BESS Mechanical Design

Key Responsibilities

• Mechanical Architecture & Enclosure Design

• Design product and system-level mechanical architecture for:

• Solar inverters (string & central)

• PCS & BESS containers

• EV chargers (AC/DC)

• Electrolysers & power supply cabinets

• Develop enclosures, cabinets, skids, and container layouts.

• Ensure IP protection, corrosion resistance, and environmental robustness.

• Thermal & Cooling Design

• Design thermal management solutions:

• Forced air cooling

• Liquid cooling (cold plates, heat exchangers)

• Perform thermal simulations (CFD) and support validation.

• Optimize airflow paths, heat sink design, and component placement.

• Structural & Mechanical Analysis

• Perform structural analysis for:

• Static & dynamic loads

• Transportation & seismic conditions

• Ensure compliance with wind, seismic, and shock/vibration requirements.

• Design for safe lifting, handling, and installation.

• Integration with Electrical & Control Systems

• Coordinate with electrical and control teams on:

• Component placement & clearances

• Cable routing and bending radius

• EMI shielding & segregation

• Ensure creepage, clearance, and safety requirements are mechanically supported.

• DFM, DFA & Industrialization

• Design for manufacturability, assembly, and serviceability.

• Select materials and finishes considering cost, durability, and environment.

• Support prototype builds, NPI, and production ramp-up.

• Drive cost reduction and weight optimization initiatives.

• Testing, Validation & Compliance

• Support mechanical and environmental testing:

• Thermal cycling

• IP / ingress tests

• Vibration & shock tests

• Support certification to IEC, UL, and ISO standards.

• Resolve mechanical field issues and drive corrective actions.

• Documentation & Configuration Control

• Prepare and maintain:

• 3D models & 2D drawings

• BOMs & assembly instructions

• Installation and service manuals

Ensure proper revision and change management