Senior Staff Engineer-Battery

Mechanical Engineering Austin, Texas


Description

 

Role Title

Sr. Staff Engineer - Battery

Function

Mechanical Engg

Reports To

Director - Mechanical

Location

Austin/TX

 

Mission (Why does this role exist?) and Scope (About the Job)

 You will be a Subject Matter Expert (SME) in the field of Battery Energy Storage System (BESS) involving LFP Cells and Cell module, managing the thermal and structural design of the Cell pack. You will work with a global cross functional team of Engineers who design and develop state-of-the-art Energy Management solutions.

Key Responsibilities and Outcomes (What the Person needs to accomplish in the role ?)

 Thermal runaway is one of the prime concerns for the commercialization of Li-ion battery packs and Energy Storage Systems (ESS).  This requires a well-known and accurate modeling approach and testing experience. The key responsibilities include

  • Analyzing thermal Runaway and improving Battery Pack Designs with Simulation.
  • UL9540A standard understanding and test method experience in ESS product test for wall and Ground mount products.
  • Experience in thermal Management of BESS is desired.
  • Expert in simulation using commercial software to predict Electrochemical reaction and system level thermal runaway simulation to identify solutions to challenging problems.
  • Architecture of Thermo-Mechanical and structural design of the Cell pack from concept to final design.
  • Experience in development of module and/or packs for outdoor application which meets various Ingress Protection (IP) ratings.
  • Sound knowledge in product standards like IEC, UL & NEMA standards for different countries.
  • Sound knowledge of UN38.3 packaging and shipping tests and standards
  • Excellent knowledge in mechanical design standards for various products & experience in DFMEA analysis for new product development.
  • Responsible for the development of thermal and structural design solutions and working with component suppliers of Cells, cell modules, heatsink, fan, thermal pad, etc.
  • Experience in interaction with UL and other labs (such as TUV) for conducting various experiments and tests related to Cells, modules and battery pack enclosure designs for product validation.
  • Should coordinate with UL and other test houses for test set-up preparation, verification, and approval.
  • Should have thorough knowledge of preparing test plans for validation of the solution.
  • Perform risk analysis and identified fire risk mitigation techniques for Energy Storage Systems.
  • Product qualification testing in environmentally controlled chamber following industry standards/specifications.
  • Experienced working with global development and cross-functional teams.
  • Complete documentation for simulation design, analysis, and experiment/testing results.
  • Able to guide and mentor team members.
  • Coordinate/Carry out product compliance testing as per UL and IEC standards.
  • Provide technical assistance to design team in reference to product construction review and approvals from test lab.
  • Prepare project status and report results for Energy Storage Systems performance testing.
  • Working experience in DFM/DFA in the context mass production set-up and production tooling, such as press tools/stamping, injection molding, die casting.
  • Working knowledge of material selection and UL compliance materials related plastics, metal, elastomers, etc. 
  • Minimum Requirements: 
  • Expert in Analysis Tools – Flotherm, Icepack, ANSYS Workbench, COMSOL Physics, STARCCM+, SolidWorks Flow simulation, ANSYS Fluent, MSC Nastran.
  • Ability to think laterally and solve unique.
  • Investigate, analyze, and resolve product.
  • Experienced with experimental techniques and methods using flow measurement. devices, thermocouples, flow and thermal visualization tools.
  • Good communication and documentation.

Qualifications: Education, Competencies (Knowledge, Skills & Behavior) and Experience

Minimum Qualifications: 
  • Technical Degree (Bachelor or higher qualification) in Mechanical/Electrical
  • 12+ years of experience in product development of BESS Cells, module and Cellpack design.
What would make you stand out? 
  • UL9540A standard understanding and test method experience in ESS product test for wall and Ground mount products.
  • Experience in different Battery chemistry (LFP, NMC or other Chemistry) design, development, testing, life prediction and performance degradation analysis etc.
  • Experience of Thermal and Structural Mechanical design from concept to final product.
  • Experience and thorough knowledge of preparing test plans for validation of the analysis solution.
  • Experience using Flotherm, Icepack, ANSYS Workbench, COMSOL Physics, STARCCM+, SolidWorks Flow simulation, ANSYS Fluent, MSC Nastran. Experience completing FEA (structural and thermal)
  • Experience project managing mechanical product development
  • Experience of working with global development and cross functional teams.
  • Member of Standing Committees of Regulatory bodies (UL etc.) that define and decide the evolution of applicable standards for BESS.
  • Experience in a variety of Battery chemistry (LFP, NMC or other Chemistry) design, development, testing, life prediction and performance degradation analysis would be a nice to have skillset.