REVOLO – Ready To Fit Hybrid Technology Solution By KPIT Cummins & Bharat Forge


Bharat Forge Ltd. & KPIT Cummins have announced a joint venture 4th June 2010, at Delhi for providing ready to deploy Hybrid technology solution to be fitted in Indian automobiles. The system is known as REVOLO – Revolutionary Solution for converting any car from 800 CC to 3000 CC into a parallel hybrid without tampering with the transmission of the car.


The revolutionary technology is out of the box and involves mounting of the electric motor on the crank shaft of the engine which is an innovative move which saves a lot of cost and installation efforts. This also reduces the pain of removing the transmission and installing a new one. This revolutionary indigenous innovation makes this system 80% cheaper as compared to the after-market hybrid car kits available in the US markets which cost around $20,000 USD. Not only the cost factor, this makes the system a lot less complex and light in weight in context of the moving engine components which effectively enhances the fuel efficiency to twice as compared the the existing solutions which are available globally. This cost factor and efficiency factor combined make this solution 10 times more value for money compared to the counterparts.


Keeping the technicalities apart, for a layman, this is an aftermarket kit, which will be available for installation at the authorized service partners which will include certain components like :

  • Electric Motor
  • Electric Motor Controller
  • Battery  Pack
  • Mechanical assembly & coupling
  • Controller unit with intelligent software
  • Battery Management system

This diagram shows the schematic representation of the system deployed in any conventional car. The biggest positive point about this kit is that it can be installed on all kind of card with or without MPFI / CRDI technology in them. The kits will be available as per the car’s engine capacity in various models which support cars ranging from 800CC to 3000CC.


One more interesting fact about this kit is that it will give an amazing power boost to the car in first gear because of high starting torque of an electric motor compared to moderate torque of a petrol engine at low engine speeds.

The key benefits of installing this kit are :

  • Fuel Efficiency Improvements of over 40 % as tested by ARAI. In City driving conditions, it can be as high as about 80 % improvement.
  • Green House Gases Emission Drops by over 30 %
  • Providers additional boost in power.
  • Improves driving pleasure.
  • Increases engine life by reducing load on the engine.
  • Can be fitted in 4 to 6 hours by trained technicians.
  • No additional infrastructure needed by the govt.

Below chart shows the specifications of the engines tested with this kit and the test results.


The solution is a Full Parallel Plug-in Hybrid, which means that the engine and motor will always run simultaneously and give the required boost and fuel efficiency. Plug-in means that you can connect it to the normal electrical power supply at home and charge the batteries. This means a significant reduction in running cost because the batteries are not charged by burning petrol or diesel.


It uses regenerative braking system to further save energy and makes the system even more efficient. The in-built start stop feature makes engine running much more efficient in congested stop and go like situations.

REVOLO also has an intelligent driving pattern recognition which adjusts the management of battery for maximum efficiency. Revolo is battery agnostic, which means it can run with Lead Acid or Lithium Ion batteries without changing other components of the system. It uses valve regulated lead acid batteries which uses gel based technology which avoid leakage and does not require water top-ups of any kind. 11 global patents have been files so far for REVOLO and its a break-through innovation. The REVOLO is expected to be commercially available by end of year 2010 in the Indian markets. The Price of REVOLO will be between Rs. 65,000 and Rs. 1,50,000 for various car segments.

The Joint Venture is in talks with various automobile OEMs to retrofit the REVOLO system in the cars as an aftermarket solution. Speaking at the occasion, the Heavy Industries Minister said that he will ask the Finance Ministry to encourage the eco-friendly technologies by providing them some tax incentives on production of eco-friendly technology products.

Also read- Convert Any Car To A Hybrid Car And Increase Mileage

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  1. Congrats and thanks for innovation to contribute in green planet and saving fuel for our kids.

