Grinntech Motors & Services Private Limited | Technology
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Technology

Cell and Pack Testing

 While the world witnesses amazing new things driven by innovation, some basic principles remain relevant – the need for products to meet performance expectations and safety compliance requirements.

At Grinntech, we perform battery cell testing and battery pack testing at different voltage, current, and temperature levels. To ascertain cell and battery pack quality, we perform rigorous tests to measure cycle life and calendar life of these components. And to do that, we use regularly calibrated, accurate measuring equipment such as flow stands & thermal chambers and cell & pack cyclers.

In the battery-powered equipment world, one size doesn’t fit all. Different applications – automotive & stationary, primarily – have different performance requirements from battery cells & packs; and so the rigor of tests performed vary. Our testing processes are built around the targeted applications of the cells and packs, which is also well documented in our test reports. Alternatively, our test reports done on battery cells & packs cover enough information to help organisations certify their use for specific applications.

Grinntech performs pack testing in internal labs (to certify that the batteries will perform well for a given application) as well as in external labs (to meet storage, operational & performance safety requirements) while complying with global, world-leading standards.

Our testing services are geared towards enabling our customer organisations to launch their end-products in the market quickly. To add more value to this critical offering, we’re also regularly innovating by leveraging test automation in our processes, which can further deliver tremendous economic benefits to our customers.

State of the art mechanical design of battery pack

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A high-quality battery pack is one which performs according to desired expectations but also meets stringent requirements of structural stability while being operational even at the highest vibration and drop & shock impact levels.

At Grinntech, our team of mechanical & battery design engineers leverage their years of experience in designing & developing high energy Lithium-Ion battery modules and packs across the full development cycle.

While the Grinntech approach & advantage lies in ensuring that our products are developed at the lowest cost possible, we have a strict no-compromise policy in terms of quality & safety. We accomplish this by ensuring that our products are designed to comply with even the most stringent world-leading standards.

Grinntech’s battery modules and packs custom-designed for electric vehicles comply with the AIS-048 standard that defines the safety requirements for traction batteries used in battery operated vehicles in India.

Further, our products are also tested for and comply with the UN/DOT 38.3 standard which requires transportation testing of Lithium and Lithium-Ion battery cells, modules and packs across all modes of their transport – air, road/rail, water.

The specifications of the UN/DOT 38.3 standard require multiple scenarios to be addressed – ranging from altitude simulation to thermal tests to vibration, shock, impact, external short circuit risks to overcharge and forced discharge scenarios. We work with external, third-party labs to certify our battery products in an unbiased manner, and we have a compliance rate of 100% till date. That’s our commitment to quality and safety in every single unit we produce.

Thermal design of battery packs

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Temperature variations (both during the summer and winter seasons) in India are quite extreme, especially when compared to regions like Europe, the USA, and Japan. This requires that battery packs deployed in India need to meet region-specific thermal design requirements & specifications.

Battery products produced in the West are usually bigger in form factor and hence employ different product cooling methods, which are typically not the best fit for Indian use. So, importing isn’t always the best idea even though the initial cost outlay may sometimes be competitive. This is where Grinntech’s innovation comes into the picture to address these problems.

High temperature conditions, which is really the norm in India, degrade the life of Lithium-Ion batteries at a faster-than-normal pace. On the flip side, lower temperatures affect the energy & power output capabilities adversely. So, to improve performance reliability, operational & storage safety, and product life, proper temperature control & management is essential.

Our future-ready temperature control solutions work without refrigeration, which helps reduce the product cost. To improve the economics further, we develop them using inexpensive components that are proven to work across a range of ambient climatic conditions. We do this using our patent-pending battery temperature management methodology & processes.

We also perform rigorous thermal management tests to ensure that product life (usage range, charge cycles & calendar life), performance, reliability, and safety levels are maximised. These tests are performed in scenarios of:
• normal operation such as moderate everyday usage & normal driving, and
• abnormal operation – rare usage & abuse conditions

State of the art Embedded Development (BMS)

Grinntech’s development processes are built upon domain-specific industry standards and over two decades of combined experience. This helps us build products that can stand the test of time. Our Battery Management System (BMS), which ensures that batteries are performing as per the requirements, specifications, and desired safety standards, is a testament to that.

Grinntech’s indigenously developed BMS comprising customisable hardware and software stacks is a flexible platform offering that can be leveraged for battery development targeting a varied range of applications.

Further, our BMS is feature-rich with standard, must-have, industry-leading as well as proprietary, patented options, a combination of which can be chosen according to the targeted application the batteries are used in.

When we say start of the art, we truly mean it. The Grinntech BMS meets the most stringent ASIL (Automotive Safety Integrity Level) requirements for automotive applications ranging from 2-wheelers to 6-wheelers in accordance with ISO-26262, the world-leading automotive functional safety standard. For stationery applications such as residential power backup, industrial power backup & grid energy storage.

We’re constantly innovating on our BMS, where we add more capabilities in terms of system intelligence, performance improvements, and smarter management algorithms. That’s where our incubation at IIT-Madras comes in handy, where we get access to a collaborative network of domain experts to add greater value towards overcoming energy storage & battery management challenges.

Battery Swapper

The driving/mileage range offered by electric vehicles is quite low even today compared to the fuel-powered automobiles. Additionally, refuelling a traditional automobile, whether a 2-wheeler or a 4- or even 6-wheeler, takes less than two minutes from start to finish. However, the battery charging time for electric vehicles of any size is typically 7-8 hours or more.

Battery swapping infrastructure is the solution that can be leveraged today to address this problem that’s been prevalent for years and will continue to remain a critical issue for at least two more decades.

At Grinntech, we’ve built a patent-applied battery swapper machine that’s been successfully pilot-tested for use with cars and buses. Our semi-automatic battery swappers are designed such that development and implementation/deployment costs are optimized while keeping the battery swapping time duration almost the same when compared with an expensive fully-automatic swapper. We’ve achieved end-to-end swapping times of about 106 seconds on a consistent basis, so our battery swapper machines have been tested & proven to work with sufficient robustness.

An electric vehicle can now arrive at the swapping spot in a Grinntech-powered battery swapping station, turn the vehicle off, have the batteries swapped to a completely charged one, and drive off all in less than 2 minutes.