Rahul Kumar Singh
Pirpainti ,Bhagalpur
Summary
- To enhance my engineering knowledge as a personal interest in the field of electric vehicles, and to serve myself in a reputed organization with the best of my abilities.
- A qualified graduate (Electrical Engineer) with proven experience of 7.5 years in R&D (electric vehicle automotive domain & Enegy Sector).
- Key skills to design and develop high-voltage electric components, PDU (Power Distribution Unit) for electric vehicles, battery disconnect units, sizing of high-voltage circuit protection components, high-voltage cable and bus bar sizing, HV electrical architecture development, troubleshooting and diagnostics of complete electric cars and E-BUS, generating function-level interface and requirements.
- Strong knowledge in powertrain integration and functional testing (electrical integration of electric vehicles).
- Notable knowledge on: design of PDU, VCU I/O module, actuator and sensor logic development, MATLAB and Simulink, and system-level DFMEA.
- Multi-talented Senior Manager well-versed and highly effective at developing, executing and directing key improvements to enable business enhancements and growth.
- Visionary leader with solid success leading business operations toward growth. Skilled Senior Manager skilled in cross-functional collaboration. Optimizes processes and communication and drive results. Dedicated to continuously improving professional knowledge and business operations by applying top-notch skills.
Overview
9
9
years of professional experience
1
1
Certification
Work History
Senior Manager (L5.2) :-HV E&E Design and Power train Integrator
Tata Motors Ltd.
Pune
06.2022 - Current
- Lead engineer for designing High Voltage power distribution unit(PDU) for electric Bus, All SC-EV Vehicle.
- Responsible for component sizing like HV Fuse, HV Contactor, HV Cable Sizing, Bus bar.
- Responsible for designing the HV Battery Disconnect Unit (BDU) like Pre-Charge Circuit, Contactor, Pyro Switch, Temperature Sensor Selection inside battery pack, Shunt for current sensing.
- Writing the requirement of Power Up Sequence/ Power Down/ Charging Sequence of OBC and Fast Charging Sequence of HV Component including the Contactor closing of Battery and MCU controlled from VCU and BMS.
- Designing HVIL Loop for the complete circuit (PWM Signal).
- Design and Release of Complete High Voltage Electrical Architecture of complete Powertrain of all SCEV Platform.
- As new Idea for POC (Proof of concept) vehicle, convinced to Management to delete the PDU from the vehicle and Implemented new Design in Battery and BDU, Deleted HV Fuse and Contactor from our complete HV architecture and Introduce Breaktor (resettable HV Fuse: Circuit Breaker + Contactor).
- Development of VCU with giving the entire requirement to our supplier Bosch, mainly deciding the IO Module for our complete vehicle LV and HV Component.
- Responsible for analyzing the CDS interface document from responsible for VCU IO, Design the power wakeup sequence and lv relay position for working of VCU, Writing the diagnostic requirement for our PDU, BDU and MCU where I am providing the logic for HV Contactor, Relay, Temperature Sensor for the respective component for Application software, Writing Contactor Weld strategies logic for all the HV Contactor.
- Responsible for System level DFMEA of all the Small Commercial Electric Vehicle (SCEV) Project as per AIAG 4th edition 2008 Standard.
- Responsible for sign off of QIB, SIB, Field issue.
- High Voltage Safety training and IR Testing Training of HV System With CFT and FMQ Team.
- Responsible for Lab CAR Development, Hill Testing (VCU Function), and VCU all function testing, DC-DC, OBC, MCU &Motor, BCS Testing.
- Working on building Model for digital validation/ Simulation of High Voltage Architecture for complete vehicle level Architecture so that it's easy to do the real-time fault analysis /Load flow analysis for DC and AC System, also able to measure the accurate size of HV Fuse, Contactor, Bus Bar, HV Cable and life cycle test /Ageing test for the selected component, Run the simulation for 1 day, 15 days, 1 month and analyze the fault or effect due to temperature over current on Respective Drive Cycle, which is used for the power train sizing calculation.
Executive Engineer
Mahindra Electric
Bangalore
12.2021 - 05.2022
- Through Analysis of Design of Battery pack, BMS, BMU, Motor, MCU with design team and supplier.
- Responsible for integration and validation of BMS and high voltage battery pack, EOL Testing of BMU and analysis the data of cell voltage and Leakage Current.
- Wide experience in working on software like CANoe, CAN Analyzer and Bus master and CAN Edge Data logger.
- Wide experience of Building the LABCAR and performing all the function like charging protocol, EOL test of IPDU, VCU, BCM, Motor controller Thermal sensor of battery Pack, Complete trouble shooting and Diagnosis of CAN OBD, Battery Cooling system, charger CCS-2, Logic/Algorithm testing for BCS, Battery pack, Charging and discharging related to BMS and VCU software.
Executive Engineer
JBM Auto Ltd.-(E-BUS)
Faridabad
01.2020 - 12.2021
- Planning and execution of Electric Bus prototyping activity as per Build plan.
- Root cause analysis of proto issues related to battery, BMS and BCS, Validation of CAN based OBD, Study the CAN LOG file to identify the field related issue, VCU function testing in OBD, BMS Software testing and Deep analysis of Battery and BMS function, Interaction with technology partner (Asia Star) to address technical problems.
