Lead BMS Design

Larsen & Toubro; Bengaluru; On-site; INR 4,000,000 - 7,500,000; Full time

Job summary

Larsen & Toubro is seeking a Cell-to-Pack (CTP) Design Lead for utility-scale BESS in Bengaluru. You will drive architecture from cell to container, coordinating electrochemical, thermal, mechanical, electrical, and controls engineering to deliver safe, scalable battery packs for grid applications.

The role involves leading design reviews, prototype builds, and certification activities, with focus on energy density, manufacturability, and compliance across global standards.

Qualifications

• Bachelor’s or Master’s degree in Mechanical or Electrical Engineering, Energy Systems.

Responsibilities

• Define end-to-end CTP architecture for utility-scale BESS (cell → module → unit → rack → container).
• Lead selection of cylindrical, prismatic or pouch cell platforms based on application needs.
• Determine series/parallel configurations, voltage windows, SOC/SOH limits, and pack topology.
• Develop modular, scalable pack/rack designs compatible with PCS, EMS, and container infrastructure.
• Optimize energy density, footprint, weight, and structural stability.
• Lead mechanical layout of modules, frames, busbars, holders and pack enclosure.
• Collaborate with BMS for sensing, balancing circuits, HVIL design.
• Define electrical layout, isolation, fuse protection, HV harnessing.
• Ensure pack design meets UL/IEC/NFPA grid standards and prepare certification artifacts.

Skills

Lithium-ion chemistry

Pack design

CAD tools

FEA/CFD

BMS architecture

High-voltage design

Thermal systems

Safety standards

Education

Bachelor’s or Master’s in Mechanical/Electrical Engineering or Energy Systems

Advanced Battery Technology degree (plus)

Tools

SolidWorks

CATIA

CREO

NX

ANSYS

Abaqus

Star-CCM+

Job description

Cell-to-Pack (CTP) Design Lead – Utility-Scale BESS Role Summary The Cell-to-Pack (CTP) Design Lead for Utility BESS is responsible for leading the design, architecture, and engineering of battery modules, sub-packs, racks, and container-level pack integration. The role ensures optimal energy density, thermal safety, mechanical robustness, manufacturability, and compliance with global standards. This leader works across electrochemistry, thermal, mechanical, electrical, and controls engineering teams to deliver safe, scalable, and cost-optimized BESS battery packs for grid applications.

Key Responsibilities

• Define end-to-end CTP architecture for utility-scale BESS (cell → module → unit → rack → container).
• Lead selection of cylindrical, prismatic, or pouch cell platforms based on application: frequency response, energy shifting, and hybrid storage.
• Determine series/parallel cell configurations, voltage windows, SOC/SOH limits, and pack topology.
• Develop modular, scalable pack/rack designs compatible with PCS, EMS, and container infrastructure.
• Optimize energy density, footprint, weight, and structural stability.
• Lead mechanical layout of modules, frames, busbars, holders, and pack enclosure.
• Conduct structural strength and vibration analysis (simulation + validation).
• Ensure tolerance stack-ups, manufacturability, and assembly feasibility.
• Design load-bearing frames supporting seismic, transport, lifting, and shock requirements as per relevant standards
• Collaborate with thermal engineering to define cooling strategy:
• Air-cooled, liquid-cooled, or hybrid CTP approaches.
• Ensure cell temperature uniformity, cooling channel placement, and thermal runaway (TR) mitigation.
• Drive venting paths, exhaust channels, gas detection, and propagation prevention mechanisms.
• Integrate sensors (NTC/PTC, pressure, humidity) into pack design.
• Define electrical layout, voltage isolation, creepage/clearance, fuse/circuit protection, HV harnessing, and contactor block integration.
• Collaborate with BMS team to ensure: Cell sensing accuracy, Balancing circuit integration
• High-voltage interlock loop (HVIL) design
• Define pack functional safety per relevant guidelines.
• Ensure pack design meets global grid-scale BESS standards:
• UL 9540 / 9540A, UL 1973,IEC 62619,NFPA 855 & local certification requirements
• Prepare all certification documentation, models, drawings, and test artifacts.
• Participate in design reviews and audits with UL/Intertek/TÜV.
• Lead prototype build, DVT/PVT testing, pack characterization, and reliability tests.
• Define end-of-line (EOL) testing requirements for pack manufacturing.
• Manage validation of mechanical vibration, temperature cycling, short-circuit testing, fire propagation, fault injection tests
• Support pilot manufacturing, tooling design, and vendor qualification.
• Work with system engineering, EMS, thermal, fire safety, and manufacturing teams.
• Collaborate with supply chain on cell suppliers, module makers, and component vendors.
• Provide technical guidance to BESS product managers on roadmap strategy.
• Review customer RFPs and support engineering proposals.
• Familiarity with battery safety standards and grid energy storage requirements
  

Required Qualifications

Bachelor’s or Master’s degree in Mechanical Engineering, Electrical Engineering, Energy Systems, or similar. Advanced degree in Battery Technology is a plus.

Technical Skills

• Deep understanding of lithium-ion cell chemistry, performance curves, aging, and safety.
• Expertise in pack design, module architecture, busbar design, and enclosure engineering.
• Proficiency with CAD tools: SolidWorks, CATIA, CREO, NX.
• Knowledge of FEA/CFD (ANSYS, Abaqus, Star-CCM+).
• Knowledge of BMS architecture, high-voltage design, and thermal systems
• Familiarity with battery safety standards and grid energy storage requirements

Experience

• 10–15+ years in battery pack/module engineering (EV, UPS, BESS, ESS racks).
• Minimum 5+ years leading design teams.
• Experience with utility-scale BESS racks and container architectures is a major advantage. Proven track record of taking battery products from concept → prototype → certification → mass production.