Sr. Engineer – BESS Battery Pack Design, Testing & Validation
Location: BANAGLORE
Job Type: Full-time
Experience: 5+ years preferred
About the Role:
We are hiring a Senior Engineer with in-depth expertise in the design, testing, and validation of battery packs for Battery Energy Storage Systems (BESS). This role will be responsible for developing safe, reliable, and high-performance lithium-ion battery pack systems—from cell selection and mechanical/electrical design to testing, validation, and compliance. The ideal candidate will work cross-functionally with R&D, manufacturing, and QA/QC teams to deliver battery pack solutions that meet performance, safety, thermal, and regulatory standards for grid-scale, commercial, and industrial applications.
Key Responsibilities:
- Design battery pack architecture (cell-to-module, module-to-pack) including:
- Mechanical layout
- Electrical schematics
- Thermal systems
- Select appropriate cells (LFP, NMC, etc.) based on application-specific performance and safety criteria.
- Integrate and validate Battery Management Systems (BMS), thermal protection, contactors, and fuse logic.
- Collaborate with mechanical design teams on enclosures, structural integrity, and thermal management.
- Define and execute DFMEA, validation plans, and test protocols for:
- Pack-level performance
- Lifecycle
- Thermal
- Abuse tests
- Lead charge/discharge cycle testing, aging studies, and thermal runaway simulations.
- Coordinate with external labs for certifications (e.g., UL 9540A, UN38.3, IEC 62619, etc.).
- Analyze test data for SoH, SoC, degradation, impedance, and thermal characteristics.
- Generate detailed design reports, validation reports, and compliance documentation.
- Work with component vendors (cells, BMS, thermal materials) for specifications, sourcing, and testing.
- Interface with internal engineering, field, and manufacturing teams to integrate design feedback and optimize production feasibility.
Required Qualifications:
- B.E./B.Tech or M.E./M.Tech in Electrical, Electronics, Power Systems, or Mechatronics.
- 3+ years’ experience in battery pack design, thermal/electrical integration, and validation.
- Deep understanding of Li-ion chemistry (LFP/NMC), Li-ion cell behaviour, SoC/SoH metrics, and degradation mechanisms.
- Strong knowledge of BMS design, CAN communication, and thermal runaway mitigation.