A leading vendor supplying electronics to TATA Motors and Ashok Leyland approached us after struggling with multiple consultancies that couldn’t optimize their legacy product’s current consumption beyond 20mA. The existing system was drawing nearly 70mA and faced reliability issues during vehicle cranking cycles, making OEM deployment and validation challenging.
Our engineering team redesigned the legacy architecture and optimized current consumption from 70mA down to 5mA, while improving cranking-cycle stability by 4X. This upgrade helped the customer meet performance expectations required for production deployment with both TATA and Ashok Leyland.
Along with performance, we ensured the product became compliant with key automotive EMC/EMI regulations, improving immunity and emissions performance to pass stringent validation needs. The solution was aligned with industry standards and regulatory frameworks such as CISPR 25, ISO 11452, ISO 7637-2, and OEM-specific EMC/EMI requirements, making it ready for real-world automotive environments.
Finally, the customer originally used a separate power supply and controller, increasing size and complexity. We integrated the power unit with the controller and optimized the power design, reducing the power supply footprint from the size of a smartphone to a 1-rupee coin, and achieving an overall 2X reduction in system size resulting in a compact, robust, and deployment-ready product.