Inverter Design Validation Lead

Our Story

Blue Star is India's leading Heating, Ventilation, Air conditioning and Commercial Refrigeration (HVAC&R) Company with modern manufacturing facilities including the new state-of-the-art deep freezer facility at Wada, and Blue Star Climatech Limited’s world-class facility at Sri City; 3132 employees, and 4040 channel partners. The Company has manufacturing facilities at Dadra, Himachal Pradesh, Wada and Ahmedabad, which use modern, state-of-the-art manufacturing equipment to ensure that the products have consistent quality and reliability. The Company has a manufacturing footprint of more than 1 lakh sq m, with the mainstay of product development and R&D being energy-efficiency, coupled with eco-friendly and sustainable products

What Your Role Entails

The Hardware Design Lead will be responsible for leading the design, development, and validation of inverter hardware for air-conditioning and heat pump products. This role requires deep expertise in power electronics, inverter topologies, component selection, and system-level integration with compressor drives. The individual will guide a team of hardware engineers, work closely with firmware, mechanical, and system engineering teams, and ensure timely execution of projects with high reliability, safety, and performance.

What You’ll Do:

Inverter Hardware Design & Documentation

• Complete hardware design for inverter PFC, power stage, sensing circuits and protection modules.
• Release of design documents: schematics, BOM, PCB guidelines, DFMEA, derating calculations and design justifications.

Prototype Development & Design Maturity

• Deliver hardware prototypes (EVT/DVT/PVT) as per project milestones.
• Ensure first-pass success with minimal design revisions.

Validation Planning & Execution

• Develop detailed inverter hardware validation plans: thermal, EMI/EMC, surge, ESD, EFT, reliability, stress tests.
• Lead validation execution and release of complete test reports with compliance status.

Reliability & Safety Compliance

• Ensure inverter meets internal reliability standards and field conditions (temperature, load, surge, moisture).
• Achieve compliance with IEC, BIS, UL and EMI/EMC norms.

Root Cause Analysis & Issue Resolution

• Complete RCA and corrective actions for design issues during testing, certification and field operation.
• Document and close all hardware-related NCRs, CAPAs and field failure cases.

Supplier & Component Qualification

• Evaluate, test and approve key components: IPM/IGBT/MOSFET, gate drivers, sensors, capacitors, magnetics.
• Release component qualification reports and approval notes.

Manufacturing Readiness (DFM/DFT)

• Provide DFM/DFT guidelines to EMS vendors.
• Support pilot builds, resolve production-related hardware issues and ensure stable mass production.

Cross-Functional Technical Support

• Support firmware, system engineering, mechanical, testing and quality teams during development.
• Provide technical guidance to service/field reliability teams for inverter-related issues.

Cost Optimisation & Design Improvements

• Drive cost reduction through component optimisation, design simplification and supplier bench marking.
• Deliver annual improvement projects on efficiency, reliability and thermal performance.

Team Leadership & Capability Building

• Lead and mentor hardware engineers.
• Conduct design reviews, knowledge-sharing and technical training sessions.

Your success is grounded in

• B.Tech/M.Tech in Electronics/Electrical Eng with minimum 15 years of experience.
• Strong knowledge of inverter topologies

  (

  single-phase, three-phase, PFC, active PFC, DC–DC converters).
• Expertise in IGBT/MOSFET/IPM-based power stages

  ,

  gate driver design, dead-time management, protection circuits.
• Understanding

  of

  PMSM/BLDC motor control requirements, compressor load behaviour, and torque-speed characteristics.
• Experience with DC-link design, inrush control, busbar design, snubbers, and power device thermal derating.
• firmware teams to define hardware-software interfaces, including ADC/DAC ranges, digital IO behaviour, and communication protocols (RS485, CAN, Wi-Fi, BLE, etc.). Perform system-level debugging during development and field issues.
• Hands-on experience in EMI/EMC design techniques: filtering, shielding, common-mode control, differential noise reduction.
• Knowledge of compliance standards: IEC 60335, IEC 61000 series, BIS, UL, safety and performance requirements.
• Experience with pre-compliance and full-compliance testing (conducted/radiated emissions, immunity, surge, ESD, EFT).
• Good understanding of interaction between hardware, firmware and system control.
• Strong knowledge of gate driver tuning, soft start, protection logic (over current, over-voltage, thermal, phase loss).
• Understanding of compressor drive requirements, modulation strategies, and system-level protections.
• Familiarity with communication interfaces (CAN, RS485, UART) used in HVAC systems.
• Expertise in running validation tests such as: Thermal cycling , Power cycling , HALT/HASS, Burn-in testing, Surge/ESD/EFT. Durability & stress tests.
• Proficiency in debugging using oscilloscopes, power analyzers, logic analyzers, isolation probes, DLRO etc.
• Strong skills in RCA (Root Cause Analysis), reliability engineering, and component failure analysis.

randdrecruiter@bluestarindia.com

Where you’ll be

This role is based in Hinjawadi, Pune but initial few months the role will be based in Kapurbawdi, Thane.

At Blue Star, you are not just another employee; you're part of a vibrant community that values innovation, dedication, and teamwork. We believe in investing in our people and providing opportunities for professional growth and development. You’ll be empowered to take ownership of your role and make a difference in the lives of our customers and colleagues. If you’re ready to take on this exciting challenge and make a real impact, we would love to hear from you!