Sr. Design Engineer-HVBMS

Job description

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.