  2. Dear Sir,
    I am impressed by the ‘REVOLVO’ technology and would like 2 get it fitted on my new car which I plan 2 purchase shortly. I have narrowed down my choices 2 Maruti Cervo, Nissan Micra & Hundai i10 Magnum cappa.
    I need a car for city running mainly and don’t trvel much beyond city limits as I am already 65.
    Please suggest if decision 2 get new car fitted with REVOLVO would b a good idea or not and if yes?, where from & how can I get it?
    With due regards,

  3. congrats for hybrid tech,though not so good as hue and cry……..far better option is present where 200% improvement in efficiency and approx nill .the concerned prototype was demonstrated in dec 21 press conference at papers covered.just getting patent,the fundamental invention.helping world in fact with solution to copenhagen meet.better to any standard of green house gases emittion.

    the revolo tech will not change the world. but only transfer burden with inconvenience.

  4. i was referring to the solution that is promising 200% improvement in the efficiency and approx nill the emission with prototype offering 100% improvement in the efficiency and most eco friendly or best of the world.the hidustan news paper hidi dated 24 dec 2009 page no 2009 it is not available in any web page ,i can not offer link.but i can e-mail details.some foreign institute is valuating.our system and manufacturers are not so up to the mark perhaps.

  5. @S K S GAUR
    Thanks for sharing, instead of email, you can give a summary here only via comments. I will be really thankful if you share it with our readers.

  6. thanks for … the said I C Engine is with fundamental changes so that it saves fuel [any–petrol diesel, gas] up to 66% and emission comes down to approx nil as per pollution test report . For same work by any machine not only car bus truck etc. but tractor pumping set and all end products using I C Engine will be benefited by it because this tech is applicable in all for being fundamental in nature. its pollution test report is better to all standard of URO -4 etc. the said prototype has been tested and demonstrated with bike on which new engine has been mounted. Govt institute has also certified. The prototype results are not complete but only with 100% improvement and 85% curtailing in pollution. In proper words this could be option for the current Copenhagen meet as well as the present inventive hue and cry provided that the system reacts.

  7. Mr. S K Singh, I do not understand what technology you are trying to explain. I am an automotive engineer and I dont think that any such thing exists as you are saying, so please elaborate. Revolo seems like a leap in current technology at an amazing price.

  8. dear srikar–the thing exists.not only the one i am explaining but another solution to that .actually ,to the present existing engine two option were possible with its very staring but could not be explored for either reason, the same engine conventional has two options , first —piston offset with respect to cylinder axis,that i discussed above and center off-set with respect to piston being fabricated at Banglore by Mr P. Urs. the first one’s prototype was demonstrated at Delhi in Press conference in dec 2009 and second one being prepared with tie-up with some company at south.these invention will really save the fuel not shift the burden from fuel to optional energy source as electricity. the revolo feasibility is for that reason because there is nothing new just shift of burden.
    the first one’s pollution test report says 85% curtailing in emission level. the second one’s prototype under fabrication.both applied for patent.the banglore end assisted by govt agency too.i hope you will find the rest.
    in revolo what we save is just postponing present to future, not in realty but with other help just like a lame with helping hand ….. not a solution but option of compultion.

  9. Dear Sirs, I am an automotive engineer and have three questions about this proposal, if someone directly involved with the project can answer them I would appreciate it.
    (1) if you look at the engine space in most cars it is very cramped in there, there is simply no room to fit a multi kW electric motor. How do you propose to find space?
    (2) The end of the crank shaft that doesn’t go into the transmission typically drives the pulleys for the fan, alternator etc. Can you fit the electric motor onto there without disrupting these essential services?
    (3) As everyone knows, for a petrol engine which is unpowered there is a high drag caused by pumping the air through the throttle and the cylinder. Since the engine is still connected, when running on electric power only, how can you avoid the high power drain of turning the engine? Thank you and regards.

  10. How come they are using regenerative braking if they are not replacing the stock brakes with the on hub regenerative motors? Otherwise impressive.

  11. @Doctor
    I am not 100% sure of it, but when brakes are applied, the engine fuel supply may be cut down and the motor may itself stop drawing current and operate as an alternator for a brief period for which the brakes are applied. this way, engine braking may work, but for this system to work effectively, driver needs to apply brakes without pressing the clutch. this will re-generate mild amount of energy, not all, but this will work even without any modifications to the stock brakes.

