Senior Design Engineer - High Voltage Battery Management Systems

Sr. Design Engineer-HVBMS

Job Description: Lead OR Sr. Design Engineer - HVBMS

Role Summary

The HVBMS Design Engineer will be responsible for architecting, developing, and validating high-voltage battery management systems (400V–1500V) for advanced energy storage and electrification platforms. This role demands mastery of circuit design, embedded control, functional safety, and system integration, with a strong emphasis on technical excellence and compliance.

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Core Responsibilities

· System Architecture

o Define HVBMS topology, sensing, isolation, and protection strategies for large-format Li-ion packs.

o Develop redundancy and fail-safe mechanisms aligned with ISO 26262 ASIL-D requirements.

o Architect communication interfaces (CAN FD, Ethernet, ISO 15118) for seamless integration with vehicle/grid controllers.

· Hardware Design

o Design precision measurement circuits for voltage, current, and temperature sensing with high CMRR and isolation.

o Develop balancing circuits (active/passive) optimized for efficiency and thermal performance.

o Specify high-voltage contactors, pre-charge circuits, and solid-state switching elements.

· Software & Algorithms

o Implement SOC, SOH, SOP estimation using Kalman filters, neural networks, or equivalent advanced methods.

o Develop real-time fault detection and diagnostic algorithms for over-voltage, over-current, thermal runaway, and isolation faults.

o Ensure compliance with cybersecurity standards (ISO/SAE 21434), and real-time OS constraints.

· Validation & Testing

o Conduct HIL/SIL simulations for algorithm robustness and edge-case scenarios.

o EMC/EMI compliance validation.

o Lead FMEA, FTA, and DFMEA processes for risk mitigation.

· Cross-disciplinary Integration

o Collaborate with mechanical engineers on pack enclosure, cooling, and vibration isolation.

o Interface with inverter and charger teams to ensure seamless HV system operation.

o Provide technical documentation for certification bodies and customer audits.

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Required Qualifications

· Master’s/PhD in Electrical Engineering, Power Electronics, or Control Systems.

· 5+ years of hands-on experience in HVBMS design and validation.

· Expertise in Li-ion chemistries (NMC, LFP, solid-state) and degradation modelling.

· Strong command of embedded C/C++, MATLAB/Simulink, and model-based design workflows.

· Proven track record with ISO 26262, IEC 61508, UL 2580, SAE J2464 compliance projects.

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Preferred Expertise

· Knowledge of advanced balancing (bi-directional active balancing, switched capacitor).

· Familiarity with CFD-based thermal modelling for battery packs.

· Hands-on experience with PCB design (Altium), circuit simulation (PSpice), and CAN tools (CANalyzer, Vector).

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Key Attributes

· Precision-driven, safety-first mindset.

· Ability to synthesize complex technical requirements into robust designs.

· Strong analytical and documentation skills for technical audiences.

· Innovative thinker with a focus on reliability and scalability.

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