case, relaxed voltage plays a crucial role in identifying the safe state of the battery. To estimate the relaxed cell voltage there are methods such as RC filter time constat modeling and relaxation voltage error method. The problem with these solutions is the waiting time and accuracy to determine the relaxation voltage. In this manuscript, a solution is proposed which ensures the above problem is reduced. To achieve the reduction of relaxation voltage estimation time, a python sparse identification of nonlinear dynamics (PySindy) is used which identifies and fits an equation model based on observing the battery characteristics at different SOC and temperatures. The implementation is

Pandey, Priyanshu, Nilajkar, Ankur, Panda, Abinash

System-Level Simulation to Design a Hydrogen Powered Refuse Collection Vehicle Based on Real-World Fleet Operational Data

2026-26-0399

To be published on 01/16/2026

This study addresses one of the challenges in the energy transition of heavy-duty vehicles by converting a diesel Refuse Collection Vehicle (RCV) into a hydrogen-powered prototype. The research is part of the VeH2Dem project funded by NextGenerationEU and focuses on dimensioning the complete hydrogen propulsion system for a RCV, including the energy storage capacity, without compromising payload or operational functionality. The development of the propulsion system is based on a comprehensive analysis of operational data extracted from fleet management systems, complemented by detailed instrumental monitoring of various collection routes. This methodology ensured that the prototype inherits performance equivalent to the original internal combustion engine vehicle across all evaluated scenarios. The vehicle performance objectives were established following a comparative analysis with solutions currently available in the RCV market, incorporating statistical analyses to ensure continuous

Cano, Pablo, Barrio, Roberto, Roche, Marina, de-Lima, Daniela, Batista, Sara, Bertolí, Xavier

Transforming Battery Management: The Role of Artificial Intelligence and Machine Learning in Digital Twin Technologies

2026-26-0382

To be published on 01/16/2026

The traditional Battery Management System (BMS) faces certain limitations in fully utilizing battery capacity and performance during the long cycle life operation of Electric Vehicles (EVs). These constraints include limited real-time data collection, low processing speed, lack of predictive maintenance, and minimal accuracy in predicting health and degradation chemistry. A Battery Digital Twin (BDT) can effectively address these limitations of the BMS. Battery Digital Twins (BDT) can be viewed as a cyber-physical system comprising four key elements: virtual representation, bidirectional connection, Simulation, and connection across the life cycle phases of an EV battery. The performance of a Li-ion battery largely depends on the cathode chemistry, component design, and operating conditions. The battery should be manufactured in a manner (such as cylindrical or prismatic cell) that prevents explosion, leakage, and gas generation inside the battery. To enhance the performance and safety

Chaturvedi, Vikash, M, Venkatesan, Lanke, Siddhi, Subramaniam, Anand, Karle, Manish, Pandit, Rugved, Gupta, Drishti, Karle, Ujjwala Shailesh

Driving Thermal Intelligence – Pioneering Digital Twin-Driven Hardware-In-Loop for Smart Climate Control Modules

2026-26-0380

To be published on 01/16/2026

Thermal comfort is increasingly recognized as a vital component of the in-vehicle user experience, influencing both occupant satisfaction and perceived vehicle quality. At the core of this functionality is the Climate Control Module (CCM), a dedicated embedded Electronic Control Unit (ECU) within automotive HVAC system [6]. The CCM orchestrates temperature regulation, airflow distribution, and dynamic environmental adaptation based on sensor inputs and user preferences. This paper introduces a comprehensive Hardware-in-the-Loop (HIL) [3] testing framework to validate CCM performance under realistic and repeatable conditions. The framework eliminates the dependencies on physical input devices—such as the Climate Control Head (CCH) and Infotainment Head Unit (HU)—by implementing virtual interfaces using real-time controller, and Dynamic System modelling framework for plant models. These virtual components replicate the behaviour of physical systems, enabling closed loop testing with high

More, Shweta, Shinde, Vivek, Turankar, Darshana, Patel, Dafiya, Gosavi, Santosh, Ghanwat, Hemant