  12. @ S K Singh, Is it only engine technology??? SO normal engine or some new development?? Is it possible to configure current engines for this new tech just like Revolo??

  13. @ S k Singh, are you able to give me any answers to the questions I pose above? Unless these issues can be answered, the idea is a complete non-starter as a retrofit.

  14. dear mechanic,,there is difference between two ,the said revolo can be applied to both of the engines i mentioned as fundamental invention,so if the my said engine is there applied then the mileage will become three time approx to current / present mileage and then you apply revolo thech then the mileage will again jump to three times of the origial plus claimed by revolo,
    the engines inventor are ,one at Bangalore and one at Allahabad,the new design is applicable in two ways ,1–a kit for old engines and 2—complete engine for new manufacturer. the engine can be changed to every end product using I C Engine say car rail trucks bike etc.but that is another thing ,prime thing was claims of revolo,its impact to the claims,which i do n ot agree as it is just shift of burden……………

  15. dear tim actually what u have asked is concerned with internal mechanism of fitting and as i presume surely the engineers would have considered these points developing revolo it looks that as they claims that both tech viz conventional engine and electric motor will work simultaneously which indicates that they have just avoided your question by continuous working of fuel engine.but i am not related with revolo so i could only guess but still revolo contain nothing new as like invention but a tech to shift burden of conventional engine, because the expenses user has to bear in form of battery and charging are not elaborated as life of battery and electricity consumed.but your questions in the tech are solved perhaps in the form of continuousb working of both .

  16. senthil it looks that revolo and poulsen hybrid differs at continuity of supply,otherwise same, perhaps…..

  17. Who is this Mr. P. Urs ??!!

    I am very interested to know more on this product…..any links ?? though u have said, u cant share…….

    Mohan Urs

  18. mohan,you have similarity of name .are you his brother,,,, mr p urs belongs to banglore. automobile engineer,and inventor of center off-set, what ills details you want and why.please feel free,,,,if need i may offer you complete details of any. though not web or such links.but his invention too is on progress,,,up to my best information.
    in which way you are interested in these products or better invention because they are not so far in the market.

  19. Thanks for the response, Urs family basically hails from Mysore and will be some way connected in relation, though I dont know much about P Urs. However, I would be sure interested to know more about the center off-set technology for engines and how it improves the efficiency. I am basically a electrical engg and work on various hybrid technologies mainly in the field of energy. It would be good to know the marketability of this technology and how far it gets accepted by the consumers. Cheers, Mohan Urs

  20. I’m the Strategic Manager, Hybrid Solution at KPIT Cummins. Thanks all for your interest and good to see an active discussion here.
    Couple of points I’d like to mention:

    1. The solution uses existing vehicle engine as the primary driver, the motor provides intelligent assistance to the engine. So the engine is not replaced, this allows the retrofitting to be done in a fairly short period (4 to 6 hours). The manner in which the motor and engine are coupled is one of the areas where IP has been created.
    2. We have installed this solution on multiple vehicles, media reviews of such vehicles are being scheduled at this point.

    There is an good analysis at this link:

  21. dear urs sorry for being late.thanks for interest .i can send your letter to concerned person mr.p. urs and i will be delighted to see any progress .either send your letter at so that i could forward your letter to the cocerned person or send your any other contact so that i could forard that or you suggest your option.
    dear chinmay, the mechanical energy when converted to chemical energy in the form of battery charging and again when converted into mechanical energy from that stored chemical energy there is loss of energy .the figures in the form of benefits that your ends claim, have calculated that energy losses.then what you thinks the real benefits. whether there is any net benefit or just magical datas .kindly elaborate if possible that account.the charges of battery cost and its life when it will have to change .the investement that consumer will have to bear in total is equal to existing or more .
    why do not your company explores better options????? off-set piston tech like where kit to existing engine is also possible

  22. @sk singh
    We don’t use the engine to charge the batteries. There are conditions where the energy generated by the engine is not used li eengine idling, braking etc; in such conditions we use that energy (which would have been lost otherwise) to charge the battery.

