1. Electrical Architecture & System Integration

Own and develop the drone-level electrical architecture for UAV/aerospace systems.

Develop and maintain the overall electrical power tree, including power sources, power distribution, conversion, protection, and loads.

Define electrical interfaces between:

Avionics

Flight control systems

Propulsion systems

Battery/BMS

Payloads

Communication systems

Navigation systems

Ground-support equipment

Other aircraft subsystems

Develop and maintain Interface Control Documents (ICDs), electrical interface specifications, wiring diagrams, and system architecture documents.

Define and review grounding, bonding, shielding, and return-current strategies.

Evaluate electrical architecture for redundancy, fault tolerance, fail-protected operation, and single-point failures.

Participate in system-level design reviews and provide technical recommendations on electrical architecture and integration.

Ensure electrical design decisions are aligned with aircraft-level requirements, safety requirements, performance, weight, reliability, and maintainability.

2. Electrical Power Systems

Develop and maintain the aircraft electrical power budget covering different operating and flight phases.

Define power requirements for avionics, propulsion, payloads, communication systems, sensors, actuators, and other electrical loads.

Analyse steady-state and transient power requirements, including startup current, inrush current, brownout, over-voltage, under-voltage, and load-shedding conditions.

Ensure adequate electrical power supply margins are maintained throughout the aircraft operating envelope.

3. Wiring Harness & EWIS

Own the electrical harness architecture and overall Electrical Wiring Interconnection System (EWIS).

Define wire and cable selection based on:

Current carrying capacity

Voltage rating

Temperature

Weight

Environmental conditions

Voltage drop

EMI/EMC requirements





Mechanical requirements

Review harness routing for weight optimisation, bend radius, chafe protection, maintainability, accessibility, and EMI segregation.

Define separation requirements between:

High-voltage and low-voltage wiring

Power and signal wiring

High-current and sensitive signal circuits

5RF and electrical systems

Review harness drawings, wiring diagrams, connector pinouts, wire lists, BOMs, and manufacturing documentation.

Support harness build, installation, inspection, continuity testing, and aircraft integration.

Establish and enforce harness workmanship standards based on IPC/WHMA-A-620 and applicable aerospace/military practices.

Support development of standard practices for crimping, soldering, shielding, splicing, lacing, termination, connector assembly, and inspection.

Wire harness design for the following systems:

Avionics systems

Electrical systems such as motor and ESC.

Battery and Battery management systems

Communication systems

4. Connector & Interface Management

Select appropriate connectors, contacts, backshells, terminals, and accessories based on electrical, mechanical, environmental, and reliability requirements.

Define connector specifications considering:

Current and voltage rating

Contact resistance

Retention force

Environmental sealing

Mating cycles

Vibration

Temperature

EMI/EMC requirements

Establish connector standardisation across the aircraft platform wherever practical.

Review connector derating, contact loading, pin allocation, keying, and mating requirements.





Maintain connector pinout and interface documentation and ensure configuration consistency between design, manufacturing, and aircraft installation.

5. EMI/EMC Engineering

Incorporate EMI/EMC considerations from the early design stage.

Define appropriate practices for:

Cable segregation

Shielding

Grounding

Bonding

Filtering

Termination

Cable routing

RF isolation

Identify potential EMI/EMC coupling paths between propulsion, power electronics, avionics, communication, and sensor systems.

Support troubleshooting of EMI/EMC issues during laboratory, ground, and flight testing.

Support EMI/EMC qualification activities in accordance with applicable standards such as MIL-STD-461 and MIL-STD-464.

Support environmental qualification activities in accordance with applicable requirements such as MIL-STD-810.

6. Electrical Testing & Verification

Develop electrical integration and verification plans based on system requirements.

Lead and participate in:

Continuity testing

Insulation resistance testing

Dielectric withstand/Hi-Pot testing where applicable

Ground bonding/continuity testing

Power-on testing

Load testing

Communication interface testing

Develop test procedures, test checklists, test reports, and verification records.

Review test results and ensure requirements are objectively verified.

7. Documentation & Configuration Management

Prepare and maintain:

Electrical architecture documents

Electrical schematics

Wiring diagrams

Harness drawings

ICDs

Electrical BOMs

Wire lists

Connector pinout documents

Power budgets

Electrical interface specifications

Test procedures

Test reports

Troubleshooting reports

Ensure engineering documentation is properly controlled and updated through the product lifecycle.

Work closely with configuration management/PLM teams to maintain design baselines and engineering changes.

📌 Electrical Engineer (Navi Mumbai)
🏢 Saraca Solutions
📍 Navi Mumbai