Summary
Overview
Work History
Education
Skills
Projects
Certifications And Awards
Languages
Timeline
Generic

Sai Manoj Pesala

Bangalore

Summary

Software Engineer with 3+ years of experience in automotive software integration, ePowertrain validation, and testing for electric vehicles and high-voltage systems. Skilled in Python scripting, M Scripting, CAN/LIN communication, and ASPICE-compliant testing. Recognized for driving automation initiatives that improve productivity and contributing to major OEM projects (Ford, Volvo, Mercedes-Benz). Seeking a challenging role to further apply expertise in ePowertrain systems, automotive electronics, and Software Validation

Overview

3
3
years of professional experience

Work History

Software Engineer

BorgWarner
Bengaluru
06.2023 - Current
  • Performed software integration and validation of high-voltage ePowertrain components (coolant heaters, controllers) for leading OEMs (Ford, Volvo, Mercedes-Benz).
  • Executed Software-in-the-Loop (SIL) testing to validate embedded automotive software modules in a simulated environment, ensuring early detection of defects and code stability.
  • Integrated SIL testing with model-based design processes, supporting traceability and requirement coverage in Polarion/ASPICE environments.
  • Designed and executed test cases for diagnostics, communication (CAN/LIN), UDS services, and CPU load testing.
  • Utilized OBD scan tools to analyze Diagnostic Trouble Codes and support troubleshooting during EV validation and integration activities.
  • Developed and executed OBD monitor test plans for ePowertrain components ensuring effective fault detection and compliance with safety standards
  • Conducted regression testing and HIL (Hardware-in-the-Loop) validation to ensure software stability across releases.
  • Collaborated with developers on root cause analysis of ECU failures, accelerating bug resolution.
  • Developed Python automation scripts to optimize test execution and log analysis, cutting manual test time by 20%.
  • Reviewed requirements in Polarion and ensured full ASPICE traceability from requirement → test case → report.
  • Acted as SWE5 Integrator, ensuring smooth integration of multiple software modules into ePowertrain ECUs.
  • Developed and maintained MATLAB M scripts to automate test execution and results analysis for ePowertrain and OBD projects, increasing test efficiency and reproducibility
  • Supported customer deliverables and OEM sign-off, ensuring compliance with safety-critical standards.

Senior Engineer

Greaves Electric Mobility
06.2022 - 06.2023
  • Worked on Battery Pack Calculations, Thermal Runaway Analysis, and Range Estimation for EV applications.
  • Contributed to ePowertrain integration and validation, supporting inverter–motor–battery system-level testing.
  • Designed and validated 2W ePowertrain components by preparing Statements of Requirements (SOR) and supporting supplier evaluations.
  • Assisted in Functional Safety (ISO 26262) analysis for battery and powertrain components.
  • Conducted simulation and modeling of Li-ion cells to optimize range and thermal efficiency.
  • Participated in cross-functional design reviews for EE Architecture, ensuring robust ePowertrain functionality.
  • Gained hands-on exposure to AIS156 standards, BMS validation, and FAME II testing protocols.

Education

M.Tech - Automotive Electronics

VIT
Vellore

B.Tech - Mechanical Engineering

Sathyabama University
Chennai

Skills

  • Python
  • Vector CANoe
  • J-Link
  • Jira
  • SIL Testing
  • SVN
  • Polarion
  • Git
  • Bitbucket
  • CAN
  • LIN
  • UDS
  • STLC
  • ASPICE Standards
  • Matlab/Simulink
  • HIL Testing
  • EPowertrain
  • Powertrain Integration
  • Thermal Runaway Analysis
  • ISO 26262 Functional Safety

Projects

Ford Hanon, Mercedes-Benz EVA2,

Volvo GPA

Developed test cases, performed manual and automated validation, and ensured alignment with SWE 1,2 requirements.

Executed diagnostics and communication testing (CAN/LIN), ensuring robust validation.

Designed CPU load test cases and debugged system performance issues.

Leading validation efforts, focusing on software integration and feature testing.

Certifications And Awards

  • Best Performer of the team (Spark Award) – Q3 2024.
  • Six Sigma Green Belt Certification

Languages

English, Telugu
First Language

Timeline

Software Engineer

BorgWarner
06.2023 - Current

Senior Engineer

Greaves Electric Mobility
06.2022 - 06.2023

M.Tech - Automotive Electronics

VIT

B.Tech - Mechanical Engineering

Sathyabama University

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Sai Manoj Pesala