    The battery cost and its life changes depending on the battery technology used (Li-Ion or LA etc.). Also the life of the battery depends on running of the vehicle thus the investment the consumer will have to make will depend on various such factors.

    Hope this clarifies your questions.

  23. I really feel that we have to look at more options for charging of batteries. If shoes can charge a phone, I believe a shock absorber also can.

  24. This will be better than CNG/LPG fittings. I did some calculations for myself which I guess would apply to most people who drive mostly around the city…
    Average mileage : 1500 kms/month
    Average : 30 km/l
    Petrol needed : 50 liter
    Petrol Rate : Rs.45/l
    Money Spent : Rs.2250
    Average : 30 km/kg
    Gas needed : 50 kg
    Gas Rate : Rs.27/kg
    Money Spent : Rs.1350
    Petrol + Revolo
    Fuel Efficiency = 60% to 80%
    Average : 48 to 54 km/l
    Petrol needed : 27 to 31 liter
    Petrol Rate : Rs.45/l
    Money Spent : Rs.1200 to Rs.1400

    If I didn’t happen to have made any mistakes in my calculations, it could mean that this will be cheaper than CNG!!

    Although its initial cost is a bit more than CNG kits but where I drive (Delhi) it’s a huge pain waiting in lines at refilling stations which I’d be more than happy to live without. I’m talking ‘hours’ !! Even if I have to do that just once a week it’s frustrating as hell! And it’s not like you could rest there for even a minute, I mean you constantly have to look out for those three-wheelers will cut in your line if they find a space even to squeeze in just their tiny front tire.

    I’m glad that we also have some mechanical engineers among us taking part in the discussion. I have a somewhat understanding how hybrid car works, but I have a few queries about this that I’d very much like them to be answered by someone.
    1. How much will be the capacity of additional battery ?
    2. Will we need to recharge it externally ? (like through an electrical socket?)
    2½ If so, how often ?
    3. Will this system work in parallel with the main engine or will it completely take over at low speeds (like in hybrid cars) ?
    3½ If it works in parallel, will it be something like if I’m accelerating in 2nd gear, all the torque will be provided by the system’s battery and the main engine will just be idling ?

  25. @Mukesh
    I will try to answer your questions as per my understanding :
    1. The additional battery capacity should be close to or more than the main battery. Maybe someone from KPIT cummins in this discussion thread can answer it better.
    2. Yes, you can, since its a plug-in-hybrid, which means that you can charge battery by connecting it to normal home power supply just like you charge electric scooters. It greatly cuts down the running cost as the cost of running on electricity is much lower compared to petrol. You need no special connection, domestic power supply of 220 V in India is enough for it. Rather there will be a charger attached to home power supply as the battery charging needs DC current.
    3. This is a full hybrid, since its mounting is on crank shaft, it will always be operational at all engine speeds but the load on the engine will be low as the power supplied by the motor will reduce engine load. since the system shared load with engine, the same system will double up as start-stop system, in which the engine will shut down at idling on traffic signal like conditions, the motor of the REVOLO system will be used to pick up and will also double up as starting motor as in start stop systems.

    hope it answers some of your questions. I expect some answers from KPIT guys on this thread, they are really prompt and helpful.


  26. Thanks for providing the info Rohit. @mukesh – here is some more information about your questions

    1. How much will be the capacity of additional battery ?
    The battery capacity changes with the vehicle size and battery chemistry used. For the 800cc vehicle whose ARAI results we have shared, the battery used is a valve regulated lead acid battery (‘VRLA’), it’s power output was 4.8kWh.

    2. Will we need to recharge it externally ? (like through an electrical socket?)
    In addition to what Rohit has stated, the external charging is not necessary for base vehicle performance but it is necessary of optimum performance. In case the vehicle is not charged, it will perform as a normal vehicle.

