Battery Design Engineer

• Design and develop high-voltage, high-power and high-energy battery packs from concept to prototype and qualification.
  

• Define battery architecture based on required voltage, current, power, energy, discharge duration, mass, and mission profile.
  

• Perform cell selection and characterization based on energy density, power capability, C-rate, internal resistance, temperature behaviour, cycle life, and safety.
  

• Design series/parallel cell configurations to meet required voltage, capacity, peak current, continuous current, and energy requirements.
  

• Develop battery electrical architecture including: - Cell/module interconnections - Busbars - Fuses and protection devices - Contactors - Pre-charge circuit - HV connectors - Current and voltage sensing - HV interlock and isolation monitoring
  

• Work closely with the BMS team for cell monitoring, balancing, SOC/SOH estimation, protection and fault handling.
  

• Develop battery thermal management strategies for high-current charge/discharge operation.
  

• Perform electrical, thermal, and mechanical calculations for battery modules and packs.
  

• Design and review busbars, terminals, interconnects and high-current paths, including voltage-drop and temperature-rise calculations.
  

• Analyse battery behaviour under peak-power and high-C-rate discharge conditions.
  

• Develop battery protection strategies for over-voltage, under-voltage, over-current, short circuit, over-temperature and insulation faults.
  

• Support battery pack mechanical design, enclosure integration, sealing, vibration isolation and thermal interfaces.
  

• Prepare battery system requirements, schematics, interface documents, test procedures and validation reports.
  

• Plan and execute cell, module and pack-level testing.
  

• Perform battery characterization using battery cyclers and other laboratory equipment.
  

• Analyse test data and identify battery performance, thermal and electrical issues.
  

• Support environmental qualification including vibration, thermal cycling, vacuum/low-pressure and other relevant tests.
  

• Perform failure analysis and contribute to FMEA, fault-tree analysis and design reviews.
  

• Support integration of the battery with motor drives, power distribution systems, DC/DC converters and other high-power loads.
  

• Work with vendors for cell, BMS, connector, busbar, cooling and battery-pack components.
  

• Support prototype assembly, bring-up, troubleshooting and field/vehicle testing.
  

Requirements

• 3–4 years of hands-on experience in battery pack design, battery systems, BMS or high-power energy-storage systems.
  

• Strong understanding of Li-ion battery chemistry and battery characteristics.
  

• Experience with high-voltage battery systems and high-current applications.
  

• Good understanding of:
  - Cell selection and characterization
  - Series/parallel battery configuration
  - C-rate and power/energy calculations
  - SOC/SOH fundamentals
  - Cell balancing
  - Battery protection
  - Pre-charge and contactor circuits
  - HV isolation and interlock
  - Thermal management
  - Busbar and interconnect design

• Experience with battery testing and data analysis.
  

• Ability to perform electrical and thermal calculations for battery systems.
  

• Good understanding of BMS hardware and communication interfaces such as CAN/CAN-FD.
  

• Experience with electrical schematics and battery-system architecture.
  

• Working knowledge of safety considerations associated with high-voltage and high-energy battery systems.
  

• Willingness to work extended hours as required.