Drivetrain Integration Engineer

Role Summary - Lead the design, analysis, and validation of e-transmissions (single-speed and multi-speed) optimized for 3-wheeler cargo, LCV, and passenger EV applications. Main focus on architecture development, load case derivation based on real-world duty cycles, microgeometry optimization, durability/NVH compliance, and seamless integration with high-speed PMSM/ Induction motors.

Roles and Responsibilities - 

• Define gearbox architecture (parallel axis, coaxial, dual-stage reduction) based on vehicle performance targets and shifting concepts (synchronizer/dog clutch).
• Optimize gear macro and micro geometry using Romax/Kisssoft with LTCA, gear whine and sideband noise evaluation, and profile/lead modifications for NVH and efficiency.
• Derive torque, speed, and thermal load cases from VDS, road load data, customer usage, and regulatory drive cycles (e.g., MIDC).
• Conduct bearing and shaft durability analysis including tilt stiffness, preload strategies, and service life estimation per ISO/ARB standards.
• Model drivetrain torsional vibration and perform eigenvalue analysis to avoid resonance.
• Develop thermal and lubrication systems including oil jet targeting, churning loss analysis, lubrication flow paths, and thermal soak considerations.
• Analyze electro-mechanical integration for high-speed e-drives including rotor dynamics impact on NVH, coupling stiffness, and misalignment tolerance.
• Validate housing via FE analysis for gear mesh-induced vibro-acoustics, stiffness enhancement, and manufacturability through casting/forging.
• Collaborate on drive control using MATLAB/Simulink for shift strategy calibration, efficiency mapping, and torque handover tuning.
• Support cross-functional teams across Program, Development, VI, Manufacturing, and Validation for DVP&R, DFMEA, rig/vehicle validation, durability test correlation, and root-cause analysis.
• Provide vendor and manufacturing support including DFM feasibility, heat treatment specs, gear finishing process selection (honing/shaving/grinding), GD&T release, and PPAP documentation with technical signoff.

Skills

• Expert-level proficiency in Romax, Kisssoft, Catia V5/V6, MATLAB/Simulink, and Ansys.
• Strong foundation in gear, bearing, and spline design and selection per AGMA, DIN, and ISO standards.
• Skilled in transmission NVH metrics and behavior optimization including PPTE, STE, and meshing excitation.
• Expertise in surface engineering and tribology for high torque density EV gears.
• Knowledge of thermal-efficiency trade-offs covering churning losses, bearing losses, and gear mesh losses.
• Experience in designing 48V–300V e-axle systems and high-speed motors exceeding 12,000 rpm.
• Familiar with commercial duty cycles emphasizing high load factors, fatigue, and overload durability.