- Working on External cell balancing for highly imbalance battery pack.
- Wide experience on troubleshooting and diagnostic of complete E-Bus vehicle, Co-ordination with design team for the execution of prototype vehicle.
- Assembly of Electric vehicle system -Battery pack, DC-DC charger, PDU and all HV and LV component, Wide knowledge of Charger protocol (Mainly IEC61851 System c, CCS type charger), HV Cable Rework and preparation, Layout of wiring harness, Electrical system like Li-ion Battery pack, MCU, BMS, ECU, Design related change as per requirement so, It will easy to understand the chassis issues.
- Complete Testing and validation of VMU harness for real-time application for the proto vehicles.
- System/vehicle level build and functional verification of Electric vehicle and prototype vehicles, Fault diagnosis and troubleshooting of high voltage system and low voltage system through CAN trace tools used for electric vehicles, Create process flow chart, SOP required for build and assembly, Use of Fault diagnosis tools like- Peak CAN, KVASER, ODIN TM4, Vector CAN, Software used for Fault diagnosis /CAN Log Data are Bus Master, ODIN TM4(GDD CAN trace file), BMS, BCS, VMU.
Executive Engineer
Olectra Genentech Limited - BYD (E-BUS)
Hyderabad
10.2019 - 01.2020
- Responsible for Proto Build and Power train Integration.
- IR Testing.
- SOP for VECU Software Flashing and IR Testing.
- Responsible for Electrical Function testing.
Executive Engineer
Cygni Energy (IIT Madras)
02.2017 - 09.2019
- Working on Solar Off grid Power Project where we developed 48v off grid Li-ion battery(1kw) Power pack with Non configurable BMS and electrify 20000 household in J&K and other state under Prime Minister REC Scheme.
Education
Bachelor of Technology - Electrical Engineering
KIIT UNIVERSITY
06-2017
HSC -
M.S. College
Bhagalpur, Bihar01.2012
SSC -
High School Barahat
Bhagalpur, Bihar01.2010
Skills
- HV electrical architecture
- Powertrain integration
- Developing a digital simulation platform for HV architecture
- E&E Architecture Development
- MATLAB simulation (1D Simulation)
- VECU I/O interface development
- Solar integrated EV vehicle
- DFMEA
- NPD
- Electrical component sizing for the development of HV battery BDU, PDU
- Lab car development
- Inca
- Vector canoe
- Can analyzer
- Bus master
- Peak can for software testing
- Good knowledge of Li-ion battery pack
- SOC estimation (ECM model) - temperature-based estimation
- Developed NMC_Cell_BMS model for cell testing (charge and discharge model)
- BLDC motor controller unit model development and PID tuning
- Vehicle diagnostics
- Root cause analysis
- Trouble shooting electric systems
- Project management
- Cross-functional collaboration
- Technical documentation
- Team leadership
Languages
- English
- Hindi
Hobbies and Interests
- Reading Books
- Playing Cricket
- Travelling
Projects
Part of XUV 400 Mahindra EV Vehicle as Lab Car developer and Software testing. Mahindra EBMT and S230 Project. State Govt. Project Like: PMPL (1200 Electric Bus), DTC Bus EV Project (1300 EV Vehicle). TATA Coral EV Vehicle. Tata EV Jupiter Vehicle Project. Rolled out 3 major Bus project EVNTPC (Qty.-40), EVAJL (Qty.-50) and EV NMMT (Qty.-36) successfully from production line with proto team support. Worked on 12 Meter Electric bus 100% localization for NMMT project.
Disclaimer
I hereby declare that the above-mentioned information is true to the best of my knowledge.
New Learning Skills
- Good knowledge of LI-ION Battery Pack
- SOC estimation (ECM Model) - temperature Based Estimation
- Developed NMC_Cell_BMS Model for cell testing (Charge and Discharge Model)
- BLDC Motor Controller Unit Model development and PID Tuning
Personal Information
- Emergency Contact: 7782008757
- Emergency Contact: 9534470778
- Date of Birth: 05/26/95
Accomplishments
- Best Employee of the Month Award
- Awarded with best employee for issue resolution, collaboration, meeting target timelines, agility, and project management in FY2025-26(Q1)
Languages
Hindi and Bhojpuri
First Language
English
Upper Intermediate (B2)
B2
Certification
Agility, collaboration, and project management by the Tata Motors leadership team
Member of First Aidf and QRT .
Timeline
Senior Manager (L5.2) :-HV E&E Design and Power train Integrator
Tata Motors Ltd.
06.2022 - Current
Executive Engineer
Mahindra Electric
12.2021 - 05.2022
Executive Engineer
JBM Auto Ltd.-(E-BUS)
01.2020 - 12.2021
Executive Engineer
Olectra Genentech Limited - BYD (E-BUS)
10.2019 - 01.2020
Executive Engineer
Cygni Energy (IIT Madras)
02.2017 - 09.2019
Bachelor of Technology - Electrical Engineering
KIIT UNIVERSITY
HSC -
M.S. College
SSC -
High School Barahat