Senior BMS Hardware Design Engineer

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Regular Full-Time Lake Orion, MI, US

3 days ago Requisition

Job Summary:

The Senior BMS Hardware Design Engineer leads the design, development, integration, and validation of Battery Management System (BMS) hardware for advanced energy storage and electrification applications. This role owns technical direction and design decisions for assigned BMS programs, spanning requirements definition and architecture through schematic design, PCB layout, hardware bring-up, bench and system‑level validation, and production release. The Senior Engineer serves as a technical authority on lithium‑ion battery pack electronics, resolves complex system‑level failures, and drives design maturity to ensure safe, efficient, and reliable operation.

This role partners closely with embedded software, systems, cell, manufacturing, and test engineering teams, mentors engineers, and establishes design standards and best practices across the BMS group.

Responsibilities:

• Own the design and architecture of BMS hardware, including cell sensing, protection, control, and interface circuitry.
• Develop, review, approve, and release electrical schematics, component selections, and electrical interfaces for battery packs.
• Lead Printed Circuit Board (PCB) layout reviews and board‑level hardware bring‑up, including initial power‑on, electrical measurements, debugging, and rework.
• Direct the integration of BMS hardware with battery cells, contractors, sensors, and pack‑level components.
• Define and document BMS hardware requirements, design specifications, and interface control documents in coordination with systems engineering.
• Conduct design risk assessments, including Design Failure Mode and Effects Analysis (DFMEA), tolerance stack‑up, and worst‑case circuit analysis.
• Evaluate component technologies and serve as technical lead in supplier design reviews and component selection decisions.
• Define and execute the BMS hardware validation strategy, including functional verification, protection feature testing, and fault‑injection testing.
• Develop, review, and approve electrical and functional test plans, acceptance criteria, and requirements traceability to verify BMS performance.
• Perform signal integrity, power integrity, and noise immunity evaluations.
• Direct environmental, endurance, abuse, and fault‑case testing, and interpret results to drive design decisions.
• Lead root‑cause analysis and failure analysis of complex BMS hardware, interface, and pack‑level issues, and drive corrective actions through validation and closure.
• Diagnose and resolve interface issues between embedded software and BMS hardware, including Analog‑to‑Digital Converter (ADC), Serial Peripheral Interface (SPI), Inter‑Integrated Circuit (I2C), Controller Area Network (CAN), and General Purpose Input/Output (GPIO) interfaces.
• Partner with embedded software teams to lead hardware bring‑up and system‑level debug activities.
• Support development, tuning, and validation of State of Charge (SOC), State of Health (SOH), and State of Power (SOP) algorithms, and correlate model predictions with bench, system, and field test data using MATLAB/Simulink.
• Maintain complete technical records that capture design decisions, test results, validation evidence, and lessons learned for production release and future development.
• Lead cross‑functional technical reviews, align engineering teams on design decisions and dependencies, and remove barriers affecting BMS program execution.
• Serve as the technical escalation point for production, manufacturing, and field issue investigations.
• Mentor and provide…