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Sr. Battery Module Pack Engineer - Electrical

Company: Supernal
Location: Livermore
Posted on: September 15, 2022

Job Description:

Supernal is at the forefront of creating emerging mobility solutions that will foster the development of human-centered cities. We are designing a completely new electric vertical take-off and landing (eVTOL) aircraft tailored to the mobility needs of future cities. This allows passengers a seamless intermodal journey that safely transports them to their final destination. We fuse research in autonomy, robotics, aviation and services to define a new category of mobility for the worlds communities. We believe in creative thinking and collaboration to help build a better mobility experience for everyone, improving peoples ability to move whether for work or play.
What we do:
The Sr. Battery Module/Pack Engineer Electrical will design and prototype high voltage and high-power battery systems in electrified aircraft and will focus on the electrical architecture of the Energy Storage System (ESS). This role will have their hands on every step of the ESS development process from conceptual designs, selection of components, and prototype builds, to releasing designs for manufacturing. This role works closely with other battery engineers and system technologists to advance and integrate key technologies into the design. This role also works with DAEs, test engineers, and product integration engineers to ensure a robust ESS is designed, built, and integrated into our eVTOL aircraft.
What you can do:


  • Design electrical architecture for modules and packs of an HV/HP battery system from concept to production
  • Perform analytical and physical assessments on the battery system to ensure the designs adaptability and reliability, as well as to match with requirements
  • Responsible for the selection of electrical parts like HVDC contactors, pyro fuses, current/voltage sensors for ESS at module and system level
  • Design of HV distribution boxes with functions like pre-charging, impedance monitoring, arc protection, short circuit, and overload protection
  • Design of EMI/EMC/Lightening protection strategy for electrical components and wiring systems of ESS
  • Select fuses for different fault discrimination/latency requirements of subsystems like Motor controllers, contactors, wires/busbars considering fault impedances and I2t values of components
  • Develop new and innovative electrical wiring/busbar designs to package ESS systems at module level and pack level
  • Ensure requirement traceability between ESS and other higher and lower-level systems
  • Build and develop component specifications, verification plans, and other technical documents
  • Document and release designs in the PLM system
  • Develop and release module system level requirement specifications, mechanical and electrical drawings for the busbar/wiring designs
  • Simulate power loss, temperature profiles, thermal cycle behavior of wiring, bus bars, and optimize performance
  • Conduct and participate in design reviews, incorporating team feedback, and releasing design documents
  • Develop Validation requirements for Electrical systems in ESS and approve validation results confirming agreed-upon performance
  • Collaborate with battery system technologists and suppliers to develop new electrical design systems to optimize space utilization, eliminate, or reduce common-mode failures and achieve low power loss and weight
  • Work with battery test and validation team on DVP&R activities
  • Conduct prototype builds
  • Other duties as assigned

    What you can contribute:

    • Bachelors degree in electrical engineering or relevant engineering field
    • 5-8 years of experience in electrical system design for high voltage batteries or similar systems in automotive or aerospace industries (an equivalent combination of education and experience may be considered)
    • Experienced with developing HV electrical interconnect design, bus bar design, contactors, fuses selection for HV battery-operated systems from 500 to 1500kW required
    • HV DC circuit design, protection, fault discrimination analysis, protection coordination, and safety aspects using electrical fundamentals as applicable to HV batteries required
    • Experienced in Mechanical CAD tools (CATIA, SOLIDWORK, or similar) used for the design of wiring systems with electrical components required
    • Ability to develop HW to meet Environmental, EMI/EMC, lightning, thermal, shock & vibration
    • Understanding of harmonic and ripple current effects on cabling and protection component derating required
    • Excellent skills required in technical communication, and reliance on data for issue resolution and decision making
    • Working-level understanding of Li-Ion cell characteristics required
    • Hands-on experience in prototype build high voltage battery packs
    • Developing engineering tools/processes to support analysis and design
    • Excellent verbal and written communication skills
    • Proactive delivery of communication and follow up
    • Excellent organizational skills and attention to detail
    • Must have the ability to independently prioritize and accomplish work within time constraints
    • Self-motivated and forward-thinking personality

      You may also be able to contribute:

      • A Masters degree in a related engineering field preferred
      • Experience with HV DC electrical part selection, wiring, and busbar design & release in product launch preferred.
      • Exposure to thermal and mechanical simulation-based design methodologies is preferred.
      • Experience in HV DC wiring design compatible with DO160G a plus
      • Experience with DOEs for performance evaluation and hardware test & validation for HV battery packs
      • Experience with design for mass production
      • May require up to 10% of domestic and international travels

        Any offer of employment is conditioned upon the successful completion of a background check. We are an equal opportunity employer and value diversity at our company. We do not discriminate on the basis of race, religion, color, national origin, citizenship, sex, gender, gender expression, sexual orientation, age, marital status, veteran status, or disability status. Individuals with disabilities may request to be provided reasonable accommodation to participate in the job application or interview process, to perform essential job functions, and to receive other benefits and privileges of employment. Please contact us to request accommodation at:
        This position may include access to certain technology and/or software source code, that will be subject to U.S. export control laws. If an export license or other export control authorization is required in connection with your employment, your employment is contingent upon Supernals receipt of such license or authorization and approvals and your continued compliance with all conditions and limitations contained in such license or authorization.Required
        Preferred
        Job Industries
        • Transportation

Keywords: Supernal, Livermore , Sr. Battery Module Pack Engineer - Electrical, Other , Livermore, California

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