Case Studies
Capabilities in Action
Measurable outcomes across India's embedded industries.
Automated Test Bench for a CAN-Controlled EV Charger
GSAS Test & Validation Engineering
Challenge
A CAN-controlled AC charger for a 14S Li-ion scooter pack (~50.4 V, ~3 kWh) had to hold regulation from 140 V to 270 V mains while negotiating Slow/Fast charge modes with the vehicle BMS over CAN. Validating it safely meant controlling AC input, DC output and the CAN channel together, without a hazardous live battery pack on the bench.
Solution
GSAS designed, integrated and scripted a four-instrument bench end-to-end: a GW Instek APS-7200 AC source sweeps the grid envelope, a PEL-3111AH electronic load sinks the charge current, a GPP-7250 emulates the battery pack’s state of charge, and a Total Phase Komodo CAN Duo emulates the vehicle BMS, running one automated four-phase sequence with a Schottky blocking diode for bus isolation.
Results
ISO 26262 Tool Qualification for Motor Controller Unit Testing
Two-Wheeler EV Manufacturer
Challenge
An Indian two-wheeler EV manufacturer needed ASIL-B compliant unit testing with MC/DC coverage for their motor controller and BMS firmware. Their existing testing process was manual and could not produce the evidence required for ISO 26262 Part 8 tool qualification.
Solution
GSAS deployed an automated testing workflow integrated with static analysis and their CI/CD pipeline. We conducted tool qualification per ISO 26262 Part 8, produced the Tool Qualification Plan and Report, and trained 8 engineers across motor control and battery management teams.
Results
Custom Data Acquisition Board with GPIO Interface
Defence Electronics Organisation
Challenge
A defence electronics organisation required a ruggedised 16-channel data acquisition and evaluation board with custom GPIO interfaces for field testing of sensor arrays. Off-the-shelf solutions lacked the required environmental qualification and interface flexibility.
Solution
GSAS designed a custom evaluation board with a mixed-signal front-end, configurable GPIO mapped to their sensor harness, and an Arm Cortex-M7 core running bare-metal firmware. We delivered environmental qualification (MIL-STD-810G vibration and thermal) and production-ready documentation.
Results
Sensor Interface Development for Satellite Geo-Positioning
Space Technology Company
Challenge
A space technology company developing positioning payloads needed custom sensor interface firmware for multi-constellation GNSS receivers with redundant data paths. The firmware had to meet radiation-tolerance constraints and deliver sub-metre accuracy under dynamic conditions.
Solution
GSAS developed sensor interface drivers for the GNSS receiver chain, implemented redundancy switching logic, and validated the full data pipeline against simulated orbital dynamics. We profiled power consumption across all operational modes to meet the strict power budget.
Results
Embedded Power Profiling for Battery-Powered Medical Device
Medical Device Startup
Challenge
A startup building a portable diagnostic device needed to characterize power consumption across all operating modes to validate a 72-hour battery life claim for regulatory submission.
Solution
GSAS set up a Joulescope JS220-based energy profiling workbench with automated scripted test sequences. We characterized sleep, idle, active, and wireless transmission modes and identified 3 firmware optimizations that extended battery life by 40%.
Results
Protocol Analysis for Multi-Bus Industrial Controller
Industrial Automation Manufacturer
Challenge
An industrial controller communicating over CAN, Modbus, and Ethernet/IP was experiencing intermittent failures in the field. Traditional debugging approaches could not capture the timing-dependent multi-bus interaction.
Solution
GSAS deployed protocol analyzers for simultaneous multi-protocol capture alongside oscilloscopes for timing correlation. We identified a race condition between CAN and Modbus polling that only manifested under specific load conditions.
Results
Cybersecurity Compliance for EV Charging Infrastructure
EV Charging Network Provider
Challenge
The customer needed to meet UNECE R155 and EU CRA requirements for their next-generation OCPP 2.0.1-compliant EV charger controller.
Solution
GSAS conducted a cybersecurity gap analysis, implemented TrustZone secure boot on the Arm Cortex-M33 platform, integrated wolfSSL for TLS 1.3, and helped establish a CSMS (Cybersecurity Management System) compliant with ISO/SAE 21434.
Results
Blog
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