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.
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