A part of FEV Group
Revolutionizing BEV performance with digital twin technology
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Cloud & Data Solutions
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A part of FEV Group
Introduction
At FEV.io, we harness Generative AI to drive innovation, ensuring productivity gains and personalized user experiences across engineering and non-engineering domains. By integrating advanced AI technologies, we empower industries to optimize processes, reduce costs, and redefine operational standards.
Background
We partnered with a leading OEM to revolutionize Battery Electric Vehicle (BEV) performance through a comprehensive Battery Digital Twin Framework. This project aimed to optimize battery life, enhance performance, and ensure safety for commercial BEV fleets across diverse markets.
Approach
Advanced Digital Twin Development:
- Implemented a robust digital twin framework to create virtual replicas of battery systems for real-time monitoring and predictive analytics.
- Designed algorithms for battery state estimation, covering SOC, capacity, and internal resistance.
- Developed critical event detection mechanisms for issues like short circuits and thermal runaway.
- Enabled predictive analytics for Remaining Useful Life (RUL) prediction and battery degradation tracking.
- Delivered engineering visualizations from pack to cell levels for in-depth performance analysis.
Hybrid Modeling with AI & Physics:
- Combined AI-based prognostics models with physics-driven algorithms for unparalleled accuracy.
- Ensured scalable, cloud-based deployment to integrate battery data from hundreds of vehicles seamlessly.
Comprehensive Test and Validation Strategy:
- Designed an end-to-end validation framework, testing in both virtual and real-world environments.
- Created a detailed test catalog encompassing various operational conditions and edge cases.
- Defined KPIs for success metrics such as battery health, safety, and performance optimization.
Turn-Key Implementation for Diverse Markets:
- Adapted the digital twin framework to suit regional requirements, covering PVs, CVs, 3-wheelers, and 2-wheelers.
- Ensured global compliance by aligning with international standards and regulations.
Impact
This structured, mathematics-driven approach enabled the OEM to:
- Achieve a 15% savings in operational life, optimizing battery utilization.
- Extend battery life expectancy by 7% through predictive maintenance and RUL insights.
- Deliver a scalable, reliable solution across diverse vehicle types and markets.
By integrating AI, generative AI, and advanced analytics, we transformed the OEM’s fleet management, setting a new standard for BEV performance, safety, and sustainability.
