BHARAT SANJAY JAWLE

Battery Digital Twin (TPEML-BDT-PV) & (TML-BDT-CV):

• Led development of high-fidelity electrochemical/physics-based cell models for 332.8V/120Ah/40kWh HV-PV and 365V/150Ah/55kWh HV-CV battery packs using SPM method.
• Built SoH prediction models (SEI growth, Li-plating) capturing cyclic & calendric ageing, validated against cell lab, and field data.
• Developed thermal model (energy balance, reversible/irreversible heat sources) and predicted continuous SoP under real-world operating conditions.
• Included Cell-to-Cell variation in the parallel connected cells using current distribution.
• Implemented hybrid fault diagnostic/prognostic method for underperforming cells using electrochemical & BMS data.
• Old vehicle initialization using Coulomb Counting–based Capacity Estimation during charging profile.
• Designed and executed cell test plans (characterization, cycle life, calendric ageing, durability, and field data), analyzed results, and validated model accuracy for voltage, temperature, and SoH.
• Integrated models into MATLAB FMUs within a Python-based BDT framework, enabling cloud monitoring, predictive analysis, and warranty tracking.

Model Base Design (MBD)- ADAS Testing

• Performed ADAS SIL testing for Renault-Nissan passenger vehicles: modified Simulink models, executed test cases in MATLAB, and generated acceptance reports.
• Investigated failed signals against tolerance, performed back-to-back tracing using TPT, and provided corrective actions/design correction reports.
• Automated test execution and reporting with custom MATLAB m-scripts.

• Design and benchmarking battery pack for 2W/3W application
• Developed Simulink plant models for 2W/3W battery packs and traction motors, validated simulation results against real-world road data.
• Performed complete pack benchmarking through field testing and teardown analysis (cell chemistry, casing, thermal/BMS design, form factor).
• Supported cell chemistry and supplier selection for 2W/3W applications; created ECM-based cell and pack models to assess range across load profiles.

• Battery Performance and Life Improvement – VIT ARC Lab
• Developed and validated ECM-based models for NMC cells (3.7V/31Ah) and extended to a Chevrolet Volt Gen-2 pack (360V/18.4kWh, 7 modules) with liquid cooling.
• Designed thermal estimation models (ohmic heating + convective cooling) and a BMS protection circuit in Simulink for current, voltage, and temperature control.
• Implemented SoC estimation (Coulomb Counting + OCV initialization) and passive balancing, enabling weak cell identification via IR estimation.

• Supported automated rack & pinion assembly line: diagnosed rejected products, performed root cause analysis, and recommended design/jig-fixture improvements.
• Contributed to steering system development (rack & pinion, bevel gears, radial piston pumps, EPS/HPS) for OEMs including Tata Motors, Bajaj, Volvo Eicher, and Piaggio.
• Developed MATLAB/Simulink–based models (hydraulic/electric power steering, steer-by-wire) under dynamic vehicle conditions.

• Co-founded and led the team to design and manufacture a Formula Student car for SAE BAJA, SUPRA SAEINDIA, and FSI competitions, ensuring compliance with safety and rulebook standards.
• Designed and developed lightweight steering, braking, and suspension systems with focus on performance and efficiency.
• Managed a 15-member team, overseeing task distribution, sponsorship acquisition, procurement, and manufacturing processes.
• Introduced innovative design concepts, supervised machining, and ensured timely project execution with proper documentation.