Innovation in electric commercial vehicle space

Serial EV entrepreneurs introduce an electric self-charging commercial vehicle (E-SCV) featuring a Sodium-ion battery pack, rare earth-free Synchronous Reluctance traction motor, and solar panels on three sides and the front top of the load container.

Coimbatore-based Axrad Renew Power Agri Machines (ARAM) has introduced the prototype for its upcoming electric LCV (light commercial vehicle), codenamed SCV. The vehicle introduces many industry-first features, including a 5C continuous discharging Sodium-ion battery pack, colour solar panels as the body of the vehicle, and the use of light composite materials for overall enhanced vehicle efficiency and performance.

About the Founding Team

Mr Bala Pachyappa, the company’s CEO, is a technopreneur with over 33 years of experience in diverse technologies, including semiconductors, wireless chips, MEMS, EVs, motor design, embedded systems, and battery technologies. He has founded or co-founded multiple companies, including Ampere Vehicles. He has held leadership roles in the electric vehicle industry with companies like Ampere Vehicles, Sodion Energy, and EMF Innovations.

Mr. Sethu Raj L A, Co-Founder & CTO of the company, is a mechanical engineer with over 21 years of experience. He also co-founded Anandalal Electric, focusing on EV technology development in India. He has worked with the Indian Army and logistics operators to convert vehicles to electric power. He has been involved in EV technology projects for transport, construction, and agriculture since 2022 with AR4 Tech and ARAM.

About E-SCV

SCV has been designed to compete with popular vehicles in the LCV space, such as TATA ACE and Mahindra Maxximo. The vehicle is currently undergoing roadworthiness testing to establish efficiency levels, safety compliance, and subsystem reliability. A prototype has been demonstrated in real-world environments. The aim is to get homologation in place by mid-2025 and release the vehicle to pilot customers by Q4 2025.

Key focus areas to ensure a lower environmental impact:

• Lightweighting – The vehicle body is made with lightweight composite materials. Compared to a benchmark vehicle of similar specifications, the team has been able to achieve a weight reduction of 90 kg. The target weight reduction is 250 kg.

• Energy Efficiency through Solar – The vehicle needs nearly 15 kWh of energy to run 150 km. Using body-as-battery (Power Generator) with its innovative colour solar panels on three sides and the front top of the load container, it generates up to 9kWh of energy in 6 hours (with peak sun power), fulfilling over 50% of daily energy needs.

Other Salient Features of E-SCV

• Fully electric vehicle with a range of 120 km per charge

• Payload capacity of 800 kg

• Top speed of 45 km/h. However, (it will be limited to 25 kmph for the initial trial as an in-campus vehicle).

• The vehicle uses a Sodium-ion battery 72V/200Ah, 14.4 kWh capacity with 5C continuous discharge and 3C continuous charging.

• The powertrain consists of an air-cooled, rare earth magnet free, Synchronous Reluctance traction motor (SynRM) with a maximum output of 14 Kw and 65 Nm of peak torque, with regenerative capability during braking, coasting, and downhill driving.

• AC charging time is less than 4 hours, while fast charge can add 60 km of range in 20 minutes.

In this exclusive interaction with EVreporter, Mr Bala Pachyappa shares about the electric SCV they have developed, vision and plans for the future.

What is the motivation behind developing a self-charging commercial vehicle?

Commercial vehicles in the small commercial vehicle (SCV) (300-500 kg payload) and light commercial vehicle (LCV) (600-1200 kg payload) segments are mainly used for intra-city logistics, transporting e-commerce goods, dairy products, groceries, and other small commodity items. These vehicles typically travel 120-180 km daily on predictable routes using a hub and spoke model.

The goal is to reduce operational expenses, pollution, and noise by using electric vehicles. However, electric vehicles usually require multiple charging cycles to cover this range. To address this, we introduce our “Body as Battery” concept, which uses Electro Composites to harness renewable energy, supplementing power requirements and reducing charging intervals. Additionally, we have optimized the use of composite materials and minimized metal components, which reduces the vehicle’s unladen weight and increases its operational range, Reducing the needed motor power & battery capacity.

All composite parts are designed, developed, and manufactured in-house. We plan to expand the platform for multiple use cases and applications, potentially covering various logistical needs in different sectors.

What percentage of battery pack charging requirements can be fulfilled by solar panels?

The vehicle has solar panels installed on the top and sides of the load container, which significantly contribute to its self-charging capability.

Assuming we get sunlight for 6 hours a day, in ideal conditions, we can generate 9 kW of energy per day, which is equivalent to 62.5% of the energy needed for the day. In worse conditions, we get 6 kW per day, which is equivalent to 41% of the vehicle’s daily energy requirement.

In favorable conditions, internal tests have verified that more than 50% of the battery charging needs can be fulfilled through solar energy.

How will the operating cost of this e-LCV with solar panels compare with regular ICE LCVs and other electric LCVs?

The SCV offers significant cost savings. It is priced comparably to other electric LCVs but offers a greater operating range and self-sufficiency in charging.

In comparison to other vehicles like the TATA ACE EV or ICE (internal combustion engine) variants, it offers substantial cost savings:

• Energy Savings: Solar power generation can cover nearly 60% of the energy needed for daily operations, significantly reducing electricity costs.

• Operating Cost: Due to self-power generation, the operating cost for the SCV is ₹0.40/km, while it is ₹1.23/km for the TATA ACE e-LCV and ₹5.15/km for the TATA ACE ICE vehicle, as per our calculations. The cost saving for SCV vs LCV-ICE is Rs 5.15-0.4 = 4.75/km. Assuming 120 km per day for 300 days per annum operation, the savings will be INR 1,75,000 per year.

How does the SCV battery specifications (capacity, range, voltage, and amp-hour rating) compare to a competitor vehicle?

Benchmarking:

• TheSCVhas a battery capacity of 14.4 kWh, which is lower than that of the competitive vehicle at 21.3 kWh. It also offers a higher range of 100 km per charge compared to the competitive vehicle’s 90 km.

• Additionally, the vehicle also features a power steering, a 360 degree camera for safety and an optional air-conditioner for driver comfort.

What is the expected price of the SCV?

Based on the current BOM, we expect the ex-factory price to be INR 7,50,000 + Taxes.

Where are you in the process of getting ready for vehicle homologation?

We are currently in discussion with component suppliers to finalize long-term supply agreements and component-level certification for suspension, steering, and braking systems. Once this is completed, we will proceed with homologation.

Our in-house production includes sodium batteries, drivetrain components, body-as-battery energy harvesting structures, composite body parts, and critical electrical and electronic systems. Each of these will be sent separately for certification. Our target for homologation is mid-2025.

Note: Vehicle details and specifications mentioned in this write-up are as communicated by the brand.

Also read: Mahindra Last Mile Mobility unveils ‘e-ZEO’ electric SCV on world EV day