Role Summary

Lead the development, integration, and validation of HVAC and Battery Thermal Management Systems (BTMS) for electric, hybrid, commercial, and off-highway vehicles. Responsible for thermal calculations, system sizing, component selection, packaging, HVAC ducting, battery cooling/heating architecture, supplier management, and vehicle-level thermal integration from concept through production.

Key Responsibilities

HVAC System Development

- Develop complete HVAC system architecture and thermal management concepts.
- Define cooling, heating, ventilation, defrost, and cabin comfort requirements.

Thermal Calculations & System Sizing

- Perform:

Cabin heat load calculations, Solar load analysis, Cooling load calculations, Heating load calculations, Airflow and pressure drop calculations, Refrigerant circuit sizing
- Size and select:

Compressors, Condensers, Evaporators, Expansion valves, HVAC blowers, Heater cores, Refrigerant lines, Cooling pumps and valves Battery Thermal Management System (BTMS)

- Define battery thermal management architecture for EV and hybrid platforms.
- Develop liquid-cooled and air-cooled battery thermal systems.

- Perform

- Battery heat generation calculations

- Cooling capacity calculations

- Thermal load assessments

- Coolant flow calculations

- Pressure drop calculations

- Heat exchanger sizing
- Develop battery cooling and heating strategies to meet performance, durability, charging, and safety targets.

- Define thermal requirements for

Battery packs, Battery modules, Power electronics, On-board chargers, Electric drive units
- Support quick-charging thermal management and thermal runaway mitigation strategies.
- Integrate chiller, PTC heaters, heat pumps, cooling pumps, valves,



and battery cooling circuits.

Thermal System Integration

- Integrate HVAC and battery thermal systems into a unified vehicle thermal management architecture.
- Optimize energy consumption and vehicle range through efficient thermal management.
- Coordinate interfaces between:

Battery System, Powertrain, Vehicle Controls, Electrical Architecture, Cooling System, Cabin Climate Control Plastic & Sheet Metal Component Design

- Strong knowledge of:

- Injection moulded plastic components

- Sheet metal design
- Manufacturing processes &Tooling; feasibility

Supplier Management

- Manage HVAC and BTMS suppliers through the complete development cycle.

Testing & Validation

- Develop validation plans for HVAC and thermal management systems.

Cross-Functional Collaboration

- Lead system integration activities from concept through SOP.

Required Technical Skills

- HVAC System Design & Development
- Battery Thermal Management Systems
- Cabin Thermal Load Calculations
- Battery Heat Load Calculations
- Thermal System Sizing
- Heat Exchanger Selection
- Chiller & Cooling Circuit Design
- Heat Pump Systems
- Cooling System Integration
- GD&T;
- DFMEA / PFMEA
- DFA / DFM / DFS
- Sheet Metal & Plastic Component Design
- APQP / PPAP
- Supplier Development

Preferred Tools

- CATIA V5/V6
- Teamcenter / PLM
- GT-SUITE
- MATLAB Simulink
- MS Office

Education Bachelor's Degree in Mechanical Engineering, Automobile Engineering, Thermal Engineering, Energy Engineering, or equivalent.

Key Competencies

- HVAC & Thermal Management Expertise
- EV Thermal System Integration
- Technical Leadership
- Supplier Management
- System Engineering
- Cross-functional Coordination
- Problem Solving
- Project Execution
- Cost and Quality Optimisation

📌 HVAC & Battery Thermal Management System Lead (Chennai)
🏢 Hinduja Tech
📍 Chennai