Consultancy Projects

Lithium Ion Battery Pack Diagnostic

The Challenge

A client's EV battery packs were experiencing premature capacity degradation and range loss. The challenge was to identify degraded cells and internal resistance inconsistencies within the large lithium-ion battery pack without destructive testing.

Our Solution

Our engineers developed a comprehensive diagnostic protocol using advanced electrochemical impedance spectroscopy (EIS) and cycle testing. We successfully identified and isolated the underperforming cells, implemented a cell balancing strategy, and restored the battery pack's overall capacity, extending its usable lifespan and ensuring reliable performance.

EV Powertrain Integration and Optimization

The Challenge

A client needed to integrate a high-performance electric powertrain into an existing vehicle chassis while ensuring optimal weight distribution, thermal efficiency, and mechanical reliability under various load conditions.

Our Solution

Our engineering team conducted a comprehensive mechanical teardown and redesign, optimizing the mounting points and drivetrain components. We successfully integrated the motor, inverter, and transmission, achieving a 15% increase in overall powertrain efficiency and ensuring seamless torque delivery.

Battery Air Cooling System for LFP Battery Pack

The Challenge

Lithium Iron Phosphate (LFP) battery packs used in electric vehicles generate heat during charging and discharging due to internal resistance and electrochemical reactions. If this heat is not effectively dissipated, the battery temperature can exceed the safe operating range, leading to reduced battery efficiency, faster ageing, shorter lifespan, and potential safety risks. Manual temperature monitoring is impractical for large battery packs, making an automatic thermal management system essential to ensure reliable and safe battery operation.

Our Solution

To overcome this problem, an ESP32-based Battery Air Cooling System is developed for an LFP battery pack. The system uses 14 DS18B20 digital temperature sensors connected through two OneWire communication buses to continuously monitor the temperature at different locations within the battery pack. The ESP32 collects temperature data, identifies the highest temperature, and compares it with predefined threshold values. When the temperature exceeds the set limit (33°C), the ESP32 automatically activates the corresponding inlet fan and the common outlet fan through relay modules. The temperature readings, fan status, and system status are uploaded to Firebase Realtime Database and displayed on a real-time web dashboard for remote monitoring. This automatic air cooling system helps maintain the battery pack within a safe temperature range, improving battery performance, enhancing safety, and extending battery life.

Advanced Liquid Cooling System for High-Performance EV Batteries

The Challenge

As electric vehicles demand higher energy densities and ultra-fast charging capabilities, traditional air cooling systems often fall short in maintaining optimal battery temperatures. Excessive heat generated during high-speed driving or rapid charging can cause thermal runaway, degrade cell chemistry, and drastically reduce the battery's lifespan. A more robust, highly efficient thermal management solution is required to handle these extreme thermal loads.

Our Solution

We developed an advanced Liquid Cooling System designed to actively circulate coolant through strategically placed cold plates within the battery pack. This system provides superior heat dissipation compared to air cooling by maintaining uniform temperature distribution across all cells, even under heavy loads. Integrated thermal sensors and a smart controller continuously adjust the coolant flow rate based on real-time temperature data. This ensures the battery remains within its optimal operating window, maximizing charging efficiency, extending battery longevity, and ensuring the highest level of safety for high-performance EVs.

Comprehensive EV Powertrain Teardown & Reassembly Analysis

The Challenge

A key industry partner needed a detailed mechanical and electrical teardown of an existing electric vehicle powertrain to analyze component wear, identify inefficiencies in the motor-to-axle power delivery, and evaluate the structural integrity of the chassis mounting systems.

Our Solution

Our team conducted a full dismantling of the vehicle's powertrain assembly, carefully analyzing the motor, reduction gear, and associated mechanical linkages. Through this rigorous hands-on teardown and rebuild process, we identified areas for mechanical optimization, proposed a more robust mounting solution to reduce NVH (Noise, Vibration, and Harshness), and provided the client with a comprehensive engineering roadmap for their next-generation drivetrain design.

Hybrid Engine Disassembly and Testing of Engine

The Challenge

Understanding the internal mechanics and identifying wear patterns within a hybrid engine requires a complete, meticulous teardown. The challenge was to systematically disassemble the engine while preserving all components for detailed inspection and subsequent diagnostic testing.