Simulation Based Approach to Optimize Electric Vehicle Battery Thermal System

2026-26-0376

To be published on 01/16/2026

The performance and longevity of Li-ion batteries in electric vehicles are significantly influenced by the cell temperature. Hence, efficient thermal management techniques are essential for battery packs. Simulation based optimization approaches improves the efficiency of the battery pack thermal management during the early stage of product development. In this paper, a simulation-based methodology has been introduced to increase the heat transfer from/to coolant via cooling plate as well as to reduce the heat transfer from/to the external environment. The heat transfer coefficient between cooling plate and coolant needs to be enhanced to achieve efficient heat transfer through cooling plate, without exceeding the coolant pressure drop the target limit. A one-dimensional simulation methodology described in this work analyzed numerous design of experiments for coolant layout without performing CAD iteration loops and optimized the cooling channel width, height and number of channels to

U, Reghunath, P S, Shebin

Integrated Simulation of Electric Vehicle Model Using the ROM Approach

2026-26-0369

To be published on 01/16/2026

The growing demand for Electric Vehicles (EVs) has highlighted the importance of efficient and accurate simulation tools for design and performance optimization. The architecture of electric vehicles is distinct from that of internal combustion engine vehicles. It consists of on-board charger, DC-DC converter, Lithium ion battery pack, Inverter, electric motor, controllers and transmission. The battery pack supplies electric current to the traction motor, which then converts this electrical energy into mechanical energy, resulting in the rotational motion needed to drive the vehicle. Wide range of Multi-physics is involved in the simulation which involves Power electronics, Electromagnetics, Fluid Mechanics, Thermal engineering. This paper presents an integrated simulation and range prediction methodology for Electric Vehicles (EVs) using the Reduced Order Model (ROM) approach. The methodology includes simulation in both 3D and 1D domain. CFD simulation is performed to understand the

Shandilya, Anand, Kumar, Vivek

Effects of Battery Integration in Modal Behaviour of Electric Two Wheeler Frame

2026-26-0310

To be published on 01/16/2026

This research investigates the dynamic characteristics of an electric two-wheeler chassis through a combined experimental and numerical approach, and understands the contribution of battery towards overall behaviour of the frame in a structural manner. The study commences with the development of a detailed CAD model, which serves as the basis for Finite Element Analysis (FEA) to predict the chassis's natural frequencies and mode shapes. These numerical simulations offer initial insights into the structural vibration behavior crucial for ensuring vehicle stability and rider comfort. To validate the FEA predictions, experimental modal analysis is performed on a physical prototype of the electric two-wheeler chassis using impact hammer excitation. Multiple response measurements are acquired via accelerometers, and the resulting data is processed to extract experimental modal parameters. The correlation between the simulated and experimental mode shapes is quantitatively assessed using the

Das Sharma, Aritrya, Iyer, Siddharth, Prasad, Sathish, Anandh, Sudheep

Design of the BIW Structure for Battery Pack Protection in Case of Side Pole Impact

2026-26-0025

To be published on 01/16/2026

Electric vehicles (EVs) are becoming more popular than Internal Combustion Engine (ICE) powered vehicles, but their battery and motor components elevate their Gross Vehicle Weight (GVW), posing unique collision risks. Manufacturers strategically mount the high voltage (HV) battery packs under the passenger compartment to lower the Centre of Gravity and shield them from the front impacts. However, side impacts remain a concern, as the battery deformation in such instances could trigger fires or explosions, endangering occupants. To address this, crashworthiness designs adhere to New Car Assessment Program (NCAP) standards, particularly against side pole impact and side mobile barrier impact. Unlike the frontal section of BIW, which typically has larger crush space to absorb the crash energy, extensive design attention is required to the vehicle's side structure to absorb pole impacts without transmitting excessive force to the battery pack. Utilizing aluminium extrusions and sheet

Nivesh, Dharun, Namani, Prasad, Ramaraj, Rajasekar

Structural Design and Simulation of Composite Metal Hybrid Based Battery Enclosure for an Electric Vehicle

2026-26-0300

To be published on 01/16/2026

Addressing the critical need for lightweight and safe energy storage solutions in electric vehicles, this paper presents the design and optimization of a novel Composite Metal Hybrid (CMH) battery pack structure. A computer aided simulation using Abaqus software was performed to optimize the weight of battery pack. The structural integrity and crashworthiness of the optimized lightweight design were rigorously evaluated under various load cases like side impact (crush), shock loading and underfloor impact. Modal analysis and load tests addressed, demonstrate the CMH battery pack as a viable and promising lightweight solution for electric vehicle applications. Manufacturing aspects are also discussed to ensure feasibility and integration.