    2½ If so, how often ?
    The frequency of charging depends on many factors such as daily driving distance, driving conditions, vehicle specifications etc. We don’t expect charging to be required more often than once in a day for optimum performance.

    3. Will this system work in parallel with the main engine or will it completely take over at low speeds (like in hybrid cars) ?
    Again Rohit has made my job easy here… 🙂 The system does not substitute for the engine at any time. This allows us to use a relatively smaller motor as we are not creating an alternate to the engine.

    3½ If it works in parallel, will it be something like if I’m accelerating in 2nd gear, all the torque will be provided by the system’s battery and the main engine will just be idling ?
    Rohit, I believe has succinctly answered your question already. The motor will reduce the load on the engine

  27. Its an interesting solution.
    Dear Chinamy can you tel me what is the cost of the system when lithium batteries?. I understand it depend on KW and car under consideration, but considering a 1000cc car, what may the cost of such a retrofitting go. Would it remain the same as said $1500-$3000??
    Secondly are these Lithium batteries of good quality. Since the Indian manufactures of lead acid like amaraja, exide may not be have expertise for lithium batteries. Which make would they be.
    Lastly, I just wanted to confirm that this is not a plug in solution right ?

    Thanks for enlightening us;)

  28. @Gourav,

    We are working with/on multiple Lithium Ion options. Unfortunately it is a little too early at this point of time to comment on the price range or make of the Li-Ion battery based Revolo.

    On your last question, Rohit has again beaten me to the answer! Like he says, Revolo is a plug-in solution

  29. @Chinamy: Thanks for your response. Do lead acid batteries take such a large current out of regeneration ? Does that not harm the life and performance of battery??

    Though I really appreciate the technology, I am cautious about the batteries type/make before I use them on my car..

  30. 1>In cooperative societies, it is difficult nowadays to even park your car let alone find a charging point. Can the battery be detached from the car and carried to my apartment for external charging?
    2>Can this kit be attached to Tata Indigo Diesel version?
    21/2>If yes, What is the cost like?
    3>To whom can I get in touch with to have my car assessed and the kit attached?

    Thanks for the innovation.

  31. Hi Vaibhav

    1. I am not sure, as per my guess the answer will be no, you may not be able to detach the batteries for charging.
    2. Yes, this solution can be attached to both petrol and diesel cars alike.
    3. use this page to get in touch with concerned authorities –


  32. Hi chinamy,
    Can the car run only with electric motor in neutral mode? Have any extra accelerator (variable power pedal) for this system. And what about when the car is in reverse gear. When the car is in reverse gear the electric motor will be in a forward rotational mode and it can be damage the motor and how much it will be coast to fit on a 1200 cc car. Please clarify.

  33. Girish,

    The motor is not sized to drive the vehicle by itself. In other words, Revolo does not have a ‘pure EV mode’. On your question on extra accelerator, the solution does not increase points of interaction with the driver. Revolo works in the background collecting various parameters ( The solution adds sensors in the vehicle to collect this) to optimize vehicle performance. On your observation on reverse, the manner in which the motor is coupled to the engine ensures that irrespective to the gear (forward or reverse) the motor works in tandem with the engine.

    On the pricing front, we have already announced that the pricing will be in the range of INR60,000 to INR150,000. Pricing for specific vehicles will be announced in due course of time.

    Hope that answers your doubts…


  34. Hello ,

    If anybody can answer me, does this system use one clutch or two clutches ?

    Is it a parallel hybrid with one clutch (P1 HEV) or a parallel hybrid with 2 clutches (P2 HEV).

  35. @Swaroop
    Its a parallel hybrid and fits at the crank shaft, i don’t think there is an external clutch installed on it as its a retrofit outside the transmission.

  36. Dear sir
    AS considering of your technology is very nice,but considering clearance distance for ground ,so it is tough to manage in revolow.

  37. Your product is really good but i have one confusion that this product can fitted in petrol car without removing petrol engine.and if it work with petrol engine then both work simultaneously or one by one.

