Senior Testing Engineer Battery Testing & ValidationDepartment

Technology Reliability & Application Engineering.

Experience- 4 to Years | EV Battery Domain

Location- Mohan Estate, Delhi

ROLE OVERVIEW

Euler Motors is seeking a highly competent Senior Testing Engineer for the Battery Testing & Validation team. The role spans validation, reliability engineering, safety assessment, and performance evaluation of EV lithium-ion battery systems at cell, component, pack, BMS, and vehicle integration levels, ensuring electrical reliability, regulatory compliance, mechanical and thermal stability under real-world operating conditions.

KEY RESPONSIBILITIES

1. Battery Pack & System Bench Validation

As a Senior Testing Engineer, you will design and execute end-to-end bench validation test plans for battery packs and associated systems, covering Precharge characterization to verify contactor sequencing and inrush current limits, On-Board Charger (OBC) charging validation to confirm charge acceptance and BMS latch behaviour, and DC fast charging performance evaluation under varied SoC and thermal conditions. The role further includes cell and pack-level balancing verification to ensure uniform charge distribution, isolation resistance testing to detect HV leakage paths, DC Internal Resistance (DCIR) measurement to assess cell and pack health, and Hybrid Pulse Power Characterization (HPPC) testing to evaluate dynamic power capability across SoC windows. Test criteria will be defined in collaboration with BMS, electrical, and systems engineering teams, with results systematically analysed to identify failure modes and drive corrective actions.

The ideal candidate brings hands-on experience with battery test equipment, data acquisition systems, and HV safety protocols, along with strong analytical skills to interpret electrochemical and electrical test data and translate findings into documented engineering insights.

2. BMS Hardware Validation

You will execute bench-level validation of Battery Management System hardware across the full spectrum of functional and safety test scenarios. The scope covers Input Supply Verification, Input Reverse Polarity Protection, and Load Enable and Disable functionality, along with voltage dependency testing for battery positive and negative input behaviour, Precharge circuit validation for resistor sizing and timing, and open wire or disconnection case testing across pack voltage, cell voltage, and temperature harnesses. Power consumption measurement across all BMS states at 12V, CAN compatibility testing, current verification, busbar compensation, and voltage measurement accuracy validation are also included, along with AUX sensing and balancing verification.

The suite is completed by isolation and temperature verification, low AUX voltage behaviour analysis, SOC estimation validation, and protection logic testing covering OV, UV, OC, SC,



and OT conditions, ensuring robust and fault-tolerant BMS hardware performance across all operating scenarios.

3. Battery & BMS Validation on Vehicle

You will execute comprehensive vehicle-level Battery and BMS validation per the defined SOP framework across 3W and 4W battery platforms and both in-house and third-party BMS variants. The role covers basic sanity validation including UV discharge, SoC jump, cell imbalance, and energy consumption, along with OBC and fast charging end-to-end validation, and discharging behaviour across vehicle modes under rated and overload conditions. Low AUX voltage robustness testing verifies BMS stability against LV dips, while EMC and EMI immunity validation against horn and ESC disturbances ensures CAN communication integrity and uninterrupted BMS logic.

Isolation leakage validation across all vehicles operating states confirms correct warning-to-alarm fault escalation and HV-to-chassis isolation integrity. Pack current validation, power cycle testing, wire disconnection fault scenarios, pack voltage comparison, and OV, UV, OC, and SC protection trigger validation complete the framework, ensuring full state machine robustness and smooth battery interaction with the VCU, DC-DC converter, and motor controller.

4. Third-Party BMS Validation

You will manage the full evaluation lifecycle of externally sourced BMS hardware and firmware against Euler Motors' technical and performance benchmarks. The role begins with preparing and sharing a comprehensive Statement of Requirements (SOR) with vendors, followed by firmware evaluation for SOC and SOH estimation accuracy, cell voltage and temperature measurement precision, balancing algorithm effectiveness, and fault detection response times across OV, UV, OC, SC, and OT conditions. Hardware-level assessment will cover PCB layout, connector compatibility, isolation barrier integrity, CAN transceiver performance, and thermal design adequacy.

A structured comparative analysis will benchmark key performance parameters of third-party BMS variants against the in-house BMS across charging, discharging, thermal management, and fault handling domains. Bench-level validation will be followed by vehicle-level integration testing including fault injection and communication protocol compliance, with all findings documented in formal test reports with clear pass or fail criteria and sign-off recommendations for production approval.

5. Component & Advanced Validation





You will carry out reliability and performance testing of the battery pack's electrical and mechanical components to confirm safe and durable operation over the vehicle service life. Busbars, contactors, fuses, pre-charge resistors, shunt resistors, and connectors will be evaluated for current carrying capability, voltage drop, contact resistance stability, temperature rise, and endurance performance across defined thermal and mechanical stress cycles. Welded joints and fastening systems will be assessed using a Universal Testing Machine for tensile and shear strength, while X-ray diffraction analysis will confirm alloy composition and metallurgical conformance of conductive materials.

Advanced activities include differential pressure leak testing, EOL battery tester operation, cell and battery cycler operation for characterization and abuse testing, and fire-retardant material validation per applicable safety standards. You will also contribute to the development and standardization of validation methodologies, reliability growth studies, and safety assessment protocols supporting continuous improvement of next-generation EV battery systems.

6. Cross-Functional Coordination & Technical Support

As a Senior Testing Engineer, you will play a central coordination role across engineering disciplines to align validation activities with design intent, manufacturing capability, and vehicle integration requirements. You will collaborate with the Cell Testing team to cross-validate electrochemical parameters, with the Thermal team to correlate pack-level thermal data against simulation models, and with the Powertrain team to validate battery performance under motor load profiles and regenerative braking conditions. Regular engagement with the Battery Design team will support DVP preparation, DFMEA reviews, and early-stage design feedback, while structured root cause analysis reports for field failures will be delivered to the Battery Service team with corrective actions tracked through to laboratory-validated resolution.

Bench and vehicle validation test frameworks will be regularly updated to reflect design changes, emerging field failure modes, and evolving regulatory requirements, with all outcomes documented in formal reports to drive informed decision-making across design, process, and manufacturing teams.

REQUIREMENTS

BE / B.

Tech Mechanical

Engineering HV safety practices & EV regulatory standards knowledge 46 years in EV Battery Testing & Validation Solid analytical, reporting & data interpretation skills¢ Strong knowledge of Li-ion battery systems & validation frameworks¢ Excellent troubleshooting & root cause analysis capabilities¢ Hands-on: battery cyclers, cell cyclers, UTM, environmental chambers¢ Cross-functional coordination & technical leadership skills¢ Experience with BMS testers, vibration systems & thermal test setups

📌 Senior Testing Engineer-Battery (New Delhi)
🏢 Euler Motors
📍 New Delhi