Tata Elxsi, in a conversation with the Electronics For You team, revealed they are working on an electric vehicle motor which, instead of rare-earth metals, is based on ferrite. This innovation, aimed at small commercial vehicles, not only promises economic advantages but also reduces India’s reliance on rare-earth metal imports from China. In an exclusive interview, Anush G Nair, Senior Technology Manager in the Electrification Practice Group at Tata Elxsi, provides insights into this game-changing technology.
According to Nair, the motor has undergone almost all tests and has come out with better
results than expected. It will also be economical to produce and service.
“It is simple in construction. The nature of it is rugged, resulting in lessened wear and tear. The only complexities lie in the control and the software, but that should be fine in the longer run, as much of the same depends on power electronics and software. India only has a slight dependency on one particular geography for the same,” he says.
Here are some more exciting excerpts from the conversation
Q. What segment of electric vehicles are you aiming at with this innovation?
A. We are targeting small commercial vehicles with these new motors. The engine has
undergone testing on both a dynamo and a Tata ACE vehicle. We are currently in the conceptual testing phase, not as a production-ready entity. We aim to qualify it as a concept, and the design has successfully undergone various tests, all showing the
motor’s performance to exceed expectations.
Usually, component makers or vehicle OEMs conduct tests to qualify a design as a product.
Tata Elxsi provides support to such entities.
Q. Do you see use cases for this motor beyond the small commercial segment?
A. While we are exploring applications in two-wheelers, our primary focus is on commercial
vehicles. This technology, due to its higher noise levels (NVH characteristics), has historically seen limited use in passenger cars.
Given that commercial vehicles traditionally have higher noise levels, we are initially testing the motor in this segment. As we make progress in improving NVH characteristics, size, and weight, we will explore its application in other segments such as two-wheelers and passenger cars.
Q. Would this be a new patent grant for Tata Elxsi?
A. While this technology is not entirely new, being based on the SCM design, certain aspects will be considered for patenting. Continuous improvements and innovations, particularly in NVH reduction, have been carried out by the Tata Elxsi team, making some elements potentially patentable.
Q. Will this be a fit into hybrids as well?
A. It can function as a standalone motor in hybrid vehicles.
Q. What are the advantages associated with the motor?
A. Firstly, it contributes to reducing India’s automobile industry’s import dependence, offsetting costs. The materials used are abundantly available, ensuring sustainability.
Q. Are there any challenges associated with the development?
A. The construction is simple and rugged, resulting in reduced wear and tear. The only
complexities lie in control and software, but these challenges should be manageable in the long run, as they largely depend on power electronics and software. India has minimal dependency on one specific geography for these components.
Q. Motors are the second most expensive component in an EV. Are these easy to service?
A. These motors are more rugged than their counterparts, ensuring easy serviceability. Apart from routine issues, there are no significant challenges. They can be compared to the
ruggedness of induction motors used in homes.
Q. Induction motors used at home do not encounter potholes and extreme temperature changes. What about this motor in those conditions?
A. Indeed, we have considered all these factors in the design. Motor manufacturers account for these considerations from the initial design stages. The design complies with stringent factors, including terrain, humidity, temperature, and ingress protection. This motor is IP67 compliant.
Q. Can this be fitted into vehicles powered by Hydrogen Fuel Cells, considering cars generate more humidity as a byproduct?
A. The motor is designed for harsh environments by default. Hydrogen fuel cells are part of the powertrain, and replacing a battery with a Hydrogen Fuel Cell system doesn’t change the motor’s functionality. The water byproduct is manageable through the vehicle’s existing thermal, air, and moisture management systems. The motor’s IP67 rating ensures compatibility with such conditions, and future designs can further enhance performance.
Q. Would you partner with vehicle OEMs and component makers to mass-produce this?
A. As a design services provider, Tata Elxsi does not manufacture products but offers design
support. Any supplier or vehicle OEM interested in mass production can obtain the design from Tata Elxsi. The company provides complete support during design and development, and while it can assist during manufacturing, the manufacturing process is the partner’s responsibility. The product’s ownership lies with the customer, while Tata Elxsi retains intellectual property rights around the design.
Q. When do you expect this to be deployed on the ground?
A. Discussions are underway with suppliers and vehicle OEMs, and we anticipate seeing the
product in operation in about one to two years.
Q. Regarding EV adoption in India versus other countries, have you seen any significant differences?
A. India is a cost-conscious mass market compared to many other countries. Interactions with U.S. EV enthusiasts highlight different perspectives; in India, cost considerations drive the market rather than environmental consciousness.
Q. What are your views on the Government of India’s role in accelerating the EV adoption rate in India?
A. The government has played a significant role in strengthening the EV sector. Global
initiatives like the Paris Climate Summit have led to consensus among major economies to
reduce carbon emissions.
Niti Aayog, while pushing electrification, aimed for targets like 100% electrification of two-
wheeler segments. Though initially set for 2025, they later revised it to 2030. But still, we are catching up on that target. So, similar policy pushes everywhere have driven policies, subsidies, and awareness creation.
Q. Why are people still deciding about buying electric vehicles?
A. Range anxiety, limited range requiring frequent recharging, pricing concerns, and
uncertainties about vehicle reliability and longevity are key factors influencing individuals’
decisions regarding EV adoption.