Our Solution

Our team executed a full hybrid engine disassembly, carefully cataloging each component. We then performed comprehensive testing on the core mechanical and electrical parts to evaluate their condition. This rigorous testing phase provided essential data for rebuilding and optimizing the engine's performance.

Hybrid Fuel System Integration & Engine Startup

The Challenge

Following electrical integration, the hybrid powertrain required precise mechanical integration of the fuel system, followed by thorough troubleshooting to achieve a successful engine start.

Our Solution

The hybrid team connected and pressure-tested the fuel system. We systematically troubleshot the setup, resolving minor integration issues, which culminated in a highly successful engine start, validating the complete hybrid powertrain assembly.

Comprehensive 2-Wheeler Diagnostic Setup

The Challenge

As electric two-wheelers become increasingly sophisticated, pinpointing faults within the electrical systems, motor, or controller requires specialized diagnostic testing. Rapidly identifying faults in the throttle, brake cutoffs, BLDC hub motor sensors, and the battery management system is critical for efficient servicing and development.

Our Solution

We established a comprehensive 2-wheeler diagnostic setup capable of testing all critical powertrain components either in isolation or as a fully integrated system. By systematically checking voltage signals, hall sensor outputs, and controller responses, we can quickly diagnose complex electrical issues. This setup serves as an invaluable tool for troubleshooting faults and validating components before final vehicle assembly.

Testing of the Diagnostic Setup using OLA Battery pack

The Challenge

Service centers frequently struggle with intermittent electrical issues in 2-wheelers. Identifying whether a problem stems from a degraded cell within a 51.8V OLA battery pack, a failing motor winding, or a communication error in the wiring harness is often a time-consuming trial-and-error process.

Our Solution

We engineered a live fault-finding workflow utilizing a specialized 51.8V OLA battery testing diagnostic setup. By interfacing directly with the drivetrain and simulating real-world load conditions, our team monitors live telemetry data to instantly pinpoint intermittent failures, preventing unnecessary component replacements.

High-Voltage Solar-to-Battery Charging System Integration for an Electric Three-Wheeler

The Challenge

Integrating a high-voltage solar array directly with an electric three-wheeler's battery pack requires overcoming significant voltage mismatches. The core challenge was ensuring safe, highly efficient power transfer without degrading battery health, triggering thermal issues, or overcharging the cells during peak sunlight hours.

Our Solution

We designed and integrated a custom high-voltage MPPT (Maximum Power Point Tracking) charge controller precisely tailored for the battery pack's specific chemistry. This system actively regulates the solar array's voltage, maximizing energy capture while communicating directly with the vehicle's BMS to enforce strict overcharge protection and optimize the on-the-go charging curve.

12 V vehicle Architecture

The Challenge

Ensuring systematic and sequence-wise observation for complex EV powertrain components requires precision tracking and robust quality control metrics during assembly and testing phases.

Our Solution

We implemented a comprehensive wire-harness and sequence observation protocol, allowing for meticulous step-by-step verification, enhancing reliability and safety of the vehicle's core systems.

TVS I Qube vehicle Dismantling

The Challenge

Understanding the structural integration and powertrain layout of modern electric 2-wheelers requires systematic dismantling and reverse engineering to analyze the BMS, battery pack placement, and electric motor mounting.

Our Solution

We performed a complete teardown and dismantling of the TVS iQube, documenting the entire architectural breakdown to train engineers on OEM-level EV packaging and thermal management strategies.

Hall Sensor Testing

The Challenge

Hall sensors are critical for precise motor commutation and speed detection in electric vehicle powertrains. Accurately diagnosing faults and verifying sensor signals requires rigorous testing procedures before high-voltage integration.

Key Procedures

1. Checking phase sequence
2. Directly connecting

Our Solution

We established a systematic testing protocol for the BLDC motor's Hall sensors, successfully completing the initial low-voltage signal verification. The setup is now primed for advanced diagnostics using a 48V battery system and precision multimeters to ensure flawless powertrain synchronization.

