Senior Hardware Test Engineer - Power Electronics for Electric Vehicles

Ford Motor; Bengaluru; On-site; INR 2,600,000 - 3,800,000; Full time

Job summary

Ford Motor in Bengaluru is seeking a Senior Hardware Test Engineer to lead validation strategies for low- and high-voltage power electronics in electric vehicles. You will drive hardware testing, test automation, HIL validation, and cross-functional collaboration with global teams to validate electrification technologies across vehicle programs.

Responsibilities include developing test plans for OBC, HV-BMS, and inverters; leading initial bring-up, EMI/EMC testing, DVP&R support; building

Qualifications

• Bachelor's or Master's degree in Electrical Engineering, Electronics Engineering, Computer Engineering, Mechatronics Engineering, or a related field.
• 5+ years of hardware testing and validation of power electronics systems (OBC, inverters, DC-DC, HV-BMS, EV charging equipment).
• Strong understanding of power electronics fundamentals (IGBT, MOSFET, SiC), EMI/EMC principles, and high-voltage systems.
• Hands-on lab experience with oscilloscopes, power analyzers, electronic loads, and environmental chambers.

Responsibilities

• Lead hardware test plans for LV/HV power electronics and EVSE components.
• Develop and maintain test automation scripts to improve efficiency and data logging.
• Analyze test results to identify failure modes and drive design improvements.
• Collaborate with global hardware, software, controls, systems, and manufacturing teams.

Skills

Python for test automation

Analytical skills

Communication skills

Mentoring juniors

Education

Electrical/Electronics/Mechatronics degree

Tools

MATLAB/Simulink

NI LabVIEW

Test Stand

Job description

Senior Hardware Test Engineer

The Senior Hardware Test Engineer will be responsible for developing and executing validation strategies for Low & high-voltage power electronics products used in electric vehicles. This role combines hardware testing, test automation, Hardware-in-the-Loop (HIL) validation, laboratory development, and cross-functional collaboration. You will work closely with global hardware, software, controls, systems, and manufacturing teams to validate next-generation electrification technologies and support their successful deployment across Ford vehicle programmes. The position requires strong expertise in power electronics testing, automation frameworks, real-time simulation environments, and automotive validation processes.

Hardware Testing

• Develop and execute comprehensive Component PCBA and System-level test plans for Low Voltage and High Voltage systems Electric Vehicle Supply Equipment (EVSE) Onboard Chargers (OBC) DC-DC Converters Inverters High-Voltage Battery Management Systems (HV-BMS)
• Lead initial Hardware Bring-Up Testing on new PCBA revisions and generate detailed technical reports.
• Perform EMI/EMC testing on development hardware and provide direct technical feedback to the HW Design team.
• Define validation requirements, test methodologies, success criteria, and acceptance metrics.
• Support Design Verification Plan & Report (DVP&R) development and execution.

Test Automation Development

• Develop and maintain HW bench-level test automation scripts using Python (and/or NI LabVIEW) to improve test efficiency, repeatability, and logging.Create automated test scripts to improve test efficiency, repeatability, and reporting.
• Lead Tester Board design and development, including custom test fixtures, wiring harnesses, and instrumentation setups.
• Perform MATLAB circuit simulations to verify and optimize tester board designs before build.
• Integrate power electronics hardware with real-time simulation systems and controllers.
• Develop custom test fixtures, wiring harnesses, and instrumentation systems.

Quality & Problem Resolution

• Analyse test results to identify failure modes, root causes, and design improvement opportunities.
• Prepare and review system-level DFMEAs in close alignment with Cross-Functional Teams (CFT).
• Generate detailed technical reports and validation documentation.
• Troubleshoot automated test systems, instrumentation, and hardware-software integration issues.
• Support issue resolution activities with design, controls, and systems engineering teams.

Cross-Functional Collaboration

• Collaborate with global hardware, software, controls, systems engineering, and manufacturing teams.
• Participate in design reviews and provide recommendations related to testability, reliability, and product performance.
• Support programme milestones and validation deliverables across global vehicle programmes.
• Interface with stakeholders across multiple time zones to align validation strategies and programme schedules.

Required Qualifications

• Bachelor's or Master's degree in Electrical Engineering, Electronics Engineering, Computer Engineering, Mechatronics Engineering, or a related field.
• 5 + years of experience in hardware testing and validation of power electronics systems such as: Onboard Chargers (OBC) Inverters DC-DC Converters Motor Drives Battery Management Systems EV Charging Equipment
• Strong understanding of power electronics fundamentals, including: IGBT, MOSFET, and Silicon Carbide (SiC) devices Gate driver circuits Power conversion architectures Thermal management EMI/EMC principles
• Hands-on experience with laboratory equipment including: Oscilloscopes Power analysers Electronic loads AC/DC power supplies Environmental chambers
• Strong proficiency in Python for test automation, scripting, and data analysis.
• Working knowledge of automotive EMC and electrical validation standards.
• Basic understanding of embedded systems and firmware interactions.
• Strong analytical, troubleshooting, and problem-solving skills.
• Excellent verbal and written communication skills.
• Experience mentoring or guiding junior engineers.

Preferred Qualifications

• Hands-on experience with Python/ NI LabVIEW for automated test system development.
• Experience in Tester Board design and circuit simulation using MATLAB/Simulink.
• Familiarity with Test Stand, SQL, or similar test data management tools.
• Experience supporting automotive electrification or energy management products.
• Knowledge of ISO 26262 Functional Safety requirements.
• Familiarity with automotive communication protocols such as CAN.
• Knowledge of automotive and regulatory standards including AIS, IEC, ISO, and UL standards.
• Experience collaborating with global engineering teams and suppliers.
• Experience Level Senior Level