Shah, Bijay Kumar, Singh, Pundan Kumar, G., Manikandan

Comparative Assessment of Lithium-Ion Battery Recycling Strategies: Unveiling Challenges, Optimizing Benefits, and Exploring Future Potential

2026-26-0201

To be published on 01/16/2026

This research paper offers a comprehensive evaluation of lithium-ion battery recycling methods, tracing the entire journey from global demand to the practical challenges and solutions for sustainable battery recycling. It starts with the analysis of worldwide LIB demand growth alongside the exponential growth in volumes of spent batteries and recycling rates. The study focuses on the imbalance in production and recovery of critical battery components and its environmental and economic effects. The paper then systematically examines six major recycling methodologies: mechanical, pyrometallurgical, hydrometallurgical, biotechnological, direct, and ion-exchange recycling. It goes into detail about their advantages, limitations, and roles in maximizing the recovery of valuable metals such as lithium, cobalt, and nickel. Traditional techniques like hydrometallurgical and pyrometallurgical methods, and emerging approaches including bioleaching and ion-exchange, are evaluated for their

Jain, Gaurav, Premal, P, Pathak, Rahul, Gore, Pandurang

Enhanced Integrated Cooling-Protection Plate for Battery pack Underbody Impact Resistance in Electric Vehicles

2026-26-0169

To be published on 01/16/2026

In the quest for enhancing electric vehicle performance and safety, this paper presents a comprehensive investigation into the design and performance of high-voltage (HV) battery cooling plates featuring dedicated cooling channels, integrated with structural bottom protection members. The study aims to address the dual challenges of thermal management and crash protection in electric vehicles during bottom impacts. The research evaluates the cooling efficiency and structural resilience of the proposed design through a combination of design iterations, thermal performance evaluation, and crash simulations. Findings reveal that the integrated cooling plates not only maintain optimal battery temperatures under various operating conditions but also significantly improve the vehicle's crashworthiness. It was found that the cooling efficiency of the HV battery plates improved compared to competitor’s design, resulting in a more stable thermal environment for the battery cells. Moreover

Dusad, Sagar, Kummuru, Srikanth, Joshi, Amarja

A Comprehensive Analysis of Sealing Methods for EV Battery Packs - Trends and Insights

2026-26-0180

To be published on 01/16/2026

The widespread adoption of electric vehicles (EVs) has introduced distinct engineering challenges, particularly in the design of battery packs, which are crucial for vehicle performance, safety, and longevity. A critical requirement is maintaining ingress protection (IP) ratings of IP67 or higher to protect the high voltage battery packs against water and dust exposure. These ratings are crucial for ensuring compliance with homologation standards and meeting the demands of diverse terrains and operating conditions. Consequently, achieving effective sealing of EV battery packs is a fundamental aspect of their design and engineering. This study presents a comprehensive analysis of sealing technologies employed in EV battery packs, focusing on four primary types: adhesive-based sealants, Formed-In-Place Gaskets, foam cut seals, and rubber gaskets. Benchmarking data collected from over 100 vehicle models across more than 50 brands provides insights into adoption trends, historical shifts

Varambally, Vishakha, Sithick basha, Abubakker, Chalumuru, Madhu, Yaser, K U Syed, Sasikumar, K

Development of Busbar with New Locking Mechanism for High Voltage EV Battery Applications

2026-26-0155

To be published on 01/16/2026

In the development of high-voltage (HV) batteries, ensuring secure connections between HV conductors and maintaining the safety and performance of the battery pack is paramount. Therefore, In the pursuit of enhancing efficiency and reliability in electrical connections, this paper explores the innovative alternate for a traditional screwing method with a friction locking mechanism for connecting busbars. The novel design reimagines the busbar as a Friction clamp (Female part) that securely holds the male part of the Busbar, significantly increasing the contact surface area up to 50%. This enhanced surface area not only improves electrical conductivity but also addresses heat generation issues associated with traditional screw-based connection. By eliminating the need for screws, the new design streamlines the assembly process, resulting in reduced cycle times and improved overall assembly line efficiency. This study presents the design methodology, performance analysis, and potential

