Summary
Overview
Work History
Education
Skills
Timeline
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MANOJ KUMAR K

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

4
4
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

Hardware Integration Engineer

Exponent Energy pvt ltd
09.2024 - Current

Validation Engineer

SUN Mobility Technology Centre
12.2021 - 09.2024

Bachelor of Engineering - Mechanical Engineering

Adhiyamaan College of Engineering

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