MANOJ KUMAR K

Hosur

Summary

I am an experienced professional specializing in Testing and Validation of EV charging stations and Swappable Li-ion batteries. I have a strong background in ensuring adherence to international standards while executing rigorous testing. My proactive approach and effective communication skills enable me to collaborate efficiently with cross-functional teams to achieve project objectives. I am seeking to leverage my expertise in a dynamic organization within the EV sector.

Overview

years of professional experience

Work History

Hardware Integration Engineer

Exponent Energy pvt ltd

Bangalore

09.2024 - Current

Conducted end-to-end validation and testing of fast-charging stations and battery packs at the vehicle level, ensuring alignment with functional, performance, and safety requirements.
Led the creation of EVT (Engineering Validation Test) and DVT (Design Validation Test) plans based on project timelines for chargers, battery systems, and other related components.
Integrated and tested industrial-grade chargers/rectifiers (e.g. 3kW Delta, 30kW Megmeet, energy meters, thermistors, and motor controllers to ensure reliable operation within EV platforms.
Developed and executed test cases derived from system-level requirements; summarised EVT/DVT results, emphasising critical issues, and potential design risks.
Identified and replicated field failures by implementing innovative test methodologies; contributed to root cause analysis, and corrective action planning.
Performed battery performance tests, including electrical, mechanical, thermal, and integration tests, and compiled clear, data-backed test reports.
Continuously reviewed and improved test procedures, updating test standards, and infrastructure to meet evolving product needs.
Contributed to design validation planning (DVP) with lifecycle considerations, including End-of-Life (EOL) assessments.
Proactively discovered new failure modes in battery pack and charging system designs, feeding back into the design and QA processes to enhance long-term reliability.

Validation Engineer

SUN Mobility Technology Centre

Bangalore

12.2021 - 09.2024

On testing and validating charging stations and swappable Li-ion batteries for EVs.
Led the integration of industrial chargers – 2 kW, 3 kW Delta, and Exicom; HVAC systems; energy meters; tilt switches; and monitoring sensors into battery swapping stations, ensuring seamless operation.
Testing and validation of battery packs: bench level and vehicle level.
DVP preparation as per AIS, IEC, ISO, and UL standards, and sign-off with all stakeholders.
Execution of component and system (battery pack) level testing as per DVP, and preparing the report within the stipulated time.
Conduct the tests based on R&D team requirements, give suggestions for improvements, and submit reports on time.
Capture design failures during the test, and raise concerns with the CFT to find a solution.
Verifying the software logic as per the SOR.
Perform various swap tests in the Manual Quick Interchange charging station.
Product homologation and certification with ARAL.
Maintain 55 in the department.
Operational skills in thermal chambers, pack and cell testers, vibration testers, data loggers, and power analyzers.

Education

Bachelor of Engineering - Mechanical Engineering

Adhiyamaan College of Engineering

Hosur, TN

04-2021

Skills

System integration and validation
Battery pack testing (bench and vehicle level)
EVT, DVT planning and execution
Battery pack testing and analysis
Root cause analysis and failure replication

Software logic verification and SOR validation
Product homologation and certification (ARAI)
Test infrastructure and equipment operation
Cross-functional collaboration and process improvement

Timeline