Position Summary
This role is responsible for the end-to-end hardware development of Battery Management System (BMS) electronics – including BMU/master and CSC/slave boards – for on- and off-highway commercial vehicles and energy storage system (ESS) applications. The engineer will independently deliver circuit design, schematic capture and PCB layout in Altium Designer, translating system requirements into robust, EMC-compliant, HV-safe and manufacturable hardware. The position covers the full cycle from hardware requirements, component selection and design analysis to sample bring-up, verification/validation and product release, working closely with system, software, mechanical, functional safety, testing and manufacturing teams.
Key Accountabilities / Responsibilities 1. BMS Hardware Circuit Design
- Design and develop BMS electronic circuits (BMU/master and CSC/slave) for on-/off-highway vehicles and ESS, covering MCU system, 12V/24V power supply (SBC/PMIC, DC/DC, LDO), wake-up and low-power circuits.
- Design cell voltage/temperature monitoring (AFE, e.g. ADBMS/BQ series), isoSPI/daisy-chain communication, CAN/CAN FD, HV voltage measurement, insulation monitoring, current sensing (shunt/Hall), contactor/relay drivers and pre-charge circuits.
- Derive hardware requirements from system requirements and ensure bidirectional traceability; ensure products meet all customer and internal electrical requirements.
- Lead component selection, including HV components (contactors, fuses, shunts, pre-charge resistors, HV connectors); ensure AEC-Q qualification, derating, lifecycle and second-source availability.
- Apply CAD/CAE tools for design analysis and evaluation: circuit simulation (LTspice/PSpice), worst-case circuit analysis (WCCA), tolerance, power dissipation and thermal analysis.
2. PCB Layout Design (Altium Designer)
- Independently complete multi-layer PCB layout in Altium Designer, including stack-up definition, placement, routing, high-current copper design and thermal management.
- Implement HV isolation design, creepage and clearance in line with IEC 60664-1 / ISO 6469 / IPC-2221 requirements.
- Perform EMC-oriented, low-emission layout (grounding and partitioning, return paths, filtering, ESD/transient protection) to meet CISPR 25, ISO 11452, ISO 7637 and ISO 10605.
- Ensure DFM/DFA/DFT together with PCB fab and EMS suppliers; generate and release Gerber, BOM, assembly drawings and manufacturing documentation.
3. Functional Safety & Design Quality
- Support ISO 26262 hardware development: implement hardware safety mechanisms, support FMEDA and hardware metrics (SPFM/LFM/PMHF), and participate in DFMEA.
- Organize and participate in schematic and layout design reviews; follow the engineering design process and product release procedures.
4. Verification, Validation & Issue Resolution
- Commission initial sample boards (bring-up); verify and validate designs on bench, in vehicle and in ESS as necessary.
- Define and support hardware DV/PV testing, EMC and environmental tests, and system-level validation.
- Find root cause and implement corrective actions (e.g. 8D) for any electrical design-related issues during development, production and field.
5. Teamwork & EHS
- Participate in new product development as a team player with system, software, mechanical, test, purchasing, quality and customer teams.
- Adhere to the Global Star Safety Program and BorgWarner Safety Policy Manual (safety rules, practices, training, PPE); report all injuries, incidents and potentially dangerous situations to the immediate supervisor; meet EHS responsibility requirements. Requirements / Qualifications - Bachelor’s degree or above in Electrical, Electronic, Automation, Automotive Engineering or related field.
- 3+ years of electrical/hardware design experience; automotive electronic module design experience required, BMS hardware design experience strongly preferred.
- Must be able to independently…