Headline

Battery Systems Engineer (Li-ion/Flow Batteries) | Railways & Heavy-Duty ESS | Pack Architecture, BMS, Functional Safety

About

Battery Systems Engineer specializing in railway-grade lithium-ion energy storage systems, currently working on 45–70 kWh locomotive battery packs and indigenous BMS development for rolling stock applications. My work spans end-to-end battery system engineering—including pack architecture, thermal design (passive & cold-weather), fault tolerance, isolation strategies, and TRDP/CAN-based BMS firmware and diagnostics, with strict adherence to railway safety and functional reliability standards (IEC 62619, IEC 61508, EN 50155). Previously, I led multi-disciplinary engineering teams developing non-Li-ion electrochemical systems (aluminum-air / flow batteries), scaling products from concept to pilot deployments. This included system-level design ownership, thermal and fluid flow optimization, material strategy, and filing 11+ patents across electrochemistry, thermal management, and power electronics. Earlier in my career, I worked extensively in the UAV domain, focusing on battery standardization, validation, environmental qualification (MIL-STD-810G), and certification under Indian regulatory frameworks (DGCA, BIS, DGQA). I am particularly interested in high-reliability lithium-ion systems for rail, EV, and grid-adjacent applications, where safety, lifecycle performance, and system integration drive engineering decisions. Loves ambiguity, if you have got a problem which needs a description & a solution, you have come to the right profile.

Location

Bengaluru

AI stack

ChatGPT

Work experience

ESS Systems Engineer at Alstom, Oct 2024 - Present · 2 yrs 1 mo, Bengaluru, Karnataka, India, ESS Systems Engineer | Alstom - Led architecture and engineering of 45–70 kWh modular Li-ion battery packs for locomotive and rolling stock applications, optimized for vibration, shock, and serviceability. - Designed rail-compliant thermal systems (passive cooling and cold-weather operation) aligned with long-duty-cycle requirements. - Developed and implemented indigenous Battery Management Systems (BMS) covering hardware, firmware, and diagnostics for large-format Li-ion packs. - Implemented cell monitoring, passive balancing, fault detection, protection logic, and CAN-based communication for system integration. - Owned system-level safety and reliability engineering, ensuring compliance with IEC 62619, IEC 61508, and EN 50155. - Coordinated battery system integration with auxiliary, inverter, and regenerative braking systems. - Defined fault isolation, insulation monitoring, emergency disconnects, and modular service architectures.

Senior Executive Engineer - Industrial Design at Log9 Materials, Dec 2022 - Sep 2024 · 1 yr 10 mos, Bengaluru, Karnataka, India, This role built my foundation in electrochemical system design, thermal behavior, and scale-up—skills directly applied today in Li-ion rail battery safety and architecture. Program lead for Aluminum Air Battery Systems: 1. Built & overseen a 13 member team comprising of Mechanical, Electronics & Chemical Engineers 2. Led design of Mechanical systems with focus on Fluid flow management (corrosive fluids), thermal management systems & manufacturing techniques including injection molding, 3D printing, vacuum casting. Also worked adhesives for highly alkaline environment at high temperatures. 3. Led Cell performance characterization team to get the maximum performances in terms of power & energy densities, improved energy density by 25% by flow optimizations. 4. Developed control algorithms on Low voltage dc power electronics side mimicking MPPT & implemented on commercial dc/dc converters & software first approach 5. Developed Energy Management Systems for Off grid/On grid switching & optimization of Fuel Cell working 6. Development of CAN based master-slave architecture & control systems for Fuel cell operations 7. Built 2.5kW spec units with Parallel current sharing architecture implementing Modular design 8. Developed novel injection molding methods to actively scale production & mold membrane like structures by material & process optimizations 9. Worked on strategizing material design for Aluminum Alloys, alloy treatment & their supply chain optimization for production 10. Built a team around developing digital twin with CNN (Convoluted Neural Networks) to predict performance & identity heat management due to side reactions. 11. Helped with techno-commercial analysis, scaled up cost & models for revenue using the fuel cell 12. Actively designed pilots & took part in raising funds for their deployments.

Executive Engineer - Industrial Design at Log9 Materials, Oct 2021 - Dec 2022 · 1 yr 3 mos, Bengaluru, Karnataka, India, Technical Lead for Battery Thermals LFP Chemistry (LiFePO4): 1. Team & Capacity building for enabling fast charging using Thermal Mgmt.. 2. Understanding heat generation in various charge/discharge conditions at various C rates. 3. Design test conditions by incorporating heat generation due to capacitance residual by modelling the battery on DCIR modelling 4. Selection of battery thermal management components such as compressors, pumps and other assembly components 5. Design of cold plate, selection of commercially available cold plates for battery pack designs 6. Understanding Heat Generation at Cell level & its implications in various environmental conditions 7. Thermal Management Solutions for both Passive & Active Systems

Engineer - Mechanical Systems at ideaForge, Apr 2018 - Oct 2021 · 3 yrs 7 mos, Mumbai, Maharashtra, India, - System-Level Engineering reviews of Unmanned Aerial Vehicles and associated Hardware. - Li-Ion Battery standardization, technology validation, integration challenges & Lab certifications. - Hardware Development for conceptual UAVs. - UAV public policy review & technical standardization lead for the organization. - Design of experiments, prototype validations & subsystem level testing for UAVs as per MIL-STD-810g - Lead technology for UAV fleet management & tracking using IIoT managing a team of 2 Engineers. - Data analytics tool development using excel, gsuite, and dashboards for visibility of process & technologies.

Engineer - Mechanical Design at ideaForge, Aug 2016 - Mar 2018 · 1 yr 8 mos, Mumbai Area, India, - Lead Platform development for Tethered UAV systems - Research and Development in the design of Unmanned Aerial Vehicles - Reverse Engineering and maximum utilization of current systems in place - Lead Aerodynamics Simulations (Shape and Form Drag Analysis) and Finite Elements Analysis (static & Dynamic) - Standardization of designs & drawings using GD&T principles - Team Member to determine the Enterprise Resource Planning Solution for the company

Product Support Engineer Design R&D at ideaForge, Sep 2015 - Aug 2016 · 1 yr, Navi Mumbai, - Design support on the existing products & testing. - Manufacturing process & time optimisation - Vendor development & shortlisting

Education

Battery Market Understanding, BESS, BatteryMBA

Business Administration and Management, General, Stoa