Senior Engineer - Battery Pack Electrical Design Engineer

Prolegion; Bengaluru; On-site; INR 1,200,000 - 2,100,000; Full time

Job summary

Prolegion seeks a Senior Engineer with hands-on electrical design of Lithium-ion battery packs for BESS applications. You will own the electrical architecture, cell configuration, pack sizing, and HV system integration, ensuring safety and reliability across the pack.

Your role includes BMS integration, CAN communication, thermal considerations, and collaborating with mechanical/thermal teams to achieve full pack integration. 4+ years of experience in this field is required.

Qualifications

• Hands-on experience in electrical design of Li‑ion battery packs.
• Strong knowledge of battery pack electrical architecture and design.
• Experience with BMS integration and CAN communication.
• Understanding of HV systems, busbars, contactors, fuses, pre-charge and electrical protection.
• Experience with LFP/NMC battery systems.
• Knowledge of SOC/SOH, cell behavior and battery safety.

Responsibilities

• Design electrical architecture of Li-ion battery packs for BESS applications.
• Configure cell series/parallel architecture, pack voltage and power calculations.
• Size busbars and electrical interconnections based on current, voltage and thermal requirements.
• Integrate HV systems, contactors, fuses, pre-charge circuits, HVIL and protection circuits.
• Integrate BMS, CAN communication, cell monitoring, balancing and protection logic.
• Prepare electrical schematics, wiring diagrams, BOMs and design specifications.
• Collaborate with suppliers on cells, BMS, contactors, fuses and connectors.
• Participate in DFMEA and electrical safety/design reviews.
• Coordinate with mechanical and thermal teams for pack integration.

Skills

Electrical design

Battery packs

CAN communication

HV systems

BMS integration

DFMEA

LFP/NMC cells

Battery safety

Education

B.E./B.Tech in Electrical

Job description

Job Title: Senior Engineer BESS Battery Pack Electrical Design

Location: Bangalore

Job Type: Full-time

Experience: 4+ years

ATS LINK : https://www.prolegion.com/jobs/c43f615f-44ca-4adb-ae6a-74da9923fb22 ?utm_source=naukri

About the Role

We are looking for a Senior Engineer with strong hands-on experience in electrical design of Lithium-ion battery packs, preferably for BESS / Energy Storage applications.

The role will primarily focus on battery pack electrical architecture and design, including cell configuration, pack sizing, HV electrical systems, busbars, contactors, fuses, pre-charge circuits, BMS integration, and electrical protection.

The role will also involve supporting battery pack testing and validation to ensure the design meets performance, safety, and reliability requirements.

Key requirement: Candidates must have hands-on experience in electrical design of battery packs. Candidates whose experience is primarily mechanical pack design, enclosure/CAD design, thermal design, BMS testing, or battery testing will not be preferred.

Key Responsibilities

Electrical Battery Pack Design 70%

• Design and develop electrical architecture of Lithium-ion battery packs for BESS applications.
• Develop cell configuration, series/parallel architecture, pack voltage, capacity and power calculations.
• Design and size busbars and electrical interconnections based on current, voltage and thermal requirements.
• Design/integrate HV systems, contactors, fuses, pre-charge circuits, HVIL, connectors and protection circuits.
• Integrate BMS, CAN communication, cell monitoring, balancing and protection logic.
• Select appropriate LFP/NMC cells and electrical components based on application requirements.
• Prepare electrical schematics, wiring diagrams, BOMs and design specifications.
• Work with suppliers on cells, BMS, contactors, fuses, connectors and other electrical components.
• Participate in DFMEA and electrical safety/design reviews.
• Work closely with mechanical and thermal teams to ensure complete pack-level integration.

Battery Testing 15%

• Support and/or execute battery pack electrical and performance testing.
• Perform/support charge-discharge, capacity, cycle-life and electrical safety testing.
• Support thermal and IP testing as required.
• Troubleshoot electrical issues identified during testing and implement design improvements.

Validation & Compliance – 15%

• Support battery pack validation plans, test protocols and acceptance criteria.
• Analyze test results and support validation of pack performance and safety.
• Support thermal runaway testing and safety validation.
• Coordinate with external laboratories for applicable certifications such as UN38.3, IEC 62619, UL 9540A, etc.
• Prepare validation and technical reports.

Required Qualifications

• B.E./B.Tech or M.E./M.Tech in Electrical, Electronics, EEE, ECE, Mechatronics, or related engineering disciplines.
• 4+ years of hands‑on experience in electrical design of Lithium‑ion battery packs.
• Strong experience in battery pack electrical architecture and design.
• Hands-on experience with BMS integration and CAN communication.
• Strong knowledge of HV systems, busbars, contactors, fuses, pre-charge and electrical protection.
• Experience with LFP/NMC battery systems.
• Understanding of SOC/SOH, cell behaviour and battery safety.

Preferred Experience

• Experience in BESS / Energy Storage / EV battery systems.
• Experience with high-voltage battery packs (400V–1000V+).
• Exposure to thermal runaway mitigation and battery safety.
• Experience with DFMEA and battery certification.
• Experience working with cell/BMS/electrical component suppliers.