EV Certification

Electric Vehicle Certification - Complete Guide to EV Compliance in India

A single battery pack is capable of powering a vehicle for hundreds of kilometres, but in order to get that vehicle legally onto the roads in India, there is much more required than a good battery.

Before an electric vehicle can be put on the market, it has to meet a variety of requirements relating to safety, performance, electrical systems, batteries, charging, and the vehicle as a whole. For manufacturers, importers, and EV start-ups, it is important to understand the compliance process at an early stage in order to avoid costly redesigns, having to carry out repeated testing, and delays when entering the market.

At UMSPCS, we assist companies in understanding the relevant regulatory framework, in identifying the appropriate standards, in arranging the testing, and in preparing the documentation needed for compliance with and certification of EVs.

What Does Electric Vehicle Certification Mean in India?

In India, the certification process of electric vehicles encompasses different regulatory trials, type approvals, conformity checks, and other types of compliance procedures that are necessary with regard to an electric vehicle or an electric vehicle-related item.

The main regulatory structure that governs vehicles used in public transport is based on the Central Motor Vehicle Rules 1989 (CMVR) and the relevant Automotive Industry Standards (AIS), and thus the testing and certification procedures for vehicles and their components are performed by the recognized governmental testing institutes.

The operational guidelines for the E-DRIVE programme issued by the Ministry of Heavy Industries specify that all vehicle models and variants must conform to the relevant CMVR requirements and to the notified AIS/IS standards. For instance, the guidelines name AIS 049 and AIS 156 as the applicable standards for battery electric vehicles, whereas different requirements are applicable to hybrid vehicles.

The Automotive Research Association of India (ARAI), which is one of the notified organisations concerned with automotive testing and certification, carries out CMVR type approval for electric two-wheelers, three-wheelers and four-wheelers.

EV Certification ought to be seen as a full compliance process rather than just applying for a single licence.

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What Products May be Required to Comply with EV Regulations?

The specific requirements vary greatly depending on the product and on the way it is to be used.

Major categories include:

Electric two-wheelers
Electric three-wheelers
E-rickshaws
E-carts
Electric passenger vehicles
Electric commercial vehicles
Electric buses
Electric trucks
Battery-operated vehicles
Hybrid electric vehicles
Traction battery/REESS systems
EV charging equipment
AC and DC charging systems
EV connectors and vehicle inlets
Battery swapping systems
Certain EV electrical and electronic components
Retrofitment systems, where applicable

ARAI provides type-approval services with regard to battery-powered vehicles, e-rickshaws and e-carts among the various categories of vehicles.

Understanding AIS 156 and EV Battery Safety

One of the most important parts of an electric vehicle is the traction battery.

Battery testing for electric two- and three-wheelers is linked with AIS 156, and the testing information published by ARAI specifies that for 2W/3W vehicles it is governed by AIS 156 and for 4W vehicles by the relevant AIS 038 requirements.

The documentation for AIS-156 includes detailed information about the vehicle, the propulsion system, the electric motor, and the REESS, such as the battery cell chemistry, the dimensions, the capacity, and the construction of the REESS.

That is the reason why manufacturers ought to consider battery compliance together with vehicle compliance rather than treating it as a secondary issue.

Basic Eligibility Requirements for EV Certification

Before beginning the certification process, a manufacturer should generally be able to establish:

Clearly defined vehicle category
Manufacturer and applicant details
Defined vehicle model and variants
Complete technical specifications
Identified traction motor
Defined battery/REESS configuration
Electrical and electronic architecture
Technical drawings and layouts
Required safety systems
Prototype availability
Applicable standards identified
Testing facilities available for the required assessments

In order to obtain vehicle type approval, ARAI specifies requirements including technical specifications in the prescribed formats, drawings and layouts, the relevant type-approval and conformity certificates, BIS licences for safety-critical components where applicable, WMI documentation, and details concerning the submission of the prototype or test vehicle.

Step-by-Step Electric Vehicle Certification Process

Step 1: Product & Category Assessment

The very first thing to do is to make clear precisely what is in question regarding the certification. UMSPCS examines the type of vehicle, its intended use, the power it has, its speed, the way in which the battery is configured, its category, and the technology that applies.

Step 2: Regulatory Mapping

The relevant provisions of the CMVR, the AIS standards, the battery requirements, and all other pertinent requirements are listed. As a result, businesses are unable to test against the wrong standard.

Step 3: Technical Documentation

The technical specifications that are required, together with the drawings, the information about the components, and the other supporting documents, have been organised.

Step 4: Prototype Readiness

The manufacturer produces the prototype or typical vehicle/system in accordance with the relevant test requirements.

Step 5: Testing

The testing is carried out in coordination with the relevant notified or recognised testing agency. Arai carries out certification and homologation work with regard to vehicles and components and offers CMVR type approval services for the various EV categories.

Step 6: Test Report Review

The test results are checked to ensure that they comply with the relevant regulatory requirements. Corrective action or further testing might then be required if any deficiencies

Step 7: Type Certification

When the requirements have been successfully demonstrated, the appropriate approval or certification documentation will be processed.

Step 8: Post-Approval Compliance

Manufacturers might also have to ensure that their production is in conformity with the required standards and maintain compliance as long as production goes on.

Documents Required for EV Certification

The list of documents needed will depend on the type of vehicle and the certification route taken; typical documentation may comprise:

Documents required for the business include a company registration certificate, IEC numbers, and authorization letters to establish the company's identity.
Description of the product: Information concerning the charger's technical specifications, such as its power rating, voltage capacity, etc.
Test reports: Reports concerning electrical safety, performance, and environmental testing carried out in authorized laboratories.
Regarding quality control: details on the quality control of the product.

