Senior Manager - HV Pack/ BESS

Job Title: HV Battery Pack Engineer - BESS

Location: Chennai (Plant / R&D)
Department: Product Engineering / Manufacturing Engineering
Experience: 5-12 years

Role Summary

The HV Battery Pack Engineer will be responsible for the design, development, integration, and industrialization of high-voltage battery packs used in Battery Energy Storage Systems (BESS). The role involves working across electrical, mechanical, and thermal domains to ensure safe, reliable, and scalable HV pack solutions.

Key Responsibilities

1. HV Pack Design & Development

• Design and develop high-voltage battery packs (600V-1500V) for BESS applications
• Define architecture: modules, racks, busbars, harness, connectors, enclosure
• Work on cell-to-pack / module-to-pack integration strategies
• Selection of components: contactors, fuses, relays, HV connectors

2. Electrical Integration

• Integrate Battery Management System (BMS) with HV pack
• Design HV/LV wiring harness and interconnections
• Ensure proper insulation, grounding, and isolation compliance
• Perform electrical schematics and validation

3. Thermal & Safety Engineering

• Develop thermal management systems (air/liquid cooling)
• Ensure compliance with safety standards (IEC, UL, UN38.3)
• Conduct DFMEA / PFMEA and hazard analysis
• Implement thermal runaway mitigation strategies

4. Manufacturing & Industrialization

• Support prototype builds pilot mass production
• Define assembly processes, SOPs, and line setup
• Work closely with manufacturing for line balancing & yield improvement
• Troubleshoot production issues related to HV packs

5. Testing & Validation

• Define and execute DVP (Design Validation Plan)
• Conduct electrical, thermal, vibration, and lifecycle testing
• Root cause analysis of failures and implement corrective actions

6. Cross-Functional Collaboration

• Work with R&D, Quality, Supply Chain, and Manufacturing teams
• Coordinate with suppliers for component development & qualification
• Support certification and compliance activities

Required Skills & Expertise

Technical Skills

• Strong knowledge of HV battery systems (600V-1500V)
• Experience in BMS, HV interconnects, busbar design
• Understanding of thermal management in battery packs
• Knowledge of DFMEA, PFMEA, DVP&R
• Familiar with CAD tools (CATIA/SolidWorks) and electrical design tools

Domain Experience

• BESS / EV / Battery manufacturing industry experience
• Hands-on experience in pack assembly or integration
• Exposure to containerized BESS systems is a plus

Educational Qualification

• B.E./B.Tech in Electrical / Electronics / Mechanical Engineering