Intelligent Engineering for Vehicle Electrification

In the rapidly evolving automotive and mobility sector, efficient battery management is a key challenge. Traditional wired Battery Management Systems (BMS) often prove complex and inflexible. The industry is shifting towards wireless BMS solutions that optimize vehicle design, cut costs, and provide real-time battery performance data. As EV adoption surges, ensuring scalability and safety across various battery configurations is crucial. There's also a growing demand for predictive maintenance systems to foresee motor failures, minimizing unexpected downtime. Additionally, the need for rapid, universally compatible charging infrastructure is increasingly pressing.

Cyient addresses these challenges with cutting-edge solutions in Wireless BMS, Motor Prognostics, and Charging Systems. Our advanced BMS technologies enhance battery monitoring, boost flexibility, and reduce vehicle weight. Our Motor Prognostics employ predictive analytics to prevent failures and ensure smooth operations. Our Charging Systems offer fast, dependable performance, supporting the transition to sustainable mobility. Cyient is your partner in delivering scalable, future-ready solutions that boost vehicle performance and speed up time-to-market.

Electrification Unleashed: Powering the Next Era of Mobility

Wireline and Wireless BMS

Motor Controller

Power Electronics

Cyient delivers Wireline and Wireless Battery Management Systems for seamless battery monitoring and optimization, with Wireless BMS addressing wired system limitations to ensure reliable, future-ready battery management solutions. Our capabilities include:

System Engineering

Architecture design, safety analysis, and wireless channel simulation, MBSE for wireless channel simulation, SW Development, Testing and HW-SW integration Design Documentation and Engineering Files.

System Validation

Signal integrity, power, and thermal testing, with HIL system development, KPI definition and measurement and test reports validation.

Verification and Validation:

Test Infrastructure: Automation, HIL systems, validation tests, and ML model training, DV Tests for all make parts, KPI Definition and measurement, Vehicle level tests – static and field tests, Validation Test Reports, Test Vehicle Set up – sensors and instrumentation for data collection, Data annotation and ground truth labeling, Object classification ML model training and validation.

Testing & Integration

Comprehensive validation, functional testing, and integration of wireless nodes.

Cyient offers end-to-end motor controller solutions for automotive electrification, combining 15+ years of system engineering with 30+ years in power electronics. We specialize in Motor Angle Estimation, FOC (Field-Oriented Control), and Torque Control for efficient, reliable EV motor management. Our capabilities include:

Concept Development

System engineering, modeling, simulation, and BOM preparation.

Hardware Development

Power and thermal management, sensor integration, and PCB prototyping.

Software Development

AUTOSAR-compliant ECU, motor angle estimation, and advanced diagnostics.

Testing & Validation

Comprehensive unit, integration, and HIL testing for reliability.

Cyient delivers end-to-end Power Electronics solutions for vehicle electrification, ensuring performance, safety, and scalability, from ideation to series production. With advanced technologies like ZVS/ZCS switching and thermal management, Cyient powers efficient, future-ready EVs. Our capabilities include:

Distribution

Power distribution panels, control units, and protection systems.

Battery Management

Chargers and monitoring systems for lithium-ion batteries.

Generation

SPUs, voltage regulators, and source converters.

Conversion

DC-DC converters, inverters, and EMI filters.

Control & Actuation

Solutions for steering, brakes, gears, and motor drives.

Intelligent Engineering for Connected
and Autonomous Equipment

Platform Engineering

Product Design & Development

System Engineering
Mechanical & Electrical Design
Analysis & Simulation
Manufacturing Engineering

Electronics & Software Development

Hardware Development
Embedded Systems
ECU Development
Software Integration

Vehicle Integration

ECU Integration and Testing
Test Automation
Mechanical, Electrical, and Software Integration

Testing and Validation

Unit & Integration Testing
Zero-Code Test Automation
Comprehensive Testing Services Including Functional, Durability, Environmental, and Compliance testing