The documentation for the AIS-156 requires a detailed description to include information about the manufacturer, the vehicle, the traction motor, and the REESS.

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How Long Does it Take to Get EV Certification?

One cannot say that all electric vehicles follow the same timeline.

It depends on:

Vehicle category
Number of variants
Testing scope
Battery technology
Prototype readiness
Documentation quality
Testing-agency schedule
Test failures
Modifications
Retesting
Extension/variant requirements

As a benchmark figure, ARAI presently gives a period of 45 working days for full-level vehicle type approval, 30 working days for partial-level approval, and 10 working days for documentation approvals, on condition that the relevant request and circumstances apply.

It would be wrong to regard this as a guaranteed total duration of the project since further activities such as preparation, sample development, testing, corrective action, and others might take extra time.

What Does Electric Vehicle Certification Cost?

Electric Vehicle (EV) certification in India typically costs between ₹1 lakh and ₹10 lakh+ per model, depending on the vehicle category, applicable standards, testing requirements, battery configuration, laboratory charges, and certification scope.

The final cost can depend on:

EV category
Number of models/variants
Number of prototypes
Battery configuration
Applicable tests
Component testing
Laboratory/testing-agency charges
Documentation requirements
Retesting
Modification requirements
Certification and statutory charges

For example, the data in BIS's present laboratory database shows that the charges for testing EV charging equipment can vary greatly according to the standard, the laboratory, and the scope of the testing; its entries for IS 17017 show different charges together with detailed components per test.

It is therefore necessary to calculate the accurate cost of EV certification following technical profiling rather than giving an arbitrary package price.

Benefits of Electric Vehicle Certification

EV manufacturers enjoy important benefits as a result of complying properly.

In terms of entering the legal market, it ensures compliance with the relevant Indian regulatory framework for vehicles.
There will be an improvement in product safety since testing can pinpoint possible problems relating to electrical, battery, and vehicle levels.
Improved market credibility: When compliance is documented, confidence is gained among customers, distributors, and business partners.
Regarding support for government schemes: If a manufacturer wishes to take part in a government incentive programme, it must also meet the eligibility requirements specified in that scheme.
It will reduce compliance risks since any gaps can be identified in advance and thus avoid the need for repeated testing and redesign.

EV Certification vs EVF Credential: Don't Confuse the Two

The Educational Credential known as the Electric Vehicle Fundamentals (EVF) is aimed at providing a solid understanding of electric vehicles and at supporting career development.

That is not equivalent to Indian vehicle type approval or regulatory certification. The same applies to an academic programme which covers the fundamentals of EVs, MATLAB simulation, vehicle dynamics, battery design, or powertrain design in terms of developing professional knowledge; it does not take the place of the mandatory Indian regulatory approvals.

The issue for a manufacturer of electric vehicles that wishes to introduce a road vehicle into the Indian market is not merely whether its staff understands EV technology, but whether the vehicle and its relevant components comply with India's regulatory requirements. Read more also: CE Certification in India.

What Makes UMSPCS the Choice for Electric Vehicle Compliance?

The correct selection of a compliance consultant can have a major impact when a product has to meet several technical standards.

UMSPCS has extensive experience covering more than 600 product compliance requirements and has more than 6 years of experience, enabling companies to deal with regulatory projects by using a structured compliance strategy.

UMSPCS can support businesses with:

Initial EV compliance assessment
Product profiling
Applicable standard identification
CMVR/AIS requirement mapping
Battery compliance guidance
Documentation support
Test requirement identification
Testing coordination
Application-related assistance
Test report review
Clarification of compliance gaps
Certification process coordination
Support for variants and modifications
Regulatory update tracking

Conclusion

The ecosystem for electric mobility in India is developing rapidly, but simply having innovative ideas is not sufficient to ensure that an electric vehicle succeeds in reaching the market.

Whatever the product may be, the entire compliance chain, covering CMVR Type Approval and EV Homologation, AIS 156 battery compliance, EV testing, charging-equipment standards, and scheme-specific requirements, must be taken into account.

The way to proceed is to systematically coordinate the certification pathway, properly prepare the technical documentation, and identify the relevant requirements before testing starts.

If you are planning to develop, manufacture, import, or launch an electric vehicle or an EV-related product in India, make sure your compliance requirements have been identified before you carry out any testing.

Connect with UMSPCS now if you need advice regarding Electric Vehicle Certification in India and find out the compliance route that applies to your EV product. Also, get to know more about Cybersecurity Certification.

Frequently Asked Questions (FAQs)

The standards that apply will vary according to the type of vehicle and the technology involved; these can be CMVR requirements, AIS 049, AIS 156, AIS 038, and other relevant standards.

It isn't universally applicable; instead, it varies according to the type of vehicle and the relevant regulatory requirements. The battery requirements differ from one type of vehicle to another.

The regulatory testing and approval requirements for traction batteries will depend on the type of vehicle and the relevant standards.

BIS certification and vehicle type approval are two separate compliance procedures, and the one that applies will depend on the specific EV product or component.

The cost will vary according to the vehicle category, the number of variants, the testing requirements, the battery configuration, the laboratory charges, the need for documentation, and the possibility of retesting.

Yes, altering the motor, the controller, the REESS, the working voltage, the charger, or any other parameters may cause extra verification to be required depending on the relevant standard.

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