Role & Responsibilities:
- Perform Electrical and coupled electro-thermal simulations using CAE tools like Ansys electronic enterprise (AEDT) (Maxwell, Icepak etc and Ansys mechanical enterprise).
- Minimum 3 years of hands-on experience in electrical simulation and validation of automotive electrical and electronic systems.
- Conduct
voltage drop analysis, over-current and Insulation resistance simulations
for wiring harnesses, connectors, busbars, terminals, fuse boxes, and power distribution systems to ensure electrical performance requirements. - Analyse
electrical resistance characteristics
, including conductor resistance, contact resistance simulations and assessments to ensure electrical isolation, leakage current control, and safety compliance in low-voltage and high-voltage systems. - Validate simulation results through physical testing and correlate findings.
- Ensure compliance with automotive and industry standards such as
ISO 16750, LV 124, LV 148, IEC 60664, IEC 60512, ISO 6469, UL standards, and OEM-specific electrical requirements
. - Document simulation methodologies, results, and design recommendations.
- Support root cause analysis of Electrical test failures and propose corrective actions.
- Carry out
temperature rise and thermal distribution analysis
caused by current loading, contact resistance, ambient conditions, and power dissipation. - Strong Verbal and written communication.
Should be willing to travel outside India for short and long duration.
- Perform detailed electrical and coupled electro-thermal simulations to optimize product performance, electrical safety, thermal reliability and design robustness for automotive power-distribution, charging and electronic products.
- Understanding of customer requirement, circuit architecture, rated voltage/current, duty cycle, ambient conditions, material properties, test methods and acceptance criteria into documented CAE load cases and boundary conditions.
- Proficiency to perform pre-processing of model such as design operations, material assignment, contact/interface definition, mesh generation, local mesh refinement and mesh-independence checks.
- Perform voltage-drop and resistance analysis at component, interface and assembly level. Quantify terminal-to-terminal voltage drop, equivalent resistance, current density and localized power loss.
- Perform steady-state and transient over-current analysis using specified current-time profiles. Assess conductor, busbar, terminal, fuse and PCB temperature rise, IR loss, It energy, overload duration, thermal capacity and recovery after the event.
Correlate simulation results with physical tests including contact resistance, insulation resistance, dielectric withstand, temperature rise, continuous-current and over-current tests.
