Senior Engineer BESS Battery Pack Electrical Design

Job Title: Senior Engineer – BESS Battery Pack Electrical Design

Location: Bangalore

Job Type: Full-time

Experience: 4+ years

About the Role

We are looking for a Senior Engineer with strong hands-on experience in electrical design of Lithium-ion battery packs, preferably for BESS / Energy Storage applications.

The role will primarily focus on battery pack electrical architecture and design, including cell configuration, pack sizing, HV electrical systems, busbars, contactors, fuses, pre-charge circuits, BMS integration, and electrical protection.

The role will also involve supporting battery pack testing and validation to ensure the design meets performance, safety, and reliability requirements.

Key requirement: Candidates must have hands-on experience in electrical design of battery packs. Candidates whose experience is primarily mechanical pack design, enclosure/CAD design, thermal design, BMS testing, or battery testing will not be preferred.

Key Responsibilities

Electrical Battery Pack Design – 70%

• Design and develop electrical architecture of Lithium-ion battery packs for BESS applications.
• Develop cell configuration, series/parallel architecture, pack voltage, capacity and power calculations.
• Design and size busbars and electrical interconnections based on current, voltage and thermal requirements.
• Design/integrate HV systems, contactors, fuses, pre-charge circuits, HVIL, connectors and protection circuits.
• Integrate BMS, CAN communication, cell monitoring, balancing and protection logic.
• Select appropriate LFP/NMC cells and electrical components based on application requirements.
• Prepare electrical schematics, wiring diagrams, BOMs and design specifications.
• Work with suppliers on cells, BMS, contactors, fuses, connectors and other electrical components.
• Participate in DFMEA and electrical safety/design reviews.
• Work closely with mechanical and thermal teams to ensure complete pack-level integration.

Battery Testing – 15%

• Support and/or execute battery pack electrical and performance testing.
• Perform/support charge-discharge, capacity, cycle-life and electrical safety testing.
• Support thermal and IP testing as required.
• Troubleshoot electrical issues identified during testing and implement design improvements.

Validation & Compliance – 15%

• Support battery pack validation plans, test protocols and acceptance criteria.
• Analyze test results and support validation of pack performance and safety.
• Support thermal runaway testing and safety validation.
• Coordinate with external laboratories for applicable certifications such as UN38.3, IEC 62619, UL 9540A, etc.
• Prepare validation and technical reports.

Required Qualifications

• B.E./B.Tech or M.E./M.Tech in Electrical, Electronics, EEE, ECE, Mechatronics, or related engineering disciplines.
• 4+ years of hands-on experience in electrical design of Lithium-ion battery packs.
• Strong experience in battery pack electrical architecture and design.
• Hands-on experience with BMS integration and CAN communication.
• Strong knowledge of HV systems, busbars, contactors, fuses, pre-charge and electrical protection.
• Experience with LFP/NMC battery systems.
• Understanding of SOC/SOH, cell behaviour and battery safety.

Preferred Experience

• Experience in BESS / Energy Storage / EV battery systems.
• Experience with high-voltage battery packs (400V–1000V+).
• Exposure to thermal runaway mitigation and battery safety.
• Experience with DFMEA and battery certification.
• Experience working with cell/BMS/electrical component suppliers.