Job Purpose (Significance of the role & Objectives)
As a Testing and Validation Engineer, you will be responsible for planning, executing, and analyzing validation activities to ensure the performance, safety, durability, and compliance of electric vehicles. This role demands hands-on expertise in vehicle testing, a solid understanding of EV systems, and cross-functional collaboration with design, homologation, and quality teams.
Key Responsibilities and Deliverables
- Perform extensive DFMEA with respective design and development teams, and subsequently prepare DVPs.
- Work directly with design engineers to create design validation test plans as per DVPs.
- Develop and perform functionality, performance, safety and reliability tests for electric vehicle technologies with fellow design and test engineers, including but not limited to vehicle Traction battery, Traction motors, electronic components and systems like DC-DC converter, Cluster, Infotainment, On-board Charger, pumps, valves etc. catering to different R&D applications.
- Perform system and vehicle level validation for designated test cycles, under dynamic and environmental conditions – to replicate actual real-world conditions to validate the vehicle as a whole.
- Review test scenarios, issues, root cause analysis, MiL, SiL and HiL tests from testing of other subsystems and overlook testing plans.
- Work with design and development engineers to validate and refine models/algorithms, and document the issues observed during testing.
- Analyze test data, investigate root cause of failures, communicate test results, write and review test reports and collaborate with design and development engineers to drive product improvement.
- Ability to collaborate cross-functionally with design and development engineers and manufacturing engineers to suggest design and/or process improvements.
- Support in system/vehicle level certification as per Industry Standards.
- Procure and develop required test equipment, instrumentation, and data acquisition systems to enhance creative component and product level testing.
- Ensure validation activities meet program timelines, budgets, and quality standards.
- Continuously monitor industry trends and new validation methodologies, especially in EV technologies.
Desired Qualifications: Required Qualification, Knowledge, and Experience
- Bachelor’s or Master’s degree in Mechanical, Electrical, Automotive, or related engineering fields.
- 2+ years of hands-on experience in design validation, hardware testing and analysis of mechanical, thermal, electrical and electronic systems for 2W / 4W Electric Vehicles
- Prior knowledge and experience in development and execution of DVP&R, DFMEA.
- Hands-on knowledge of EV Powertrain systems, Battery systems, BMS, Thermal systems, Electrical & Electronics systems and Vehicle Dynamics.
- Automotive component/system testing experience, including certification testing. Preferred knowledge of respective certification/homologation tests
- Experience creating and executing design validation plans and test methods to validate performance requirements; And reviewing test reports, escalation of issues
- Experience specifying sensors for test instrumentation and utilizing data acquisition systems
- Strong problem-solving and analytical skills.
- Ability to work in cross-functional teams and manage multiple projects.
- Willingness to travel for testing at different locations.
- Excellent written and verbal communication as well as organization and documentation skills.
Key Competencies
- Must Have - Experience in Electric 2W & 4W Vehicles, Systems and Components.
- Must Have - Familiarity with testing standards and regulations for EVs (AIS, IS, IEC, ISO, GTR etc.).
- Must Have - Proficient in using data acquisition systems, CAN tools (e.g., Vector, ETAS), and analysis software.
- Must Have - Experience in development and execution of DFMEA and DVP&R.
- Must Have – Experience of common automotive communication protocols (CAN, Ethernet).
- Good to Have - Experience with Matlab, Python scripting.
- Good to Have - Knowledge and experience in ISO 26262 Functional Safety.