  38. Hi Keyur,

    You sure have interesting questions for us! So here are our responses. Let us know if you have any followup questions. One blanket statement: we are currently conducting mass trials of Revolo, so there might be some changes we might bring in compared to what we discuss here. However we don’t expect them to be significant.

    1. On the ground clearance point: none of our components are installed below the vehicle to cause reduction of ground clearance. In normal driving conditions with 2 or 3 passengers, the additional weight of Revolo will not significantly reduce the ground clearance.
    2. On your clarification about Revolo and engine working: In a Revolo fitted vehicle, both Revolo and the engine work together to provide maximum efficiency.
    3. To your question on CNG fitted vehicles: Yes, we can fit Revolo to vehicles which run on CNG. The way Revolo works, it makes no difference what fuel the engine uses.

  39. Dear Sir,
    My main question of source of getting ‘REVOLO’ kit fitted, remains unanswered.Please enlighten me about cost and source. I stay at Vadodara,Gujarat.
    Waiting for ur reply,
    With due regards,

  40. Hello everybody,
    Its indeed a great work by KPIT team.
    However I have following questions. If someone can answer
    1)Who are the technology partners for KPIT ?
    2)Are there any plans to be associated with any automobile OEM?
    3) With the fitments of the kit on a vehicle who are the going to be the warranty owners for failures?
    I am still gathering the inputs on this subject. request help on some technical matters as well.
    Kaustubh Panchi

  41. I am interested to know what the entry strategies are for this product in foreign markets. In particular are there plans for this product to enter the Irish car market? Ireland is very vulnerable to high fuel prices and has deadlines to meet on GHG emissions so a product like this will have huge market potential. Please contact me with any possible information relating to my questions.
    Conor Greenan

  42. There is inordinate delay in commercial launch of Revolo hybrid system. Can any one from co explain and provide us with details or the product still at development stage?

  43. The way I see it is: Traction is 25+% (depending on tire condition), Breaking is 50% (in India / city driving / rush hour), Wind resistance & Joint movements balance of the energy losses. So the main advantage of electric driven cars is the Breaking storage of energy.

    Therefore, small battery with full breaking would be best in such a solution. ??

    If Yes, then can the existing car battery be used, in such a solution ?? Storage space & cost advantage ?

    If Yes, then the existing alternator can be used to recharge battery when below say 50% & when not accelerating hard (to avoid load on the engine) as you say idle or light load time ?

    I assume AC drives & AC motors are used ? or DC Drives & DC motor ?

  44. The need for a “Bus” / Truck model where engine size is over 3000 CC is also a big market where the toned down model payback of 4 months.

    Really, you product is to Vehicles what the the PC was to Information Technology back in ’81 and what Smartphones are to everyone over the last few years. Wishing you all the best & speedy Gov’t safety approvals.

  45. @BS5 Emission Norms: When are they to be implemented ?

    For less than Rs. 2K some 25%+ (unquantified for Cars) efficiency can be achieved under certain conditions.
    Would it reduce emissions ?

  46. I have asked about the launch of this many times. When will it be launched? Any news about its launch in Delhi?

  47. Hello Anoop,

    We do not have any news about Revolo as of now. We will keep you posted.


    Associate Editor | Car Blog India

  48. For Indian (at least Delhi) driving condition one can pick up 20+% fuel saving and enjoy driving the car – Better pick up & less gear changing & quieter car by clean the air filter frequently (depending on driving condition & Fuel) & add 125ml of Synthetic Oil –

    CNG car & driving condition – Clean Air filter at every fill up (change at every 1000km) & Add Syn Oil every 750KM
    Petrol Car & Driving conditions – Clean Air filter at every fill up (change at 1500+km) & Add Syn Oil every 1500KM
    Diesel also but do not have experience to tell you & with turbo charged great Air filers are usually provided but likely every fillup clean air filter & Add Syn Oil likely every 2000-3000KM.

    It like driving a brand new car every day & Service as you are use to likely 6 months & 6K KM (for petrol)

    Noting your Car User Manual says for Dusty condition servicing 2ice as often & Hot condition also 2ic as often.

    Enjoy !


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