Senior Principal Hardware Engineer- BMS

Senior Principal Hardware Engineer – BMS

Regular Full-Time Lake Orion, MI, US

2 days ago Requisition

The Senior Principal Hardware Engineer – Battery Management Systems (BMS) is the company’s top technical authority in the design, development, and validation of hardware used in high-voltage (HV) automotive battery monitoring. This role drives the definition and implementation of advanced measurement, sensing, and protection electronics used in modern lithium-ion battery packs.

The Senior Principal Hardware Engineer - BMS provides deep domain expertise in high-voltage measurement architecture, cell and pack monitoring circuits, functional safety design, and the hardware aspects of American Battery Solutions ("ABS") product design. This position influences product strategy, leads key technical decisions, mentors engineering teams, and ensures ABS battery monitoring hardware meets world-class standards for safety, reliability, and performance.

• Serve as the company’s subject matter expert for hardware in high-voltage automotive battery systems.
• Define system-level and hardware-level architectures for voltage sensing, current measurement, isolation monitoring, temperature monitoring, and pack-level diagnostics.
• Lead the development of high-voltage measurement circuits.
• Establish best-in-class design methodologies for sensing accuracy, noise mitigation, EMC (Electromagnetic Compatibility) robustness, and functional safety compliance.
• Drive detailed circuit design for all BMS monitoring hardware, including HV measurement networks, isolation devices, ADC (Analog to Digital Converter) interfaces, measurement ASICs (Application Specific Integrated Circuit)/AFEs (Analog Front End), balancing elements, and protection circuits.
• Select components, create schematics, and collaborate with PCB (Printed Circuit Board) designers to implement robust high-voltage designs appropriate for harsh automotive environments.
• Develop and validate signal-conditioning circuits to support precise measurement of voltage, current, temperature, and insulation resistance.
• Build, test, and characterize prototypes, ensuring designs meet performance, accuracy, reliability, and safety requirements.
• Ensure monitoring hardware meets ISO 26262 (International Organization for Standardization), UL (Underwriters Laboratories), IEC (International Electrical Commission), and OEM (Original Equipment Manufacturer) safety requirements.
• Lead hardware safety analyses including FMEDA (Failure Modes, Effects, and Diagnostic Analysis), DFMEA (Design Failure Mode and Effects Analysis), WCCA (Worst Case Circuit Analysis), and fault-injection test planning.
• Define safety goals and technical safety requirements related to battery monitoring functions.
• Work closely with systems engineering, software engineering, test engineering, manufacturing, and program management to ensure seamless integration of monitoring hardware into ABS battery systems.
• Support customer discussions and technical reviews as the primary expert for battery monitoring subsystems.
• Provide technical guidance for supplier selection and hardware strategy.
• Produce clear documentation including electrical specifications, architecture diagrams, design reviews, test plans, and technical reports.
• Lead root-cause analysis and resolution of hardware issues across product programs.
• Stay current on emerging technologies, new measurement techniques, and industry best practices in battery monitoring and automotive HV systems.
• Mentor junior engineers and provide technical leadership across BMS team.
• Adhere to federal and state regulations.
• Adhere to all company policies, processes, and procedures.
• Performs other duties as requested, directed, or assigned.
• Predictable and reliable attendance.

• Bachelor’s degree in Electrical Engineering or related field required.
• Minimum twelve (12) years of experience in automotive or high-voltage hardware development.
• Expert‑level knowledge of analog/digital circuit design, ADC‑based measurement circuits, and high‑voltage sensing techniques.
• Strong understanding of automotive safety standards (ISO 26262), EMC/EMI requirements, and…