Senior Engineer

$The High Voltage (HV) Engineer is responsible for the design, development, integration, validation, and manufacturing support of high-voltage electrical systems used in electric vehicles (EVs). The role involves working with battery packs, power distribution units, inverters, onboard chargers, DC-DC converters, high-voltage wiring harnesses, and vehicle safety systems to ensure compliance with automotive standards, quality requirements, and regulatory guidelines.

Design & Development

• Design and develop high-voltage electrical architectures for electric vehicles.
• Define specifications for HV components including battery packs, inverters, power electronics, contactors, fuses, and charging systems.
• Develop and optimize HV cable routing, connectors, and power distribution systems.
• Support component selection and supplier evaluation activities.

System Integration

• Integrate battery systems, traction motors, charging systems, and power electronics into vehicle platforms.
• Ensure seamless interaction between HV and low-voltage vehicle systems.
• Coordinate with Mechanical Design, Battery Systems, Power Electronics, Software Controls, Manufacturing and validation teams.
• Ensuring compliance with safety, quality, cost, and production targets -throughout the EV development and manufacturing lifecycle

Safety & Compliance

• Ensure compliance with automotive functional safety standards including ISO 26262.

• Conduct electrical safety analyses such as:

• FMEA (Failure Mode and Effects Analysis)

• FTA (Fault Tree Analysis)

• Hazard and Risk Assessment

• Ensure compliance with relevant standards such as:

$$ Testing & Validation

• Develop DV/PV (Design Validation/Production Validation) test plans.
• Perform HV insulation, dielectric, grounding, and isolation tests.
• Support EMC/EMI testing and vehicle certification activities.
• Analyze test data and implement corrective actions.

Manufacturing Support

• Support production launch activities and resolve manufacturing issues.
• Develop assembly and testing procedures for HV systems.
• Participate in root cause analysis and continuous improvement initiatives.
• Ensure manufacturability and serviceability of electrical designs.

Documentation

• Create and maintain engineering drawings, schematics, BOMs, and technical specifications.
• Prepare test reports, validation documents, and safety documentation.
• Support audits and regulatory submissions.

Technical Skills

• Strong understanding of:

• High-voltage systems (400V to 1000V)

• Lithium-ion battery technology

• Power electronics

• Electric drive systems

• Charging technologies (AC/DC fast charging)

• Experience with:

• SolidWorks, or AutoCAD

• CAN, LIN, and Ethernet communication protocols

• Electrical simulation software

Knowledge Areas

• HV safety procedures and lockout/tagout practices.
• Functional safety and cybersecurity awareness.
• Manufacturing and quality systems.
• Experience in EV manufacturing plants or automotive OEMs.
• Certification in High Voltage Safety.
• Knowledge of Battery Management Systems (BMS).
• Familiarity with Six Sigma or Lean Manufacturing principles.
• Experience with global automotive regulations and homologation requirements.