Motor controllers
Power stage, gate drive, control and communication faults on two- and three-wheeler motor controllers.
Repair-return · EV
EV controller, charger, DC-DC converter and motor repair
Star Automations repairs EV motor controllers, chargers, DC-DC converters and power boards, and refurbishes EV motors, for EV OEMs and their dealer networks in India. Star works to the OEM's test methods, acceptance criteria and reporting, and returns a test report per unit. The work is done at our refurbishment factory in Puducherry.
01Scope
What we repair
Chargers
On-board and off-board chargers: power stage, control and protection faults.
DC-DC converters
Converters that feed the vehicle's low-voltage system, repaired and tested under load.
Power boards
Power and control boards from the vehicle and from charging equipment.
Four-wheeler low-voltage boards
Low-voltage electronic boards for electric four-wheelers.
EV, BLDC and EC motors
Traction and auxiliary motors, BLDC and EC motors, refurbished and run-tested. EV motor refurbishment.
02Dealer network flow
From your dealer to Star and back
Failed units move from dealers to your hub, from the hub to Star, and back into your network with a report for each one.
Dealer
The dealer removes the failed unit and logs the complaint in your system.
Your hub
Units are consolidated at your regional hub and sent to Star in batches.
Star
Inward check, diagnosis, repair and test to your acceptance criteria.
Test report
A report per unit, by serial number, with the root cause.
Back to the network
Repaired units return to your hub or dealer, ready for replacement stock.
03Data per unit
What each unit's report records
Star works to your test methods, acceptance criteria and reporting. Our universal servo test system and test rigs let Star verify each unit against your criteria and report per unit.
- Unit ID and serial number, dealer and job reference, inward photos.
- Reported complaint and the fault codes read from the unit.
- Failed components, with board reference, and the parts replaced with part and lot numbers.
- Firmware version before and after, where it applies.
- Test results against your criteria: for EV, BLDC and EC motors, phase resistance balance, insulation resistance, hi-pot (dielectric withstand), back-EMF and Hall or encoder signals; for controllers, CAN communication; for chargers and DC-DC converters, output voltage, ripple and efficiency.
- Load test result and a pass or fail.
- Root-cause code, and warranty observations such as water ingress or physical damage.
04Bench trial
Start with 2–3 failed units
Send a few failed units from one product line. We repair and test them to your criteria and send a report per unit. You judge the results before any programme is agreed.
- NDA signed before specifications or firmware are shared.
- All work at ESD-protected benches.
- ISO 9001:2015 quality management system.
Enquiry received
This is what happens next:
- We reply by email and sign your NDA.
- We agree which 2–3 units to test and how results are reported.
- You send the units; we return them with a report per unit.
Which EV electronics do you repair?
Star repairs EV motor controllers, on-board and off-board chargers, DC-DC converters and power boards for two- and three-wheelers, and low-voltage boards for four-wheelers. We also refurbish EV traction and auxiliary motors.
Can you work with our dealer network?
Yes. Dealers send failed units to your hub, the hub sends them to Star, and repaired units return to your network with a test report per unit, traceable by serial number.
What data do you return for each unit?
Each report records the unit's serial number and job reference, the complaint and fault codes, failed and replaced components, firmware version where relevant, test results against your acceptance criteria, a pass or fail, and a root-cause code. Star works to your reporting format.
How does a bench trial work?
You send 2–3 failed units from one product line. We repair and test them to your criteria and send a report per unit. You review the results before deciding on a programme.
Do you repair four-wheeler EV electronics?
Yes, low-voltage electronic boards for electric four-wheelers. Send the board type and fault, and we confirm before you ship.
Propose a bench trial.
Email info@starautomations.com or WhatsApp +91 97866 22233.