High-Voltage Batteries And MSMEs Can Fuel India’s EV Revolution

A nuanced explanation of low- and high-voltage EV batteries by Dr Gokhale, Vice President for Battery Technology at JSW Energy, illuminates their advancements and influence. The essential role of MSMEs and academia in developing a strong EV ecosystem emerges, marking their significance for India’s push towards self-reliance in this innovative field.

Q. Dr Gokhale, can you explain the difference between low-speed EV batteries and high-speed, high-voltage EV batteries, perhaps with an example?

A. Typically, low-voltage batteries are defined as those up to 48 volts, while high-voltage batteries exceed this threshold. This distinction is fundamental in electrical engineering studies. The critical difference lies in the electron transport between the anode and cathode during energy generation, which can be stored in various forms, such as batteries or supercapacitors.

Q. Are most vehicles in India equipped with low- or high-voltage systems?

A. Most vehicles in India, particularly two-wheelers and three-wheeler autos, use low-voltage systems around 48 volts. Brands like Ola, Ampere, Bgauss, and Bajaj predominantly use these low-voltage batteries.

Q. Which type of battery do you consider safer for electric vehicles?

A. Both types have their risks if not handled properly. Safety largely depends on the quality of the battery management system (BMS), which is crucial for preventing issues like thermal propagation that can lead to fires. In India, regulatory measures like AIS 156 for materials traceability and AIS 038 for vehicles have been introduced to enhance safety by ensuring that thermal propagation in batteries is contained.

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Q. Are the components used in low-voltage and high-voltage EV batteries the same, or are there significant differences?

A. There are significant differences, particularly in the wiring harnesses, fuses, and connectors, which must handle higher voltages, such as 350, 650, or 800 volts. Low-voltage components cannot be used for high-voltage applications due to their lower current-carrying capacity, which makes them susceptible to damage during operation.

Q. Considering that India primarily uses low-voltage batteries, especially in two- and three-wheelers, do you see the shift to high-voltage batteries as an opportunity for MSMEs in the component ecosystem?

A. Absolutely, this transition offers a substantial opportunity for MSMEs. The current low-voltage battery market in India only sees about 10-20% value addition locally, which is a significant loss. However, as India shifts towards high-voltage batteries, MSMEs can contribute to manufacturing critical components like wiring harnesses, flexible bus bars, and thermal management systems like cold plates. This shift is not just about assembling imported components but increasing the ‘Make in India’ percentage, which the government mandates to be over 50%. This approach supports local manufacturing and aligns with the needs of diverse Indian climates, from the cold of Jammu and Kashmir to the humidity of Guwahati and the heat of Chennai and Nagpur. The upcoming PLI schemes and the focus on local production could be game changers in India’s EV ecosystem.

Q. How do battery OEMs typically source their components, and what criteria determine whether they partner with MSMEs or startups?

A. OEMs generally follow a standardised process, such as PPAP (production part approval process), when selecting suppliers. Many components, especially for batteries, were initially sourced from countries like China, Korea, Japan, or Europe due to quality and cost considerations. However, with the push for self-reliance (‘Atmanirbhar Bharat’) and increased awareness of the risks of low-quality imports—like thermal events due to poor components—there is a shift towards sourcing locally. OEMs are now more cautious and thorough in testing components, even locally sourced, to ensure they meet stringent quality standards.

Q. How can MSMEs increase their contribution to what major investment-heavy OEMs are trying to achieve?

A. MSMEs should invest in R&D and align with global standards to improve their offerings. The trend is shifting from having everything in-house to leveraging external expertise. By adopting proven technologies and innovating, MSMEs can enhance their value proposition. There is a governmental push for higher local content, which will increase from current levels to mandate higher domestic production percentages in the coming years. This shift creates a substantial opportunity for MSMEs to scale up their capabilities and meet the increasing demand for locally produced components. Additionally, testing facilities in India are becoming more sophisticated and accessible, further supporting the development of high-quality, locally manufactured battery components.

Q. Given the significant downturn in the electric two-wheeler and three-wheeler market from March to April, with sales dropping over 50% and the segment decreasing by more than 70%, should MSMEs view this as a critical area of focus?

A. Yes, this should be a focus area. The downturn is temporary, reflecting short-term challenges rather than long-term issues. The shift towards electric vehicles is inevitable and expected to encompass 70 to 80% of the two-wheeler and three-wheeler market in the next three to four years. Regulatory changes and evolving consumer preferences are driving this shift. As electric vehicle (EV) costs become competitive with traditional vehicles and the long-term viability of EVs increases, the market is poised for recovery. This presents an opportunity for MSMEs to position themselves strategically for upcoming demand, particularly in high-voltage systems and components.

Q. With academia struggling to engage effectively with large and small companies, what role do you see for academic institutions in developing high-voltage batteries, and how can this collaboration be extended to MSMEs?

A. Academic institutions play a crucial role in addressing the skill gaps in the EV sector. There is a substantial need for programmes that go beyond theoretical knowledge to provide hands-on experience with high-voltage systems and other critical components. I advocate for extended practical training programmes, perhaps up to a year, to equip students with the necessary skills. Collaborations between academia and MSMEs can be particularly beneficial, facilitating internships and practical training that prepare students for real-world challenges. This partnership can significantly enhance the skilled workforce needed in the rapidly evolving EV industry.

Q. Given that global players are far ahead in high-voltage battery technology, does India have sufficient time to catch up and develop in this area?

A. Yes, India can develop and advance in high-voltage battery technology despite the current global lead by other countries. India has significant market potential for high-voltage batteries, with projections suggesting a 40 to 50% market share in electric vehicles over the next 5 to 10 years. Several Indian companies are already making strides in this area, like Tata with its buses and Nexon EVs, and Mahindra, which are contributing to the growth of this sector. While newer technologies such as sodium-ion and hydrogen fuel cells are emerging, they still require a few more years to mature. Meanwhile, lithium-ion technology remains a primary focus, and continued investment and innovation are crucial for catching up and potentially leading in specific segments.

Q. What are five areas MSMEs should focus on within the high-voltage battery sector to capitalise on market opportunities?

A. MSMEs should concentrate on developing components where there is both a high demand and a technological gap that can be filled locally:

1. Wiring harnesses – Essential for connecting various electrical components in high-voltage systems

2. Cold plates – Crucial for thermal management in battery packs, ensuring batteries operate within safe temperature ranges

3. Bus bars – Conductors that distribute power across the battery cells, needing to handle high voltages efficiently

4. Lightweight enclosures – Such as those made from low-pressure die-cast aluminium, which provide robust protection for battery packs while maintaining lower weight to optimise energy density

5. Defence sector components – Given their strategic importance and mandated local production, developing battery technologies for defence applications can be a lucrative focus area.

By concentrating on these components, MSMEs can significantly contribute to the local ecosystem, reduce dependencies on imports, and align with national goals for self-reliance and technological advancement in the EV sector.