Ola S1 pro dismantling and diagnosing

The Challenge

High-performance electric scooters like the Ola S1 Pro feature tightly integrated powertrain components, sophisticated thermal management, and complex wiring harnesses that require deep analysis for diagnostic and reverse engineering purposes.

Our Solution

We executed a comprehensive teardown and diagnostic procedure of the Ola S1 Pro, thoroughly mapping its motor controller architecture, battery pack structural integration, and overall system packaging to enhance OEM-level troubleshooting capabilities.

High voltage solar- battery charging system integration for Electric 4 wheeler

The Challenge

Integrating a high-voltage solar array directly with an electric four-wheeler's battery pack requires overcoming significant voltage mismatches. The core challenge was ensuring safe, highly efficient power transfer without degrading battery health or overcharging the cells.

Our Solution

We designed and integrated a custom high-voltage MPPT (Maximum Power Point Tracking) charge controller tailored for the 4-wheeler's battery pack. This system regulates the solar array's voltage, maximizing energy capture while communicating directly with the BMS.

Ola battery pack removal and testing a ola battery pack

The Challenge

Removing and testing the high-voltage battery pack from an Ola electric scooter demands strict adherence to safety protocols, specialized tooling for secure extraction, and precise diagnostic equipment to evaluate cell health and BMS communication integrity.

Our Solution

We executed a safe and systematic removal of the Ola battery pack, followed by comprehensive multi-point diagnostic testing to analyze thermal characteristics, discharge rates, and internal resistance across the battery modules.

Drive train Testing

The Challenge

Validating EV drive train efficiency requires rigorous testing of the motor, reduction gear, and axle assembly under varied load conditions to ensure optimal torque delivery and minimal mechanical loss.

Our Solution

We conducted comprehensive drive train testing, analyzing torque output, vibration metrics, and continuous power delivery, ensuring the system meets strict performance and durability standards.

Regenerative Breaking Using Matlab simulink

The Challenge

Maximizing electric vehicle range requires efficient regenerative braking systems that effectively convert kinetic energy back into stored battery power. Simulating and tuning this dynamic energy transfer mathematically is complex due to the variable braking forces and battery charge acceptance limits.

Our Solution

We developed an advanced regenerative braking model in MATLAB Simulink, simulating real-world deceleration scenarios. This model successfully optimized the control algorithms, maximizing energy recovery while ensuring passenger comfort and battery health.

Real time Battery cooling system ( 48V battery pack )

The Challenge

Operating high-capacity 48V battery packs under extreme loads generates significant thermal stress. Preventing thermal runaway and ensuring consistent power delivery requires an active, real-time cooling system capable of dynamically responding to cell temperature spikes.

Our Solution

We engineered and tested a real-time active battery cooling system specifically designed for a 48V architecture. This system continuously monitors module temperatures and intelligently regulates coolant flow, successfully maintaining optimal thermal conditions under peak stress.

Active cell balancing

The Challenge

In high-capacity battery packs, individual cell voltages drift over time due to manufacturing variances and thermal gradients. Passive balancing dissipates excess energy as heat, which reduces overall efficiency and pack lifespan.

Our Solution

We implemented an advanced active cell balancing BMS architecture that dynamically transfers charge from stronger cells to weaker ones during both charge and discharge cycles, significantly extending the usable range and battery pack longevity.

Ola Battery Pack Testing & Battery Diagnostics

The Challenge

Ensuring the safety, capacity retention, and peak performance of Ola EV battery packs demands rigorous cell-level and module-level testing to identify internal resistance variances, voltage drifts, and thermal weak points.

Our Solution

We implemented a multi-stage diagnostic testing protocol for the Ola battery pack, combining deep-cycle charge/discharge analysis with real-time BMS data extraction to accurately benchmark battery health and operational reliability.

300V Battery Pack cooling system

The Challenge

High-voltage battery packs, such as a 300V system, generate significant heat during rapid charging and high-discharge cycles. Maintaining optimal thermal performance is critical for extending battery lifespan and ensuring safety.

Our Solution

We engineered and tested a comprehensive thermal management and cooling system specifically designed for a 300V battery architecture. The integration ensures uniform temperature distribution, maximizing efficiency and performance under peak loads.