Sai-Kumar P.
Senior Electrical & Battery Systems Engineer Hv Component Validation High-current Hv Specialist @Zero Motorcycles Inc.
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WORK HISTORY
Senior Electrical & Battery Systems Engineer Hv Component Validation High-current Hv Specialist @Zero Motorcycles Inc.
Scotts Valley, CA, US
HV Component Validation: Taking full ownership of the validation lifecycle for HV battery systems, specifically finalizing the design and reliability of HV contactors (100A–550A break capacity) and pre-charge assemblies.Technical Lead for 3rd-Party Validation: Serving as the SME for external environmental and mechanical testing. I define requirements and perform critical reviews of 3rd-party reports for Vibration (ISO 16750-3), Mechanical Shock, and Thermal Stress, ensuring vendor data meets Zero’s rigorous safety standards.High-Current Path Optimization: Designing and executing in-house electrical characterization tests for busbars and interconnects, focusing on minimizing I^2R losses and localized heating at 500Amps+ peak loads.DFMEA & Design Refinement: Translating lab discoveries into immediate design improvements. Closing the loop between failure mode identification and hardware implementation to ensure production readiness.System Integration & Troubleshooting: Diagnosing complex interactions between BMS logic and HV hardware, ensuring robust operation of the HVIL and safety disconnect systems.
EDUCATION
Bradley University
Masters in electrical engineering, Electronics and computer Engineering
Narayana Junior College
Intermediate, maths, physics, chemistry
New Era High School
SSC, ssc
CMR Institute Of Technology
Bachelor of Technology (B.Tech.), Electrical, Electronics and Communications Engineering
ABOUT SAI-KUMAR P.
With over 12+ years at Bollinger Motors, LG energy solutions and others, contributed to the successful launch of the B4 Class 4 electric truck in September 2024. Led the Vehicle Controls Software Development team, translating complex requirements into scalable control systems and collaborating with multidisciplinary teams to achieve seamless vehicle integration. led teams and contributed towards bug free and quality software delivery.Possessing expertise in requirements engineering, verification, and validation, and Jira, supported innovative vehicle features in a dynamic startup environment and structured OEMs. Aims to continue empowering electric vehicle advancements through efficient control systems and robust software and electrical solutions.
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