Designing a system for managing EV batteries.
Team Project
Contextual Research, Prototyping and DFM
Yuma is a joint venture by Yulu and Magna. The company offers a Battery-as-a-Service platform for a network of electric two wheelers including Yulu. It has completed 10 million swaps and is present in 175 locations pan-India (source).
Battery swapping refers to the process of replacing a depleted battery in an electric vehicle (EV) with a fully charged one within minutes. This system eliminates the need for lengthy charging times, drastically reducing vehicle downtime and improving operational efficiency.
As a group, we wanted to work create a mobility solution. We explored topics like Ridesharing, Last mile commute and Drone technology. We found micromobility to be the most impactful and feasible area to work on.
What is Micromobility?
Micromobility is a type of transportation that uses lightweight vehicles to travel short distances. Micromobility vehicles include bicycles, scooters, skateboards, and other vehicles that typically travel under 15 miles per hour.
E-Micromobility solution companies have seen a lot of investor interest in recent times with many new playeres entering the field. However, many companies fail due to difficulties in building the right infrastructure and integrating their system into urban environments.
To practically understand the scenario on roads, we first visited the IIT Bombay campus and studied the various mobility solutions there as well as the experiece of students who need to get around the campus. We found the Electric Buggies to be an innovative mode that stood out but we knew we had to dig deeper.
To understand everyday office commuters, the team head out to BKC, one of the busiest location in Mumbai for commuters to try and understand the problems people face while commuting to work.
From the various options we explored, Yulu stood out as an idea that had the potential to solve major problems. This was something that we knew we had to explore deeper.
Our first contextual inquiry was aimed to help us understand the service in action. This inquiry was conducted at a Yulu station equipped with both charging and bike collection facilities. We interviewed the maintenance crew and commuters.
We decided to shadow a commuter as they went to work to understand their experience with the service.
The service could be considered well ahead of its time, with the Indian infrastructure having a lot of catching up to do to be compatible.
Accessibility and Availability: Yulu bikes were not always readily available near the station, leading to delays for commuters. Some locations were overcrowded while others were underserved.
Infrastructure: The infrastructure around BKC was not always conducive to micromobility. Narrow sidewalks, lack of dedicated bike lanes, and heavy traffic made it challenging and unsafe for users to navigate, particularly during peak hours.
Guided by our observations, we built task flows and different contextual models for the entire system.
The models indicated that there was a need for the micromobility services, however the surrounding infrastructure was not conducive to it.
As we analyzed our findings, we were faced with a pivotal decision: should we design an entirely new micromobility solution or address the issues within the existing Yulu system?
While Yulu faces several challenges, it remains an innovative and forward-thinking service. Helping it become more feasable and efficient would be a better utilization of our resources and time.
Therefore, we decided to concentrate our efforts on refining and optimizing the existing service.
Our second contextual inquiry aimed to delve deeper into the operational aspects of the service by specifically studying Yuma, a sister company that focuses on battery swapping.
We interviewed the maintenance crew and shadowed him as he performed various tasks such as battery swapping, battery maintenance, charging, and overseeing station operations.
We can observe that most of the batteries at the station were marked with stickers, indicating that they had been through the maintainence wareehouse at some point, either for charge or some fault. The system however does not give any more information to the crew.
After thorough research on site, we were able to understand the entire system at work and were able to construct models that map the system and help discover points of intervention.
Our key takeaways from the research were:
Digitally monitored workflows: All tasks at the station were managed through a mobile app, which was part of an integrated IoT system designed to automate the process with minimal human intervention.
Battery Management: The battery swapping stations were central to our findings, with piles of batteries waiting to be charged, swapped, or maintained. The system’s effectiveness relied heavily on how these batteries were managed, monitored, and maintained.
Touchpoints: The entire system had various touchpoints working together like the bikes, mobile applications and charging docks. The touchpoints interacted through different methods:
Vodafone's IoT SIM Connection: This technology connects the bikes to the servers, enabling tracking, ride management, and preventive measures.
Bluetooth Technology: Bluetooth technology is used throughout the system for locking and unlocking bikes, charging batteries and connecting to the charging dock. Essentially when more immediate actions are needed.
Human Intervention: A maintenance crew, guided by the automated system, ensures the smooth operation of the network. Their tasks include checking and maintaining batteries, retrieving stranded bikes, and managing charging stations.
