Stephanie Lee
Image: Dr. Muhammad Fahad via LinkedIn
The global shift toward electric vehicles (EVs) promises a cleaner, more sustainable future.
But one major roadblock remains—cost.
While EV technology continues to advance rapidly, making high-performance electric vehicles affordable for the average consumer is still a challenge.
Enter Dr. Muhammad Fahad—an electrical engineer and control systems expert whose groundbreaking work revolutionizes EV motor control.
Dr. Fahad is making EV technology smarter, more efficient, and significantly more cost-effective, from developing advanced torque-control algorithms for hybrid powertrains to eliminating expensive dyno-cell testing through innovative HiL simulations.
But how exactly does he do it? And what impact do they have on the future of EV affordability?
Read on and explore his transformative work that shapes the next generation of electric mobility.
The Challenge of Cost in EV Development
A major obstacle to widespread EV adoption involves the high cost of production and testing.
Developing efficient, high-performance electric powertrains demands cutting-edge research, sophisticated control algorithms, and rigorous validation processes—all of which contribute to rising costs.
To make EVs more accessible and affordable, engineers must innovate smarter, more efficient ways to enhance powertrain performance while minimizing development expenses.
And this is where Dr. Fahad’s expertise becomes invaluable.
His pioneering work in motor control optimization, software-driven testing, and cost-effective simulation tools has reshaped the future of EV technology, making it more efficient, scalable, and economically viable.
Revolutionizing PMSM Torque-Control Algorithms for Hybrid Powertrains
Permanent Magnet Synchronous Motors (PMSMs) are a key component of hybrid and fully electric powertrains due to their high efficiency, durability, and power density.
However, developing control algorithms that optimize their torque output while maintaining efficiency is a complex engineering challenge.
Dr. Fahad addressed these challenges by developing customized torque-control algorithms that:
- Enhance power distribution across hybrid powertrains;
- Improve overall energy efficiency;
- Minimize losses, leading to better battery performance.
Through his work, Dr. Fahad helped automakers fine-tune electric powertrains to comply with EPA and CARB emissions regulations, ensuring that EVs remain cost-efficient without sacrificing performance.
In short, he’s enabling manufacturers to produce more affordable and energy-efficient vehicles, bringing sustainable transportation closer to mainstream adoption.
Lowering Testing Costs with a Crank and Cam Signal Generator
Engine cam signal, shown on oscilloscope, before and after signal processing.
Dynamometer-based testing makes up a significant portion of EV and hybrid powertrain development costs—where automakers run physical engines for hours to validate ECU calibration and engine misfire detection.
To reduce costs, Dr. Fahad developed an innovative crank and cam signal generator, which:
- Simulates engine position sensor signals
- Allows ECU calibration without requiring full-scale engine testing
- Reduces energy consumption and operational costs.
His generator mimicked actual engine conditions in a controlled lab setting, enabling engineers to test various engine scenarios, detect misfires, and optimize powertrain calibration—all without running an actual engine.
This innovation eliminated unnecessary fuel consumption, lowered emissions, and reduced overall testing expenses, revolutionizing hybrid and EV development.
Cutting Development Costs with HiL Testing Innovations
Image: HiL setup for ECU testing
Beyond signal generation, Dr. Fahad pioneered advancements in hardware-in-the-loop (HiL) testing methodologies, which are crucial tools in modern automotive development.
But what exactly is HiL testing?
It allows engineers to validate software and control algorithms without requiring a physical prototype. With HiL testing, engineers can reduce the need for expensive dyno-cell testing and enable faster, more cost-efficient vehicle development.
Dr. Fahad’s HiL innovations help manufacturers:
- Test and refine hybrid powertrain control systems at lower costs.
- Simulate real-world driving conditions without the need for physical test vehicles.
- Accelerate development cycles while maintaining compliance with regulatory standards.
He eliminated the need for costly full-scale engine tests—significantly cutting development costs and making it easier for automakers to bring affordable electric mobility solutions to the market.
Global Collaboration and Industry Impact
Image: Global leadership of Dr. Fahad’s research work
Dr. Fahad’s expertise extends beyond technical contributions—his global collaborations played a critical role in standardizing EV control systems across different markets.
With his collaborations spanning continents, he contributed to projects integrating international regulatory standards into EV technology.
Through his role at IAV Automotive Engineering Inc., Dr. Fahad worked on:
- North American hybrid powertrain development
- European regulatory compliance and OBD-II diagnostics
- Asian market-specific electric powertrain optimizations.
His ability to adapt EV technology for different markets ensures that cost-effective solutions are accessible globally.
Academic Excellence and Recognitions
Dr. Fahad’s technical expertise wasn’t earned in a day—he credits his strong academic foundation spanning years to his knowledge and experience in innovating the EV industry. His impressive educational background includes the following:
- Ph.D. in Electrical Engineering from the Michigan Technological University
- M.S. in Electrical Engineering from the Michigan Technological University
- M.Sc. in Electrical Engineering from the University of Engineering and Technology, Lahore
- B.E. in Electronic Engineering from the Mehran University of Engineering and Technology
And his expertise isn’t in theory only—Dr. Fahad gained prestigious accolades that highlight his proficiency in EV motor control and powertrain optimization, such as:
- Fulbright Fellowship – A highly competitive US Department of State award supporting his Ph.D. research in hybrid powertrain control.
- IEEE Member – Part of the world’s largest engineering network, driving electrification advancements.
- EIT – Electrical and Computer Engg, (NCEES ID: 25-224-44), Michigan State Board of Professional Engineers
- Registered Engineer – (PEC reg no. 07537), Pakistan Engineering Council
- Siemens Gold Medal – Industry recognition for technical excellence in electrification.
- Mehran University Gold Medal – Highest faculty GPA among five engineering disciplines.
- Mehran University Silver Medal – Highest GPA in electronic engineering.
With his impressive credentials and widely cited research, Dr. Fahad continues to shape cost-effective EV technology worldwide.
Vision for Affordable and Efficient EV Technology
Dr. Fahad envisions a future where electric vehicles are efficient and accessible. His research and innovations focus on reducing costs, enhancing performance, and accelerating EV adoption worldwide.
To achieve this goal, he is actively working on:
- Optimizing PMSM Motor Control: Enhancing efficiency and power distribution to reduce energy consumption.
- Expanding HiL Testing: Eliminating costly physical testing with advanced real-time simulations.
- Advancing Onboard Diagnostics (OBD): Improving fault detection and predictive maintenance in hybrid and electric powertrains.
Dr. Fahad helps automakers lower production costs while maintaining high performance by pushing the boundaries of control algorithms, simulation methodologies, and diagnostic systems.
His vision aligns with the global push for sustainable mobility—ensuring that EV technology becomes more affordable, scalable, and widely adopted.
Driving the Future of Cost-Effective EV Technology
Dr. Muhammad Fahad’s motor control, HiL testing, and ECU calibration innovations make EVs more efficient and cost-effective. By reducing development and testing costs, his work accelerates the transition to sustainable transportation without compromising performance.
Through his research and global collaborations, he continues to push EV technology toward greater accessibility and efficiency—ensuring a future where affordable, high-performance electric vehicles are a reality.
About the Author
Stephanie Lee is a Pennsylvania-based tech writer who focuses on technologies that promote a sustainable future. As an advocate for green practices, Stephanie highlights individuals contributing to a sustainable, tech-savvy future. On her days off, she likes to hike the Appalachian Mountains, exploring its terrain and admiring its beauty and mystery.