Case Studies on Study, Testing and Maintenance of Batteries
Section 1: General Information
• What type of battery is used in the Tata Nexon EV (e.g., Lithium-ion)?
• What is the rated capacity and voltage of the battery pack (e.g., 40.5
kWh or 45 kWh)?
• How old are the batteries currently in use or serviced at the center?
• What are the primary usage applications for these batteries (e.g., electric
propulsion, auxiliary power)?
• Is there a warranty associated with the battery pack, and what does it
cover?
Section 2: Testing Procedures
• What types of tests are performed on the Nexon EV batteries? (Check all
that apply)
o Visual inspection
o Capacity (discharge) testing
o Internal resistance testing
o Thermal imaging
o Other (please specify)
• At what interval is each test performed (e.g., monthly, after every 10,000
km)?
• What instruments or measurement tools are used (e.g., multimeters,
battery analyzers, thermal cameras)?
• Have the batteries undergone acceptance and periodic capacity testing
as per standards (e.g., IEC 62619, AIS-048)?
• How long does a typical battery test take, and who performs it?
Section 3: Maintenance Routines
• What regular maintenance practices are followed for the Nexon EV
batteries? (e.g., thermal management, connection checks, software
updates)
• How frequently are maintenance routines carried out (e.g., every 6
months, per service interval)?
• Is preventive maintenance, predictive maintenance, or both used, and
how are they implemented?
• How is the battery environment (temperature, humidity) monitored and
controlled within the service center?
• Are there specific cleaning or cooling procedures for the battery pack?
Section 4: Performance and Reliability
• How long does the Nexon EV battery typically last between charges
under normal usage?
• Have there been any unexpected battery failures reported at the service
center?
• What were the observed causes of any failures (e.g., overcharging,
thermal runaway)?
• Were failures predicted by earlier test results or maintenance indicators
(e.g., capacity drop)?
• Has there been any sign of battery degradation (e.g., capacity loss > 10%,
increased internal resistance, voltage changes)?
• Are there mechanisms in place for early failure prediction or condition-
based testing (e.g., BMS alerts)?
Section 5: Safety and Compliance
• Are the Nexon EV batteries tested for compliance with relevant
standards and regulations (e.g., AIS-048, UN 38.3)?
• What safety procedures are followed during testing and maintenance
(e.g., insulation checks, personal protective equipment)?
• Have any safety incidents or hazards been recorded at the service center
involving batteries?
• What corrective actions are taken in case of test failures or detected
faults (e.g., replacement, recalibration)?
Section 6: User Feedback and Observations
• How satisfied are technicians and customers with the Nexon EV battery
performance and reliability?
• What specific issues have been observed with the batteries (e.g.,
overheating, rapid depletion, slow charging), if any?
• Are there suggestions for improving battery maintenance practices or
testing procedures?
Section 7: Open-Ended Questions
• Please describe any challenges faced during the study, testing, or
maintenance of Nexon EV batteries.
• What best practices or lessons learned would you recommend for
battery management?
• Are there any additional comments regarding battery cycling,
optimization, or future improvements?
Case Studies on Automotive Electronics (Sensors, Clusters, Controls,
Semiconductor’s Devices etc.)
Section 1: General Information
• What are the key electronic components used in the Tata Nexon EV (e.g.,
battery management system [BMS], sensors, control units)?
• What types of sensors are installed (e.g., temperature, voltage, current
sensors)?
• How long have these electronic systems been in use in the vehicles
serviced here?
• What are the primary applications of these electronics (e.g., battery
monitoring, regenerative braking)?
Section 2: Testing Procedures
• What types of tests are performed on the Nexon EV’s electronic
systems? (Check all that apply)
o Visual inspection
o Signal integrity testing
o Fault detection
o Calibration checks
o Other (please specify)
• At what interval is each test performed (e.g., per service, after software
updates)?
• What instruments or measurement tools are used (e.g., oscilloscopes,
diagnostic software, multimeters)?
• Are these tests conducted as per automotive standards (e.g., AIS-004,
ISO 26262)?
• How long does a typical electronic system test take, and who performs
it?
Section 3: Maintenance Routines
• What regular maintenance practices are followed for the Nexon EV’s
electronic systems? (e.g., software updates, sensor cleaning)
• How frequently are maintenance routines carried out (e.g., every 6
months, per 20,000 km)?
• Is preventive maintenance, predictive maintenance, or both used, and
how are they applied?
