Driving Innovation in Electric Mobility: DC-DC Converter & Super Capacitor ECU Development by Hinduja Tech

As the automotive industry accelerates its transition to electrification, the need for robust, cost-effective power management solutions has never been more critical. Hinduja Tech, a leader in digital product engineering and automotive innovation, has recently partnered with a top UK Tier 1 customer to develop a high-performance, bidirectional DC-DC Converter and Supercapacitor ECU for advanced electric vehicle architectures. This case study illustrates how Hinduja Tech delivers state-of-the-art solutions that address evolving OEM requirements while optimising costs and development time.

Project Scope: Delivering High-Efficiency Power Management

The challenge involved designing a 700W, 12V to 48V bidirectional DC-DC converter, a core enabler for electric Anti-Roll Control (eARC) systems in next-generation vehicles. This converter, operating in tandem with an ultra-efficient super capacitor module, not only powers fast-reacting eARC actuators but also ensures consistent voltage stability by buffering transient loads and protecting the 12V bus. Built on the Infineon AURIX TC23X microcontroller platform, the solution was engineered to meet the strictest ASIL B functional safety and ASPICE compliance standards, reflecting Hinduja Tech’s commitment to quality and reliability.

Methodology: End-to-End Engineering Excellence

Hinduja Tech’s engineering approach draws on in-depth domain expertise, collaborative program management, and a proven digital thread strategy. The team executed a comprehensive methodology that included:

• Detailed requirements capture and function safety planning.
• Application software development and seamless integration with AUTOSAR-compliant Basic Software (BSW) and MicroSAR stack.
• Development and configuration of MCAL drivers, Secure Boot Controllers (SBC), Intersil SOCs, and a robust vector flash bootloader stack.
• FlexRay communication, network management, and non-volatile memory configuration.
• Diagnostic implementation using Unified Diagnostic Services (UDS).
• Rigorous unit, integration, and function testing aligned with international automotive standards.

By closely integrating each hardware and software layer, Hinduja Tech ensured quick validation and risk mitigation, which is essential for OEM programs that require complete lifecycle traceability and compliance.

Measurable Impact: Accelerating Time-to-Market, Optimizing Cost

The DC-DC Converter and Super Capacitor ECU solution not only met the client’s technical and safety requirements but also delivered significant commercial benefits. Through optimized digital development and value analysis, Hinduja Tech achieved a 70–75% reduction in product design and development costs compared to global benchmarks. Additionally, the use of advanced virtual validation techniques and the seamless integration of physical prototypes resulted in substantial cost optimization and a reduced time-to-market for the customer’s platform.

Why Global OEMs Trust Hinduja Tech?

Hinduja Tech’s end-to-end product engineering capabilities empower OEMs and Tier 1 suppliers to innovate with confidence:

• Comprehensive domain expertise from vehicle electronics, software, and embedded systems to powertrain and compliance.
• Agile, customer-centric engagement models tailored for business-critical timelines.
• Proven track record delivering high-performance, production-ready solutions to leading brands worldwide.

Partner With Us

Ready to accelerate your next vehicle program or electrification initiative? Learn how Hinduja Tech’s advanced vehicle electronics and software solutions can help you optimize cost, improve quality, and bring innovative products to market faster.

Email us at info@hindujatech.com to learn more about our integrated engineering and digital services.