Senior BMS Hardware Design Engineer

American Battery Solutions • Lake Orion, MI

14h • Onsite

About The Position

The Senior BMS Hardware Design Engineer leads the design, development, integration, and validation of Battery Management System (BMS) hardware for energy storage and electrification applications. The role owns technical direction and design decisions for assigned programs, from requirements definition and architecture through schematic design, PCB layout, hardware bring-up, validation, and production release. The 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. The role collaborates with embedded software, systems, cell, manufacturing, and test engineering teams; mentors engineers; and establishes BMS design standards and best practices.

The position is based at American Battery Solutions’ headquarters and Innovation Center in Orion Township, Michigan. It regularly involves laboratory, test, and industrial environments in addition to an office setting, including work on or near energized high-voltage battery systems. Travel averages less than 10%, and flexible hours may be needed.

American Battery Solutions manufactures advanced batteries for commercial, fleet, and industrial on- and off-road vehicles. Acquired by Komatsu in 2023, ABS continues to operate as an independent entity while serving Komatsu applications and expanding its commercial, fleet, and industrial business.

Requirements

• Master’s degree in Electrical Engineering or a related engineering discipline, or a bachelor’s degree and two years of equivalent experience in BMS, battery systems, embedded hardware, or power electronics.
• At least five years of engineering experience in BMS, battery systems, embedded hardware, or power electronics, or equivalent experience.
• Hands-on experience leading schematic design, hardware bring-up, and electrical debugging.
• Experience designing high-voltage and low-voltage battery systems and their communication interfaces.
• Experience taking BMS or comparable electronic hardware from concept through production release.
• Experience leading BMS validation testing, fault-case analysis, and safety mechanism verification.
• Proficiency with PCB design tools such as Altium, KiCad, or equivalent.
• Experience in automotive, commercial vehicle, energy storage, or industrial electrification applications.
• Familiarity with SOC estimation methods such as Coulomb counting, OCV correlation, and observer-based or Kalman filter techniques.
• Working knowledge of functional safety and battery safety standards such as ISO 26262, UL 2580, UL 1973, or UN 38.3.
• Strong working knowledge of embedded interfaces including CAN, SPI, I2C, UART, and ADCs.
• Proficiency using MATLAB/Simulink for modeling, algorithm support, and data analysis.
• Proficiency with Microsoft Office tools, including Word, Excel, and PowerPoint.
• Ability to travel and work flexible hours as needed; travel averages less than 10%.
• Ability to follow high-voltage safety procedures and wear required personal protective equipment when working on or near energized high-voltage battery systems.

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 PCB layout reviews and board-level hardware bring-up, including initial power-on, electrical measurements, debugging, and rework.
• Direct integration of BMS hardware with battery cells, contactors, sensors, and pack-level components.
• Define and document BMS hardware requirements, design specifications, and interface control documents with systems engineering.
• Conduct design risk assessments, including DFMEA, tolerance stack-up, and worst-case circuit analysis.
• Evaluate component technologies and lead supplier design reviews and component selection decisions.
• Define and execute BMS hardware validation strategies, including functional verification, protection feature testing, and fault-injection testing.
• Develop, review, and approve electrical and functional test plans, acceptance criteria, and requirements traceability.
• Perform signal integrity, power integrity, and noise immunity evaluations.
• Direct environmental, endurance, abuse, and fault-case testing, and interpret results to guide design decisions.
• Lead root-cause and failure analysis of complex BMS hardware, interface, and pack-level issues, and drive corrective actions through validation and closure.
• Diagnose and resolve embedded software and BMS hardware interface issues, including ADC, SPI, I2C, CAN, and GPIO interfaces.
• Partner with embedded software teams to lead hardware bring-up and system-level debugging.
• Support development, tuning, and validation of SOC, SOH, and SOP algorithms, and correlate model predictions with bench, system, and field test data using MATLAB/Simulink.
• Maintain technical records of 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 to program execution.
• Serve as the technical escalation point for production, manufacturing, and field issue investigations.
• Mentor and provide technical guidance to engineers through design review feedback and technical skills development.
• Establish and continuously improve BMS design standards, engineering processes, and best practices.
• Present technical status, design trade-offs, and recommendations to engineering leadership, program teams, and customers.
• Adhere to federal and state regulations and company policies, processes, and procedures.
• Perform other duties as requested, directed, or assigned, and maintain predictable and reliable attendance.

Benefits

• Comprehensive benefit plans described as 100% employer-paid for employees and their family.
• Competitive salary and retirement program.
• Paid time off including three weeks of vacation, up to 72 hours of sick time, 15 holidays, and parental leave.
• Company-paid medical, dental, vision, short-term disability, long-term disability, and life insurance.
• Flexible Spending Account and Health Savings Account offerings.
• Company-provided 401(k) savings plan with immediately vested matching contributions.
• Voluntary benefits offerings.
• Tuition assistance.
• Employee Referral Program.
• Employee development and career growth opportunities.

What This Job Offers

• Job Type: Full-time
• Career Level: Senior