Mahindra & Mahindra—Senior Manager - Battery Pack Design & Development (Electrical & BMS)

Job description

Description: Role Summary Lead the BMS requirement, algorithm development, validation, integration and architecture of High Voltage (HV) and Low Voltage (LV) Battery Systems for Electric Vehicles. The role involves ownership of battery system architecture, BMS requirement and algorithms, hardware development, component selection, system safety, simulation, validation, and vehicle integration activities while driving technical excellence across the complete product development lifecycle. Roles and Responsibilities Battery System & Architecture - Define and develop HV and LV battery system architecture for EV platforms, including electrical distribution, protection strategy, and system-level integration - Perform battery pack design activities including: - Cell chemistry selection and evaluation (LFP, NMC, Sodium-Ion, etc.) - Battery sizing calculations - Series-parallel configuration optimization - Energy, power, and thermal performance assessment - Design and select battery pack components including: - Contactors - Pre-charge circuits - Fuses - Current/Voltage/Temperature sensors - Connectors and relays - HV distribution components - Develop busbar architecture and design, including material selection, current carrying capacity, voltage drop, thermal rise, short-circuit withstand capability, creepage/clearance compliance, and optimization for cost, weight, and performance Battery Management System (BMS) Development - Define BMS hardware architecture, system requirements, and interface specifications for battery packs and vehicle integration - Develop and validate BMS control algorithms using MATLAB, Simulink, and Stateflow, including: - State of Charge (SOC) - State of Health (SOH) - State of Power (SOP) - Cell balancing - Fault diagnostics and protection functions - Apply advanced battery estimation and control techniques such as: - Kalman Filter and Adaptive Kalman Filter - Coulomb Counting - Model-based estimation methods - Battery plant modeling and parameter identification - Develop battery ageing, degradation, and performance prediction models to support lifecycle management and warranty assessment Verification, Validation & Functional Safety - Execute model-based development and verification activities including: - Requirement traceability - Model verification and validation - Embedded code generation - Test harness development - MIL, SIL, and HIL testing - Vehicle-level validation - Support schematic reviews, hardware validation, and system integration activities with internal teams and external development partners - Conduct failure analysis, root cause investigations, and corrective action implementation for battery and BMS-related issues - Define and validate battery safety concepts, abuse testing strategies, and electrical protection mechanisms in compliance with applicable standards Standards, Compliance & Stakeholder Management - Ensure compliance with automotive standards and regulations including ISO 26262, AIS-156, and other applicable battery safety requirements - Interface with battery cell suppliers, BMS vendors, testing agencies, and development partners throughout the product development lifecycle Preferred Skills - Strong knowledge of EV battery systems, BMS architecture, and cell technologies - Expertise in MATLAB/Simulink/Stateflow and Model-Based Development (MBD) - Hands-on experience with SOC/SOH/SOP estimation algorithms - Understanding of battery safety, abuse testing, thermal management, and functional safety - Experience with automotive V-cycle development and verification processes - Familiarity with CAN, UDS diagnostics, and vehicle network communication protocols