Venkatesh, Murali, Raghu, Arun, Bhramanna, Amol

A Strategic Approach to the Selection of Switchgear and Busbars for EV Battery Packs

2026-26-0165

To be published on 01/16/2026

With the rising adoption of electric vehicles, the need for robust and efficient power distribution systems has become increasingly important. As the battery pack is the primary energy source for an electric vehicle (EV), the strategy of selection of switchgears and busbars is paramount. Currently, the design and selection of battery protection and conducting components, such as switchgears and busbars are carried out primarily focusing on the continuous current and the peak current capabilities of the battery pack. Despite this approach ensuring that the components can withstand extreme conditions, it often results in over-engineering. The sizing should be such that it does not overdesign, which would result in unnecessary cost and material weight addition to the pack, ultimately leading to performance deterioration. As the current discharge from a battery pack is dynamic in nature and fluctuates based on driving conditions and usage a real-time heat generation studies have to be

Soman, Anu, satheesh, Goutham, K, Mathankumar

India WLTP Vs MIDC: Comparative Analytical Study on BEV Range & Energy Consumption for Proposing iWLTP 4-Phase

2026-26-0244

To be published on 01/16/2026

In India, Currently Continuous FULL MIDC (Modified Indian Driving Cycle) is used to declare the Range & Energy consumption of BEV (Battery Electric Vehicle). AISC (Automotive Industry Standards Committee) is looking to implement Worldwide Harmonized Light-Duty Test Procedure (WLTP) in India. AISC released AIS 175 for WLTP implementation from Apr 2027. The objective of WLTP is to standardize the test procedure globally for evaluating Emission/FE/Range of Light Duty Vehicles. But the effect of AIS 175 regulation on Battery Electric Vehicles Range Declaration is very less. The Range is almost same as Full MIDC declared Range. The On-road Range BEV is always lesser than the Declared Range of vehicles because of ambient conditions. Usually, the Full MIDC declared Range will be 20% ~26% higher than actual On Road Range. The Range of BEV as per India WLTP 3-Phase was observed 18% ~ 24% higher than actual On-road range of vehicles. There is only 2% difference observed between Full MIDC Range

Shiva Kumar, Mucharla, Tentu, Kavya

Circularity and LCA: Enhancing Sustainability in the Indian Electric Vehicle Sector

2026-26-0239

To be published on 01/16/2026

The global shift to electric vehicles (EVs) is vital for reducing greenhouse gas emissions, but their sustainability hinges on effective battery lifecycle management. This review examines the interplay between Life Cycle Assessment (LCA) and circular economy (CE) principles in EVs, with a focus on both international trends and India-specific challenges. We analyze CE strategies such as extending battery lifespan, second-life applications, and recycling integrated with LCA to evaluate environmental impacts from raw material extraction to disposal. Key areas include battery chemistry, LCA methodologies, policy frameworks, and industrial practices, informed by a synthesis of over 50 peer-reviewed articles, technical papers, and sustainability reports. Challenges include inconsistent LCA baselines, low material recovery in informal recycling, and regulatory gaps, particularly in India. Despite these, innovations like solid-state batteries and advanced recycling techniques offer promise

Haregaonkar, Rushikesh Sambhaji, Kumar, Om, Sankar M, Gopi, Kumar, Rajiv

Drive Cycle Based Energy Audit & Range Estimation for 4X2 Electric Truck

2026-26-0163

To be published on 01/16/2026

Transportation sector in India accounts for 12% of total energy consumption. Demand of energy consumption is being met by the imported crude oil, which makes transportation sector more vulnerable to fluctuating international crude oil prices. India is mindful of its commitment in 2016 Paris climate agreement to reduce GHG emissions intensity of its GDP by 40% by 2030 as compared to 2005 levels. To fast track the decarbonization of transportation sector, commercial vehicle manufacturers have been exploring other viable options such as battery electric vehicles (BEVs) as a part of their fleet. As on today, BEV has its own challenges such as range anxiety & high total cost of ownership. Range anxiety can be certainly addressed by optimum sizing of electric powertrain, reduction in specific energy consumption (SEC) & use of effective regeneration strategies. Higher SEC can be more effectively addressed by doing vehicle energy audit thereby estimating the energy losses occurring at each