• How is the environment (temperature, humidity, vibration) monitored
and controlled to protect electronics?
• Are there specific procedures for updating or replacing semiconductor
devices?
Section 4: Performance and Reliability
• How reliable have the electronic systems been in the Nexon EV based on
service center experience?
• Have there been any unexpected failures in the electronic components?
• What were the observed causes of any failures (e.g., sensor drift,
software glitches)?
• Were failures predicted by earlier test results or maintenance indicators?
• Have there been signs of degradation in electronic performance (e.g.,
inaccurate sensor readings)?
• Are there mechanisms for early failure prediction or condition-based
testing (e.g., diagnostic codes)?
Section 5: Safety and Compliance
• Are the Nexon EV’s electronic systems tested for compliance with
relevant standards (e.g., AIS-004, IEC 61508)?
• What safety procedures are followed during testing and maintenance
(e.g., grounding, ESD protection)?
• Have any safety incidents or hazards been recorded involving
electronics?
• What corrective actions are taken in case of test failures or detected
faults (e.g., component replacement)?
Section 6: User Feedback and Observations
• How satisfied are technicians and customers with the performance and
reliability of the Nexon EV’s electronics?
• What specific issues have been observed (e.g., sensor malfunctions,
control unit errors), if any?
• Are there suggestions for improving maintenance or testing of electronic
systems?
Section 7: Open-Ended Questions
• Please describe any challenges faced during the testing or maintenance
of Nexon EV electronics.
• What best practices or lessons learned would you recommend for
managing automotive electronics?
• Are there any additional comments regarding optimization or future
electronic upgrades?
Troubleshooting and Maintenance of Power Supply
Section 1: General Information
• What power supply systems are used in the Tata Nexon EV (e.g., onboard
charger, DC-DC converter)?
• What is the rated output and voltage range of these power supply
systems?
• How long have these power supply units been in use in the vehicles
serviced here?
• What are the primary applications of these power supplies (e.g.,
charging battery, powering 12V systems)?
Section 2: Testing Procedures
• What types of tests are performed on the Nexon EV’s power supply
systems? (Check all that apply)
o Visual inspection
o Voltage and current testing
o Efficiency checks
o Fault detection
o Other (please specify)
• At what interval is each test performed (e.g., per charge cycle, annually)?
• What instruments or measurement tools are used (e.g., power analyzers,
multimeters, oscilloscopes)?
• Are these tests conducted as per standards (e.g., IEC 61851 for chargers,
AIS-038)?
• How long does a typical power supply test take, and who performs it?
Section 3: Maintenance Routines
• What regular maintenance practices are followed for the Nexon EV’s
power supply systems? (e.g., cooling system checks, component testing)
• How frequently are maintenance routines carried out (e.g., every 6
months, per 15,000 km)?
• Is preventive maintenance, predictive maintenance, or both used, and
how are they implemented?
• How is the environment (temperature, humidity) monitored and
controlled to protect power supplies?
• Are there specific procedures for replacing or repairing power supply
components?
Section 4: Performance and Reliability
• How reliable have the power supply systems been in the Nexon EV based
on service center experience?
• Have there been any unexpected failures in the power supply units?
• What were the observed causes of any failures (e.g., overheating,
component burnout)?
• Were failures predicted by earlier test results or maintenance indicators?
• Have there been signs of degradation in power supply performance (e.g.,
voltage drops, efficiency loss)?
• Are there mechanisms for early failure prediction or condition-based
testing (e.g., monitoring logs)?
Section 5: Safety and Compliance
• Are the Nexon EV’s power supply systems tested for compliance with
relevant standards (e.g., IEC 61851, AIS-038)?
• What safety procedures are followed during testing and maintenance
(e.g., high-voltage protection, insulation tests)?
• Have any safety incidents or hazards been recorded involving power
supplies?
• What corrective actions are taken in case of test failures or detected
faults (e.g., unit replacement, recalibration)?
Section 6: User Feedback and Observations
• How satisfied are technicians and customers with the performance and
reliability of the Nexon EV’s power supplies?
• What specific issues have been observed (e.g., charging failures, 12V
system drops), if any?
• Are there suggestions for improving maintenance or troubleshooting of
power supply systems?
Section 7: Open-Ended Questions
• Please describe any challenges faced during the troubleshooting or
maintenance of Nexon EV power supplies.
• What best practices or lessons learned would you recommend for power
supply management?
• Are there any additional comments regarding power supply optimization
or future enhancements?