Our research highlights the importance of efficient battery management in Yulu's operations. The blend of digital automation and human intervention forms the backbone of the system, but our study suggests opportunities for optimizing the swapping process to further streamline operations.
The following areas of intervention were discovered from our research on ground:
We conducted an extensive ideation phase, generating over fifty unique ideas.
We used the Six Thinking Hats method to evaluate our ideas and select a final direction.
After thorough evaluation, we selected the Smart Battery Diagnostic Device as our final concept. Key features include:
Building a database of battery health by logging battery ID and health data
Easy to store and move for the station workers
Easy to operate with battery
By helping to regularly log and keep track of data through this product, Yulu would be able to optimize battery efficiency, manage repairs when needed and manage the system more efficiently.
The product would be used at the station and carried by the mobile maintenance crew to the various bike locations. The crew can connect the product directly to the battery through wires or place the battery over an accompanying tray device that simplifies the task flow.
Addressing Maintenance Worker Needs
Maintenance workers require efficient tools to diagnose battery health, identify potential issues early, and optimize overall battery maintenance. Our solution directly meets these needs, ensuring that workers can maintain high performance and reduce downtime.
Meeting Market Demands
Delivery services and companies with large fleets of electric vehicles are increasingly in need of effective battery management solutions. Our tool offers valuable insights into battery health, helping these businesses optimize fleet efficiency and minimize operational disruptions.
Problem-Solution Fit
Our tool provides a targeted solution to the challenge of limited visibility into battery health and maintenance needs. By enhancing diagnostic capabilities and offering real-time data, we bridge the gap between current maintenance practices and the demands of modern electric vehicle fleets.
Technical Feasibility
Our product is designed to integrate seamlessly with the existing Bluetooth technology and battery QR systems already used in Yulu's scooters.
Economic Feasibility
The development costs, including scanner production and worker training, must be weighed against the potential savings from extended battery life and reduced maintenance expenses.
Operational Feasibility
The tool’s design is tailored to fit effortlessly into the existing workflows of Yulu’s maintenance workers. By ensuring minimal disruption and easy integration, the product enhances operational efficiency without requiring significant changes to current practices.
Expanding Market Size
The market for electric vehicle maintenance solutions is rapidly expanding, driven by the growing adoption of electric vehicles. There's increasing demand for tools that enhance battery performance and longevity, positioning our product in a high-potential market.
Versatile Business Model
Yulu has the flexibility to either implement this tool internally, optimizing their own operations, or develop it as a commercial product for other electric scooter companies.
Competitive Advantage
By adopting this tool, Yulu can gain a significant edge in the market. The tool reduces maintenance costs, improves scooter uptime, and offers valuable insights into battery health, ensuring Yulu stays ahead of the competition.
We explored various forms through sketches and mock-ups with a focus on ergonomics and usability.
The final design direction that was settled on allowed for more versatile usage.
Materials
Body: High Impact ABS plastic for high durability. Enhanced impact resistance compared to general purpose ABS. Ideal for products that require extra durability and toughness. Matte spray finish with UV coating for protection against the elements.
Grip: Solid ABS body with TPU over-moulding for easy holding and durability in the part.
We designed the proof of concept by following standard DFM practices to ensure our product was sturdy and durable.
We developed a user-friendly interface with the following features:
Profiles:
View current connectivity status
User information display (Name, DOB, Age, Joining Date, ID number, Posting)
Profile change option
Battery Management:
Check battery function
Monitor battery status and health
History:
Track past interactions and activities
Settings:
Adjust device configurations
QR Scan Functionality:
Easy battery identification and data retrieval
I took on the challenge for building a prototype that could mimic the final products functions. This was important because it then allowed us to propose a workflow to our users and get their feedback.
We started this project with a generative approach where we had the initial idea of building a new mobility solution. However, as we went deeper into the research on ground, we realise that more than ideas, action and implementation were the challenge.
This highlighted the importance of adaptability for me because we were able to switch gears quickly and go where the research was taking us.
This project could be implemented in a lot of different ways. Due to growing demand for electric vehicles, battery maintainence becomes a major need. Even industries that work with heavy machines that operate on batteries could use such a system to regularly monitor and log health to prevent breadowns.
© Shaurya Singh
Reach out to me at shauryaa1975@gmail.com