Embedded Hardware Design Engineer - Power Converters

Embedded Hardware Design Engineer

Embedded Hardware Design Engineer – Power Converters   (P16)

Role Summary

The Embedded Hardware Engineer is responsible for designing, developing, and validating control hardware, sensing circuits, gate drivers, protection electronics, and digital interface boards used in AC-DC rectifiers, DC-DC converters, onboard/off-board chargers, SMPS, motor drives, and other power conversion systems. The engineer works closely with firmware, power hardware, and system teams to ensure robust converter performance, protection, and communication.

Key Responsibilities

1. Control & Interface Hardware Design

• Design digital control boards for AC-DC and DC-DC converters using – TI C2000 controllers (F280xx), ARM Cortex-M MCUs, Aurix, DSP/FPGA (optional)
• Develop circuits for  PWM signal conditioning, ADC sensing (voltage, current, temperature), Protection signal routing, Isolation using opto/transformer/SPI isolators
• Designwith Internal and external ADC interface 

2. Sensing & Measurement Circuits

• Design precision sensing circuits 
  • Voltage dividers (HV and LV)
    – Hall/LEM current sensors
    – Shunt-based current measurement
    – NTC/RTD temperature sensing
• Ensure high accuracy, low noise, and stable performance.

3. Gate Driver Interface & Protection Electronics

• Design interface circuits between control MCU and gate driver boards and Implement:
  1. DESAT fault routing
  2. Miller clamp signals
  3. Soft-shutdown triggering
  4. OCP/OTP/OVP signal conditioning
• Work with power hardware team for proper gate driver integration.

4. Power Supply & Auxiliary Circuits

• Design auxiliary power circuits for controller boards (5 V, 3.3 V, 12 V rails).
• Select and validate DC-DC auxiliary converters, LDOs, regulators, filters, EMI filters for control power
• Ensure isolation and creepage/clearance compliance.

5. PCB Design & Review

• Create and review PCB schematics and layouts in Altium/Cadence/Mentor.
• Ensure best practices for High-voltage isolation, Signal integrity, Mixed-signal design (Analog + digital), Separation of noisy and sensitive circuits, EMI/EMC compliance
• Prepare PCB stack-ups and review manufacturing considerations.

6. Hardware Bring-Up, Testing & Validation

• Perform board bring-up, debugging, and validation with firmware engineers.
• Validate ADC accuracy, PWM timing integrity, protection logic response.
• Support converter-level testing: PFC stage, LLC, Buck/Boost, PSFB.

7. Cross-Functional Collaboration

• Work with Firmware team for signal mapping and timing, Power hardware team for topology integration, System engineering for requirements, Certification team for compliance (IEC, CISPR, ISO)
• Participate in design reviews (DR0/DR1/DR2/DR3).

8. Documentation

• Generate hardware design documents Schematic & BOM, Design calculations, Test plans & validation reports, Board bring-up procedure, FMEA and DVP&R inputs
• Maintain version control (Altium vault/Git).

Required Skills & Qualifications

Technical Skills

• Strong understanding of power electronics converter control.
• Expertise in designing  Analog front-end circuits , ADC/PWM interfaces, High-voltage/low-voltage signal conditioning,  Isolation and protection circuits
• Experience with microcontrollers, especially TI C2000 or STM32.
• Knowledge of EMI/EMC considerations in mixed-signal boards.
• Strong PCB design skills.

Tools

• Altium Designer, Cadence Allegro, OrCAD, Mentor Graphics.
• MATLAB/Simulink for simulation (optional).
• LTSpice / PSpice / Simplis for analog simulation.

Experience

• Embedded hardware development for power converters (AC-DC, DC-DC, chargers , inverters).
• Hands-on with hardware testing on live converters.
• Understanding of converter topologies: PFC, LLC, PSFB, Buck/Boost.

Qualifications

• B.E/B.Tech/M.E/M.Tech in Electronics, Electrical, Embedded Systems, Power Electronics with experience of 3–10 years

Preferred Experience

• Experience with SiC/GaN-based converters.
• Familiarity with automotive standards (ISO 26262, LV123, LV124) or industrial standards IEC 61000/61800.
• Experience in Aux power supply design (Flyback/LLC) for control boards.
• Knowledge of CAN, RS485, SPI, I2C communication circuits.