Varunprabhu R

About Varunprabhu R

Experienced EV Design and System Expert | 17+ Years in Electric Vehicle Engineering As…

Experience

1. Srprg Manager- Xev System Engineering Design Devleopment and Validation

   Bosch Global Software Technologies

   Aug 2016 — Present · Coimbatore, IN

   HV Battery System Test Management: Inverters, eDrive, and eAxle• Leading a testing team of 30 members, managing HV system testing deployment for SYS4 and SYS5.• Provided product release support and project deployment for high-voltage systems.Thermal System Simulation - E-Axle Systems• Model-based system simulation of thermal systems using GT Suite, MATLAB, and Simulink.• Hydraulic dimensioning and lubrication system design.• Executed co-simulations with GT Suite, MATLAB, and ANSYS for system optimization.• Led coolant selection and heat exchanger/chiller unit design for optimal thermal performance.Requirements Engineering & Electrification• Managed vehicle-level system integration and requirement elicitation.• Worked with CAN communication, Canoe, INCA, and SW flashing for system validation.Battery Pack Design & Development• Designed and developed battery packs (40V-600V), focusing on energy capacity, peak power, form factor, and specific energy density.• Selected cells based on chemistry, performance, cost, and safety.• Developed pack/module architecture (central, master-slave configurations).• Designed cell interconnects, resistance welding, and wire bonding.• Implemented thermal management through intercell cooling and bottom plate design.• Spearheaded SOC/SOH, charge/discharge capacitance, and DoD specification.• Led module/pack testing and validation for performance and safety.• Performed structural/thermal analysis (FEA/FEM) and ensured high-voltage safety compliance.• Proficient in PTC Creo 3, GD & T, and experienced in DFMEA, DFA, DFM, QMS, NPD, and ECM.Functional Safety• Implemented safety concepts at the component level based on system safety requirements.• Evaluated and translated safety specifications (FSC to TSR).• Conducted safety analysis (FMEA, FTA, DFA, FMEDA).• Extensive exposure to ISO 26262 functional safety standards.