What drives the brain of an electric vehicle? Customisable, high-efficiency motor control units. Delving into their features and capabilities, Jaideep Wadhwa of Sterling Gtake E-Mobility Ltd discusses the company’s unique offerings with EFY’s Nitisha Dubey.
Q. What is Sterling Gtake E-Mobility Ltd’s contribution to the electric vehicle (EV) industry?
A. Our focus is on developing and manufacturing motor control units (MCUs). These critical components convert DC power from an EV battery into AC to drive the motor while providing intelligence to optimise efficiency, acceleration, and functionality. Alongside components such as the battery management system (BMS) and vehicle control unit (VCU), MCUs are integral to an EV’s intelligence and performance. We produce a range of these with power capacities from 1kW to 225kW and voltage ratings from 48V to 1000V, covering applications from low-speed scooters to 12-metre buses.
Q. How do you ensure motor compatibility and vehicle integration and optimise customer performance?
A. We optimise motor performance through software customisation to meet diverse customer requirements. When a customer inquiry is received, the first step involves evaluating the selected motor’s compatibility with the MCU through bench and dynamometer testing to validate specifications and plot performance curves. Next, the motor and controller are integrated into the vehicle; parameters such as acceleration, range, and ride smoothness are optimised through multiple iterations. You see, achieving streamlined performance requires extensive fine-tuning. With over 60 engineers, engineering is the largest department at Sterling Gtake. Half the team specialises in new product development, while the other half collaborates with customers on vehicle integration. The new product development team focuses on product design, software development, and innovation.
Q. What is your approach to ensuring product quality and reliability standards?
A. We follow a comprehensive design validation plan to ensure the quality and reliability of our products. In addition to the testing conducted by our Chinese partners, we independently validate the products to ensure that we comply with Indian and international standards. Our design validation process includes performance and durability testing. For instance, we use in-house dynamometers to plot performance curves and endurance machines for continuous cycle testing. We also use environmental chambers for various stress tests. Additionally, certain tests are conducted by external laboratories to complement our internal processes. Before launching any product in India, Gtake adheres to a detailed checklist to ensure it meets all necessary standards.
Q. How do your MCUs’ efficiency metrics influence vehicle range in real conditions?
A. Our MCUs typically deliver an efficiency of 97–98 per cent, playing a critical role alongside the motor. We work with motor manufacturers to optimise software for required drive cycles, continuously refining current draw from the battery to enhance efficiency.
Q. How do controllers enhance motor performance and ensure efficient power transmission?
A. The primary role of the controller is to deliver current to the motor. In two-wheelers, the motor is typically connected to a timing belt, while in other vehicles, it is linked to a gearbox and axle. We optimise the motor’s performance and collaborate with gearbox and axle manufacturers. While mechanical losses in these components are beyond our control, we focus on electrical optimisation. Our goal is for the motor to operate at peak efficiency, delivering required torque or horsepower to the shaft and transferring power to the wheels.
Q. Can MCU characteristics such as torque-speed curves be customised for performance requirements?
A. Yes, and we dedicate significant time to this. Parameters can be fine-tuned based on customer priorities, whether that is top speed, acceleration, or range. Through software customisation, we optimise the motor accordingly.
Q. How do you manage multiple software versions across shared production lines and MCUs?
A. In production, we meticulously manage the process to ensure accuracy and reliability. When a customer provides a specific vehicle specification or configuration, we collaborate with their engineers to achieve the desired performance. Once the performance requirements are met, we finalise (‘freeze’) the necessary software, which is then tightly controlled by our engineering team. The approved software is then uploaded onto a secure server. On the shop floor, this software is downloaded and transferred to the MCU via barcodes, ensuring precise version control. The correct software version is flashed onto the MCUs based on the customer requirements communicated to the shop floor through our production planning process. Each customer’s software is uniquely tailored to their requirements and applied consistently during the production process and end-of-line (EOL) testing. For customers with multiple software versions across shared production lines, strict version control ensures the correct software is applied to each vehicle. This process guarantees consistency, precision, and customer satisfaction.
Q. How do you ensure compliance with Indian and international customer-required standards?
A. We ensure compliance with all Indian and international standards our customers require. Typically, customers provide a list of standards they expect us to adhere to. We often already comply with these standards and can provide the necessary evidence. On rare occasions where a specific standard has not been tested, we conduct the required testing and supply the proof to the customer.
Q. Coming to your customers, who are they?
A. Our customers include some of the leading EV companies in the 2W, 3W, LCV (light commercial vehicle) and HCV (heavy commercial vehicle) segments.
Q. Do you sell directly or have channel partners, too?
A. Sterling Gtake only sells directly to our customers. It enables us to provide the deep technical support that our customers expect.