Aftermarket Engineering

Service Lifecycle Management
Content Management / Technical Publications
Service Performance Contracts
Field Service Management

Autonomous

ADAS

Test Drive Data Collection
Data Annotation
Vehicle Level Testing
Algorithm Design & Optimization

Perception System

Sensors (LiDAR, Ultrasonic, Cameras, RADAR)
Object Detection and Classification Algorithm

Electrification

Electric Vehicle (EV) Powertrains

Power Electronics
Control System
Noise, Vibration, and Harshness (NVH) Analysis
Motor Design

Battery Systems (BMS and Wireless BMS)

System Architecture & Design
Hardware & Embedded Software Development
Cell Balancing Techniques
Simulation & Modeling
Prototyping & Testing

Digital Engineering & Industry 4.0

PLM

PLM Consulting and Advisory
PLM Implementation, Upgrade & Migration
PLM on Cloud
Sustenance Services

Cloud and Data Analytics

Cloud Native Microservices
AI-Enabled Customer Experience

Smart Manufacturing

Industrial Automation
Operations Management
Data Engineering
Manufacturing Intelligence

In the Spotlight

Battery Management System for Industrial Battery System Supplier

Cyient designed a cost-effective BMS for a global industrial battery supplier, delivering a rugged single-board controller with Modbus-RTU communication and secure configurable I/Os. The solution reduced PCBA costs by 25% while ensuring compliance and reliability, co-creating IP with the client for innovative outcomes.

OCPP 1.6J Modbus Interface Implementation for IoT Gateway

We developed an OCPP 1.6J client for a Japanese Tier 1 IoT Gateway, enabling seamless integration with customer firmware or Modbus communication. The solution included containerized executables, testing tools, full documentation, and an OCPP server-side emulator for enhanced functionality.

Smart Sensor for Industrial Battery System Supplier

Cyient designed a compact 3-in-1 smart sensor for off-gas, temperature, and humidity detection, featuring JSON over MQTT, PoE, and RSA-256 encryption. The solution reduced system costs by 15% and offered scalable cloud architecture, firmware updates, and end-to-end support, co-creating IP with the client.

EV Motors
Prognostics

Cyient’s advanced solution for BLDC motors detects potential failures early using real-time analysis of electrical and mechanical signals, reducing downtime and boosting operational efficiency.

EV Battery
SOC and SOH

Cyient delivers hybrid wired and wireless BMS solutions for accurate SOC and SOH monitoring. This approach enhances scalability, reduces installation complexity, and lowers maintenance costs.

EV Charging

Cyient builds OCPP protocols for seamless communication between charging points and cloud systems, supporting various standards and providing real-time charging data for efficient infrastructure management.

Insights

Whitepaper

Robust Framework for Wireless Battery Management Systems

Explore Cyient's innovative approach to wireless BMS, enhancing efficiency and flexibility in EV battery management. Our solution addresses key challenges in wireless communication within complex vehicle environments, offering advanced antenna design, RF system modeling, and secure data transmission.

Read More →

Blog

Prognostics and Health Management for Safer Electric Vehicles

Discover how advanced prognostics can improve EV safety and reliability, reducing maintenance costs and enhancing performance. Learn about the shift from traditional diagnostics to predictive analytics in electric vehicle management, addressing challenges in complexity, safety, and reliability.

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Blog

Location Analytics in Site Selection for EV Charging Stations

Learn how location analytics can optimize the placement of EV charging stations, improving accessibility and utilization. Explore the use of GIS with GeoAI and Machine Learning algorithms to analyze factors such as traffic density, land ownership, and social equity in determining optimal charging station locations.

Read More →

Intelligent Engineering

Accelerating EV innovation with smarter batteries, maintenance, and charging

Electrification Unleashed: Powering the Next Era of Mobility

Cyient delivers Wireline and Wireless Battery Management Systems for seamless battery monitoring and optimization, with Wireless BMS addressing wired system limitations to ensure reliable, future-ready battery management solutions. Our capabilities include: