Hardware System Sizing Engineer - BEV

Hardware System Sizing Engineer – BEV / xHEV Propulsion Systems

Experience : 5-12 yrs

Location : Pune

Department : Electrified Propulsion Systems – Hardware Architecture

Role Summary :

Hardware System Sizing Engineer will be responsible for defining and optimizing the physical and performance characteristics of propulsion system components for Battery Electric Vehicles (BEVs) and Hybrid Electric Vehicles (xHEVs). This includes sizing of electric motors, inverters, battery packs, and associated cooling systems to meet vehicle-level performance, efficiency, and durability targets. You will work closely with cross-functional teams to ensure robust system integration and alignment with program requirements.

Key Responsibilities

Lead hardware sizing activities for propulsion system components including e-motors, inverters, battery packs, and cooling modules

Translate vehicle-level performance targets into component-level sizing and specification requirements

Perform trade-off studies and parametric analysis to balance performance, cost, weight, and thermal constraints

Develop and maintain sizing models using tools such as MATLAB / Simulink, Excel-based calculators, or proprietary platforms

Collaborate with system architects, thermal engineers, and controls teams to ensure optimal system-level integration

Support benchmarking and technology roadmap activities to inform sizing strategies

Contribute to design reviews, DFMEAs, and validation planning for hardware components

Document sizing rationale and maintain traceability to system requirements and vehicle targets

Qualifications & Skills

Bachelor’s degree in mechanical engineering or related field (master’s preferred)

Strong understanding of electromechanical systems, thermodynamics, and energy conversion

4 + years for Powertrain domain experience much required. Also experience in sizing propulsion components for automotive.

Proficiency in modelling and simulation tools (e.g., MATLAB / Simulink, GT-Suite, Excel VBA)

Familiarity with BEV / xHEV architectures and performance requirements

Knowledge of automotive development processes and system engineering principles

Strong analytical, communication, and documentation skills

Preferred Experience

Prior experience in electrified powertrain development or system architecture

Exposure to battery pack sizing, inverter thermal limits, and motor torque-speed mapping

Understanding of vehicle-level drive cycles and energy consumption modelling

Experience with requirement management tools (e.g RMDV , TRM, XRAY)