Q. Do your systems provide real-time performance data to enhance efficiency?
A. Yes, our systems have the capability to provide real-time performance data, but we typically do not connect MCUs directly to the cloud to minimise cybersecurity risks. Instead, the architecture integrates all-EV components through a CAN interface with a VCU. If the VCU has telematics capabilities, it uploads the performance data to a cloud server. This centralised system ensures security and enables vehicle manufacturers to leverage the data for preventive maintenance, marketing, and product development.
Q. How do you address cybersecurity concerns when handling performance data?
A. We prioritise cybersecurity by using a single portal or gateway for data transfer, typically through the VCU or a telematics control unit. This eliminates the risks associated with multiple gateways, as different subsystem components—such as the BMS and MCU—are not independently connected to the cloud. This centralised approach ensures robust security measures are implemented, reducing the chances of cyberattacks.
Q. What is the total number of facilities operated by Sterling Gtake Mobility?
A. Currently, we operate one manufacturing facility in Faridabad, which houses not only our MCU operations but also a design centre. Additionally, we have another design centre in Bengaluru, where a team of hardware and software engineers focuses on innovation. Beyond our MCU business, Sterling Group has three facilities dedicated to manufacturing fasteners (our original business). Two facilities are located in Faridabad, while the third is in Bengaluru. Recently, we announced new ventures in high-voltage and low-voltage contractors, with plans to establish a dedicated facility in Bengaluru. This expansion underscores our commitment to advancing technology and supporting the evolving needs of the EV industry.
Q. Can your manufacturing process accommodate sudden changes in demand or bespoke requirements?
A. Yes, our manufacturing process is highly flexible and can handle vast changes in demand. Our robust supply chain and broad customer base provide cushioning, allowing us to adapt to fluctuations effectively. Additionally, our engineering and manufacturing capabilities are designed to accommodate bespoke requirements and cater to a broader product portfolio, positioning us as a power electronics solutions provider beyond just MCUs.
Q. What is your manufacturing process, and how do you manage your supplier network effectively?
A. Our manufacturing process consists of assembly lines with Poka-yoke and interlinking on all critical operations. At the end of the assembly lines, we perform high potential (hi-pot) testing. After this, we carry out a burn-in process where we heat the MCUs to 55 degrees Celsius. While at this temperature, we power up the microprocessor and test all parameters to ensure proper functionality. After the burn-in operation, we proceed to the EOL testing, which functions like a small-scale dynamometer.
To support this operation, we have developed a network of suppliers across the country. These suppliers provide the components required for production, including extrusions, castings, and machined, rubber and plastic injection moulded parts. We collaborate with three electronics manufacturing services (EMS) companies to populate the printed circuit boards (PCBs). We have worked closely with these suppliers to build the necessary capability and capacity to meet our customers’ expectations and demands.
Q. What is your approach to managing in-house production versus outsourcing components?
A. We handle the final assembly and testing in-house, with components typically manufactured to our specifications. These components can be categorised into two groups: mechanical and electronic. Mechanical components are produced according to our designs and specifications by a network of vendors we have cultivated. On the other hand, electronic components, both active and passive, are generally imported as they are not manufactured domestically in India. Once these imported components are received, we assemble them onto PCBs using surface mount technology (SMT) and through-hole assembly processes.
Q. What post-sales services do you provide to customers?
A. We provide comprehensive post-sales support. If there are concerns in the field, our service team is available to assist. While we do not typically perform field repairs, we prefer swapping out faulty units and analysing any faults in our factory. Our team supports customers in diagnosing problems and identifying whether the issue originates from the MCU, motor, battery pack, or system integration. This helps isolate the root cause and enables corrective actions to be taken.
Q. How do you ensure data availability and its utility for vehicle manufacturers?
A. Data availability is managed through telematics systems integrated into the VCU, as I said earlier, allowing performance data to be uploaded to a cloud server. This centralised data is valuable to manufacturers for predictive maintenance, understanding driving behaviours, product development, and marketing. EVs’ digital nature enhances connectivity and data collection capabilities, offering a significant advantage over internal combustion engine (ICE) vehicles.
Q. What has been your fiscal growth since starting the project?
A. Fiscal 2021 was our starting point. By FY22, we achieved approximately ₹30 million in revenue, which grew to ₹180 million in FY 2023 and further to ₹320 million in FY 2024—a remarkable growth trajectory.
Q. What are your key strategies for future expansion and product diversification?
A. Our focus extends beyond just manufacturing MCUs. We also plan to produce other power electronics products soon. Entering these markets early through technology partnerships is crucial for us. Over time, we aim to develop these capabilities in-house, enabling us to build domain expertise and expand our knowledge base. This approach ultimately allows us to offer solutions quickly and deliver greater value to our customers.
