Job Title: Senior Engineer – BESS Battery Pack Electrical Design

Location: Bangalore

Job Type: Full time

Experience: 4+ years

About the Role

We are looking for a Senior Engineer with strong hands-on experience in electrical design of Lithium-ion battery packs , preferably for BESS / Energy Storage applications .

The role will primarily focus on battery pack electrical architecture and design , including cell configuration, pack sizing, HV electrical systems, busbars, contactors, fuses, pre-charge circuits, BMS integration, and electrical protection.

The role will also involve supporting battery pack testing and validation to ensure the design meets performance, safety, and reliability requirements.

Key requirement: Candidates must have hands-on experience in electrical design of battery packs. Candidates whose experience is primarily mechanical pack design, enclosure/CAD design, thermal design, BMS testing, or battery testing will not be preferred.

Key Responsibilities

Electrical Battery Pack Design – 70%

- Design and develop electrical architecture of Lithium-ion battery packs for BESS applications.
- Develop cell configuration, series/parallel architecture, pack voltage, capacity and power calculations .
- Design and size busbars and electrical interconnections based on current, voltage and thermal requirements.
- Design/integrate HV systems, contactors, fuses, pre-charge circuits, HVIL, connectors and protection circuits .
- Integrate BMS, CAN communication, cell monitoring, balancing and protection logic .
- Select appropriate LFP/NMC cells and electrical components based on application requirements.
- Prepare electrical schematics, wiring diagrams, BOMs and design specifications .
- Work with suppliers on cells, BMS, contactors, fuses,



connectors and other electrical components.
- Participate in DFMEA and electrical safety/design reviews .
- Work closely with mechanical and thermal teams to ensure complete pack-level integration.

Battery Testing – 15%

- Support and/or execute battery pack electrical and performance testing .
- Perform/support charge-discharge, capacity, cycle-life and electrical safety testing.
- Support thermal and IP testing as required.
- Troubleshoot electrical issues identified during testing and implement design improvements.

Validation & Compliance – 15%

- Support battery pack validation plans, test protocols and acceptance criteria .
- Analyze test results and support validation of pack performance and safety.
- Support thermal runaway testing and safety validation .
- Coordinate with external laboratories for applicable certifications such as UN38.3, IEC 62619, UL 9540A , etc.
- Prepare validation and technical reports.

Required Qualifications

- B.E./B.Tech or M.E./M.Tech in Electrical, Electronics, EEE, ECE, or related engineering disciplines .
- 4+ years of hands-on experience in electrical design of Lithium-ion battery packs.
- Strong experience in battery pack electrical architecture and design .
- Hands-on experience with BMS integration and CAN communication .
- Strong knowledge of HV systems, busbars, contactors, fuses, pre-charge and electrical protection .
- Experience with LFP/NMC battery systems .
- Understanding of SOC/SOH, cell behaviour and battery safety .

Preferred Experience

- Experience in BESS / Energy Storage / EV battery systems .
- Experience with high-voltage battery packs (400V–1000V+) .
- Exposure to thermal runaway mitigation and battery safety .
- Experience with DFMEA and battery certification .
- Experience working with cell/BMS/electrical component suppliers .

📌 Senior Engineer – BESS Battery Pack Electrical Design (Bangalore Urban)
🏢 HireFlexperts
📍 Bangalore Urban