Motor Controller Engineer

Position description:

 The MCU engineer is the technical owner of the motor controller / traction inverter as a component: he/she must define, integrate, verify and release the complete controller - power stage, gate drive, control hardware, motor control algorithms, functional software and calibration - so that the delivered inverter meets the vehicle-level performance, efficiency, thermal, EMC, safety and cost targets over the product life. The role is the single technical point of contact for the component towards the powertrain system team, the vehicle integration team, validation and the supplier. He is fully accountable for the component's requirement compliance, maturity and issue closure at every programme gate.

About TVS / Who are we?

TVS Motor Company is a reputed two and three-wheeler manufacturer globally, championing progress through Sustainable Mobility with four state-of-the-art manufacturing facilities in Hosur, Mysuru and Nalagarh in India and Karawang in Indonesia. Rooted in our 100-year legacy of Trust, Value, and Passion for Customers and Exactness, we take pride in making internationally aspirational products of the highest quality through innovative and sustainable processes. We are the only two-wheeler company to have received the prestigious Deming Prize. Our products lead in their respective categories in the J.D. Power IQS and APEAL surveys. We have been ranked No. 1 Company in /the J.D. Power Customer Service Satisfaction Survey for consecutive four years. Our group company Norton Motorcycles, based in the United Kingdom, is one of the most emotive motorcycle brands in the world. Our subsidiaries in the personal e-mobility space, Swiss E-Mobility Group (SEMG) and EGO Movement have a leading position in the e-bike market in Switzerland. TVS Motor Company endeavours to deliver the most superior customer experience across 80 countries in which we operate.

For more information, please visit www.tvsmotor.com. 

Job Title / Role: Motor Controller engineer

Section: R&D - EV Sys D&D

Location: Hosur

Education Qualification: B.Tech/M.Tech in Electrical, Electronics or Power Electronics (Power Electronics, Electric Drives or Control Systems strongly preferred)

Required Experience:

 10 years in traction inverter / motor controller development, of which at least 3 years owning a controller variant end-to-end from concept through validation to series release.

Role Description

·       "Accountability: End-to-End Technical Ownership of the Motor Controller

Tasks:

- Own the component requirement specification (electrical, functional, thermal, mechanical, EMC, safety, diagnostic) derived from the powertrain system requirements and maintain full traceability.

- Own the component design maturity through concept and series release gates; manage design reviews and drive open-point closure.

- Own the component DFMEA, interface control documents, DVP&R and the release documentation required.

- Act as the single technical interface for the inverter towards the powertrain system, vehicle integration, validation, quality, purchasing and the supplier.

- Creation, updation and maintenance of Design Guidelines and TVS Specification for Motor controllers. "                                                                  

"Accountability: Power Electronics Design and Integration

Tasks:

- Review the internal power stage design: IGBT / SiC MOSFET module selection, switching and conduction loss budget, gate driver design, short-circuit and safe-state protections.

- Specify and verify DC link capacitor sizing, busbar layout, ripple current, creepage/clearance implementations and HV isolation requirements.

- Own the thermal design and derating strategy: create a thermal model correlation, continuous and peak power capability over the operating envelope and digital twin creation.

- Review control board, sensing (current, voltage, temperature, position) accuracy and power supply design; drive design changes with the electronics design and supplier teams."                                                                              

"Accountability: Motor Control Algorithm and Calibration Ownership

Tasks:

- Own the motor control implementation: torque/current control loop, SVPWM, dead-time compensation, MTPA and field-weakening strategies.

- Own position and speed feedback handling (resolver, encoder, hall), sensorless strategoes and limp-home strategies, including plausibility and fault handling.

- Own machine parameter identification, flux/current look-up table generation, efficiency map creation and torque accuracy calibration on dyno.

- Define and validate the torque and power capability curves, derating maps and the controller behaviour at different voltage, thermal and current limits."                                                                           

"Accountability: Validation, Component Dyno and Vehicle-Level Performance Verification

Tasks:

- Define and drive the component validation plan: functional, performance, environmental, mechanical, thermal, electrical and endurance testing.

- Correlate dyno-measured efficiency, torque accuracy, thermal behaviour and derating against simulation and specification, drive corrective actions on deviations.

- Support vehicle-level testing, drive-quality and NVH investigations related to the inverter and the machine-inverter integration.

- Analyse test and field failures, lead root-cause analysis and implement countermeasures."                                                                              

"Accountability: Supplier, Change and Cross-functional Management

Tasks:

- Drive technical evaluation and benchmarking of inverter suppliers and topologies, support sourcing decisions with technical evaluation and analysis.

- Manage supplier technical reviews, deliverable tracking, sample builds, engineering change requests for the component.

- Track and drive component cost, weight and packaging targets (development and VAVE).

- Maintain lessons learned, design guidelines and reusable building blocks for future controller programmes."                                                               

"Accountability: Functional Safety, EMC and Regulatory Compliance

Tasks:

- Derive the component safety requirements from the powertrain safety concept: own the technical safety concept, safe states (active short circuit / freewheeling).

- Own EMC compliance of the inverter: conducted and radiated emission and immunity, filter and shielding definition, and closure of EMC test findings.

- Ensure compliance with applicable regulations and standards for HV electrical safety, insulation resistance, isolation monitoring and IP protection.

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