Shailesh Bhavsar

An experienced mechanical engineer with 13 years of experience in product design & development in the E-mobility sector. Also, have experience in project management & Vehicle Integration.

• E mobility Li Ion Battery Packs Design & Development
• Battery Energy Storage System Li Ion battery Pack Design & Development
• Product Design Development
• Current Collection Interconnection (Bus Bar) Application Design & Development
• Project Management
• Vehicle Integration
• CATIA V5
• Solid Works
• Creo
• Sheet Metal Design
• Plastic Design

• Passport Number: X9795378
• Date of Birth: 12/21/1981
• Nationality: Indian
• Marital Status: Married

• English
• Hindi
• Marathi

• Calculation for Energy & Power requirement as per Battery pack/Module requirement
• Stacking of Li Ion cell according to series & parallel configuration
• Selection of materials as per functionality requirement of all the components of battery pack/module
• Integration of all aggregate of battery pack. eg Mechanical, Electric, Thermal, BMS (Battery Management System)
• Design and development of all mechanical parts of Battery Pack/Modules
• Design & development of interconnection (Bus Bar)System of Battery Packs/modules (Including Intermediate & Power Bus Bar)
• Components Design & Development (Cell Holder, Main Casing, Top Cover, Bottom Cover, Reinforcement Structure etc)
• Structural Analysis of mechanical components & Thermoelectric Analysis (Bus Bar)
• Design & Development of Thermal cooling system for uniform cooling throughout the Battery Pack/Module
• IP67 Ingress protection for the battery Pack/Module
• Ensure Battery Pack/Module should meet all safety & Regulatory standards
• Integration of BMS, Chogori & Futronic Connector, IOT (Low Voltage Battery Pack)
• Integration of BMS,Main Contactors, fuses, relays, pre charge contactors, LV Connector, HV connector, MSD, Breather (High Voltage Battery Packs)

• Define the project scope and objectives while involving all relevant stakeholders.
• Develop a project plan in detail and track progress accordingly.
• Manage internal resources and third-party vendors to ensure successful project execution.
• Monitor project progress and apply adjustments to ensure successful completion.
• Manage project risks by developing contingency plans as necessary.
• Regularly communicate project status to stakeholders.

High Voltage Battery Packs

Tata Winger Electric Commercial Passenger Vehicle (63 KWh/330 Volts)

9 Meter Electric Bus (50/62 KWh/650 Volt)

(PHEV) Plug in Hybrid Battery Pack for Tata Harrier (14 KWh Capacity/350 Volts)

Low Voltage Battery Module/Packs 

• 48 Volt/38.4 Volt/ (15S1P (20Ah)/12S2P (40Ah) Configuration/A123LFP Pouch cell) - Joint project by TMETC (Tata Motors European Technical Centre) & Tata Motors Ltd.
• 22.4 Volt/ 1.4 KWh Battery (7S4P (60Ah)/ (Client-Ather Energy)
• 48 Volt/ 1.4 KWh Battery (15S2P (30Ah)/ (Client- Reliance Energy Ltd.)
• E-Bike Swappable Battery Pack 3.3 & 2.3 Kwh (72 Volt 45Ah & 30Ah)

Project Management

• Tata Tiago EV (Battery Pack Capacity- Long Range-24 KWh & Mid-Range 19.2 KWh)- High Voltage Components (HV Battery Pack,3in1 Combo (DC-DC Convertor, Power Distribution Unit & On-Board Charger), E Drive (Motor, Gear Box & Motor Controller Unit), High Voltage Cables, Vehicle Electronic Control Unit (VECU))

• Swimming
• Badminton
• Cricket
• Reading