Inverter Design & Validation

Blue Star Limited; Pune District; On-site; INR 1,500,000 - 2,400,000; Full time

Job summary

Blue Star Limited in Hinjewadi, Pune, India, seeks a seasoned inverter hardware design lead to drive hardware development for air-conditioning and heat pump products, guiding a team across hardware, firmware, mechanical and system engineering with emphasis on reliability, safety and performance.

Responsibilities include end-to-end design for PFC, power stage, sensing, DFMEA, EVT/DVT/PVT prototyping, validation planning (thermal, EMI/EMC, surge, ESD), DFx, manufacturing readiness, and

Qualifications

• Bachelor's degree in Electronics.
• Minimum 7 years of experience in inverter hardware design.
• Experience with PFC, inverter power stage and protection modules.
• Strong knowledge of IEC, UL, BIS and EMI/EMC standards.

Responsibilities

• Lead hardware design for inverter PFC, power stage, sensing and protection modules.
• Coordinate EVT/DVT/PVT prototype development and documentation.
• Plan and execute thermal, EMI/EMC, surge, ESD, and reliability tests.

Skills

Inverter topologies

Power electronics

System-level integration

Gate driver tuning

Reliability engineering

RCAs & CAPAs

Oscilloscopes & analyzers

CAN / RS485 / UART

HVAC motor control

Thermal & EMI/EMC testing

Education

Bachelor's degree in Electronics

Tools

Oscilloscopes

Power analyzers

Logic analyzers

DLRO

Job description

What Your Role Entails

Will be responsible for leading the design, development, and validation of inverter hardware for air-conditioning and heat pump products. This role requires deep expertise in power electronics, inverter topologies, component selection, and system-level integration with compressor drives. The individual will guide a team of hardware engineers, work closely with firmware, mechanical, and system engineering teams, and ensure timely execution of projects with high reliability, safety, and performance.

What You’ll Do:

Inverter Hardware Design & Documentation

• Complete hardware design for inverter PFC, power stage, sensing circuits and protection modules.
• Release of design documents: schematics, BOM, PCB guidelines, DFMEA, derating calculations and design justifications.

Prototype Development & Design Maturity

• Deliver hardware prototypes (EVT/DVT/PVT) as per project milestones.
• Ensure first-pass success with minimal design revisions.

Validation Planning & Execution

• Develop detailed inverter hardware validation plans: thermal, EMI/EMC, surge, ESD, EFT, reliability, stress tests.
• Lead validation execution and release of complete test reports with compliance status.

Reliability & Safety Compliance

• Ensure inverter meets internal reliability standards and field conditions (temperature, load, surge, moisture).
• Achieve compliance with IEC, BIS, UL and EMI/EMC norms.

Root Cause Analysis & Issue Resolution

• Complete RCA and corrective actions for design issues during testing, certification and field operation.
• Document and close all hardware-related NCRs, CAPAs and field failure cases.
• Evaluate, test and approve key components: IPM/IGBT/MOSFET, gate drivers, sensors, capacitors, magnetics.
• Release component qualification reports and approval notes.

Manufacturing Readiness (DFM/DFT)

• Provide DFM/DFT guidelines to EMS vendors.
• Support pilot builds, resolve production-related hardware issues and ensure stable mass production.

Cross-Functional Technical Support

• Support firmware, system engineering, mechanical, testing and quality teams during development.
• Provide technical guidance to service/field reliability teams for inverter-related issues.

Cost Optimization & Design Improvements

• Drive cost reduction through component optimization, design simplification and supplier benchmarking.
• Deliver annual improvement projects on efficiency, reliability and thermal performance.

Team Leadership & Capability Building

• Lead and mentor hardware engineers.
• Conduct design reviews, knowledge-sharing and technical training sessions.

Your success is grounded in

• Minimum experience of 7 years along with Bachelor's of Engineering in Electronics.
• Strong knowledge of inverter topologies (single-phase, three-phase, PFC, active PFC, DC–DC converters).
• Understanding of PMSM/BLDC motor control requirements, compressor load behaviour, and torque-speed characteristics.
• Experience with DC-link design, inrush control, busbar design, snubbers, and power device thermal derating firmware teams to define hardware-software interfaces, including ADC/DAC ranges, digital IO behaviour, and communication protocols (RS485, CAN, Wi-Fi, BLE, etc.).
• Perform system-level debugging during development and field issues.
• Knowledge of compliance standards: IEC 60335, IEC 61000 series, BIS, UL, safety and performance requirements.
• Experience with pre-compliance and full-compliance testing (conducted/radiated emissions, immunity, surge, ESD, EFT).
• Good understanding of interaction between hardware, firmware and system control.
• Strong knowledge of gate driver tuning, soft start, protection logics (overcurrent, over-voltage, thermal, phase loss).
• Understanding of compressor drive requirements, modulation strategies, and system-level protections.
• Familiarity with communication interfaces (CAN, RS485, UART) used in HVAC systems.
• Expertise in running validation tests such as: Thermal cycling , Power cycling , HALT/HASS, Burn-in testing, Surge/ESD/EFT.Durability & stress tests.
• Proficiency in debugging using oscilloscopes, power analyzers, logic analyzers, isolation probes, DLRO etc.
• Strong skills in RCA (Root Cause Analysis), reliability engineering, and component failure analysis.

Where you’ll be

This role is based in Hinjewadi, Pune, India.

At Blue Star, you are not just another employee; you're part of a vibrant community that values innovation, dedication, and teamwork. We believe in investing in our people and providing opportunities for professional growth and development. You’ll be empowered to take ownership of your role and make a difference in the lives of our customers and colleagues. If you’re ready to take on this exciting challenge and make a real impact, we would love to hear from you!