Gijare, Sumant, Karthick, K., Juttu, Simhachalam, Thipse, Sukrut S., A, Jothikumar, J, Frederick Royston, SR, Subasree, G, Harini, M, Senthil Kumar

Integrated Side Fairing and Crash Protection System for High Voltage EV Battery Safety

2026-26-0028

To be published on 01/16/2026

This paper presents a novel structural solution for side impact protection of high-voltage battery packs in electric trucks. While electric vehicles offer benefits like zero emissions and independence from fossil fuels, in turn present challenges in meeting crashworthiness standards and safety regulations. The device addresses the critical need for effective battery protection & styling of battery electric vehicles. The integration of a hybrid corrugated panel system with plastic side fairings is innovative, combining crashworthiness with aerodynamic and aesthetic benefits. The crash protection features two hat-section steel channels at the top and bottom and corrugated steel sheet with alternating ridges is attached to these channels. Corrugated panels are enforced with help of backing strips. This assembly is mounted on shear plates at both ends, secured to the vehicle's frame rail. During a side impact event, the plastic side fairings absorb the initial impact, crumpling easily. If

Badgujar, Prathamesh, Devendra, Awachare, Hansen, Benjamin

Innovative Preconditioning Solutions for Efficient High-Current Battery Charging

2026-26-0167

To be published on 01/16/2026

In high-performance charging systems, managing higher currents is crucial for efficient battery charging. Elevated battery temperature is the main challenge for limiting the duration and effectiveness of high-current charging. Our proposal of control system addresses these barriers by optimizing charging time by maintaining optimal temperature ranges for the battery. This is achieved through innovative preconditioning solutions that are incorporated with active Battery cooling configurations. Our system features a unique preconditioning approach with dedicated active cooling circuit for the battery which will provide cooling to battery even though cabin HVAC (Heat Ventilation & Air-conditioning unit) is switched off. The active liquid cooling system ensures effective temperature management without additional energy consumption, while the dedicated Battery active liquid cooling system provides enhanced cooling capabilities for more demanding scenarios and preconditioning. By integrating

Badgujar, Pankaj Ravindra, Bhosale, Subhash, Dave, Rajeev

Steel-Based Laminates for Lithium-ion Pouch Cell of Electric Vehicles

2026-26-0186

To be published on 01/16/2026

Aluminum foils have gained traction with EV battery manufacturers for their pouch cell format. Over the years, it has evolved as a material of choice, but it is still plagued by the issues of stress concentration and swelling due to lower strength and lower stiffness of base aluminum layer. Preliminary investigation revealed that laminates using steel foil material (thickness < 0.1mm) could be a potential candidate for EV pouch cell casing. Thus, steel-based laminate was developed meeting key functional requirements (e.g., barrier performance, insulation resistance, peel strength, electrolyte resistance, formable without cracking at edges, and heat sealing compliant). This innovative patented steel-based laminate [1] was further used to manufacture pouch cell prototypes (up to a maximum capacity of 2.8Ah) for key performance evaluation (e.g., cell cycling and nail penetration). The study paves the way for a low cost, sustainable and flexible yet strong steel-based laminate packaging

Singh, Pundan Kumar, Raj, Abhishek, Kumar, Ankit, Chatterjee, Sourabh, Verma, Rahul Kumar, Samantaray, Bikash, Gautam, Vikas, Pandey, Ashwani

Enhancing EV Battery Safety: Progressive Crushing and Energy Absorption Technique

2026-26-0189

To be published on 01/16/2026

A crash energy absorption technique and method improve the safety and structural integrity of electric vehicle battery packs during collisions, complying with global regulations. This analysis details an assembly featuring a battery housing for mounting battery cells, a crash member connected to the battery housing's periphery, and flexural members linked to the crash member. The flexural members are designed to absorb impact forces by deforming and storing potential energy during sudden impacts. This approach ensures energy is stored within the flexural elements and then transferred to the battery cells through progressive crushing. The design effectively delays intrusion, enhances battery safety, and minimizes cell-level damage. This solution improves occupant safety and prevents thermal runaway incidents while maintaining the battery's overall performance and reliability in EVs.

Amberkar S, Sunil, Lakshman singh, Meenakumari, Bodaindala, Anil Kumar