Role & responsibilities

Position Summary

Own electrical design, wiring harness development, electrical component integration, busbar design support and engineering documentation for HV battery packs used in EVs and energy storage systems, from concept to SOP. The role reports to the Lead Electrical Design (Battery Pack).

Experience framing: automotive electrical design and product development, with a core portion in EV battery pack, wiring harness, power distribution or related electrical systems.
Must Have Skills
HV battery pack electrical design
Wiring harness design and development (HV and LV)
Electrical CAD tools (CATIA Electrical, Siemens Capital Harness, Zuken E3, SolidWorks Electrical or AutoCAD Electrical)
Busbar design and material selection
Automotive-grade connector, terminal and cable selection
Valuable To Have Skills
Ansys for electrical, thermal and structural simulation
3D electrical routing and packaging
DFM and DFA principles
DVP&R; support
APQP, DFMEA and engineering change management
Root cause analysis
Harness manufacturing, crimping and busbar fabrication processes
BMS integration
High voltage safety systems
EMC/EMI fundamentals
AIS 156, AIS 038 and related EV standards
Cost optimization and VAVE




Roles and Responsibilities
Develop electrical designs, schematics, wiring diagrams and routing layouts for HV battery pack systems; support electrical architecture and power distribution definition.
Support integration of BMS, contactors, fuses, relays, HVIL circuits, sensors and connectors.
Design HV and LV wiring harnesses: routing layouts, drawings, cable sizing, wire specifications and protection methods.
Select and validate electrical components; prepare specifications; coordinate with suppliers on development and qualification.
Support busbar design: materials, dimensions, insulation, joining, current capability and thermal performance.
Maintain CAD databases, BOMs and release documentation using industry-standard tools; support Ansys simulation.
Support DFM, DFA, prototype and pilot builds, and SOP readiness; resolve design-related manufacturing issues.
Support DVP&R; execution and validation failure analysis; apply DFMEA, APQP and engineering change management.

Coordinate with Mechanical Design, BMS, Systems, Validation, Manufacturing, Quality and Procurement teams.

Preferred candidate profile

📌 Electrical Cad Design Engineer Battery Pack Chennai
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📍 Chennai