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. Core Responsibilities

• System Architecture
• Define HVBMS topology, sensing, isolation, and protection strategies for large-format Li-ion packs.
• Develop redundancy and fail-safe mechanisms aligned with ISO 26262 ASIL-D requirements.
• Architect communication interfaces (CAN FD, Ethernet, ISO 15118) for seamless integration with vehicle/grid controllers.
• Hardware Design
• Design precision measurement circuits for voltage, current, and temperature sensing with high CMRR and isolation.
• Develop balancing circuits (active/passive) optimized for efficiency and thermal performance.
• Specify high-voltage contactors, pre-charge circuits, and solid-state switching elements.
• Software & Algorithms
• Implement SOC, SOH, SOP estimation using Kalman filters, neural networks, or equivalent advanced methods.
• Develop real-time fault detection and diagnostic algorithms for over-voltage, over-current, thermal runaway, and isolation faults.
• Ensure compliance with cybersecurity standards (ISO/SAE 21434), and real-time OS constraints.
• Validation & Testing
• Conduct HIL/SIL simulations for algorithm robustness and edge-case scenarios.
• EMC/EMI compliance validation.
• Lead FMEA, FTA, and DFMEA processes for risk mitigation.
• Cross-disciplinary Integration
• Collaborate with mechanical engineers on pack enclosure, cooling, and vibration isolation.
• Interface with inverter and charger teams to ensure seamless HV system operation.
• Provide technical documentation for certification bodies and customer audits.

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.

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). 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.