Viji Venkatesan — Battery Systems Engineering Specialist

Career History

Work Experience

Jul 2025 – Present📍 Germany● Current Role

Battery DVP Owner

Yanmar — Electrified Construction Machinery

Battery system specification & RFI authoring — defining LFP 56–82kWh, 250–450V systems for 5 platform models across EU, US, JP, Korea markets
Requirements-to-DVP mapping — translating 100+ electrical, thermal, safety, BMS, environmental, regulatory criteria into structured test validation matrix
Active DFMEA participation — integrating failure mode analysis with DVP priority decisions
Complete DVP ownership — test sequence plans, time plans, cost estimations, resource management, external lab coordination
Cross-functional collaboration with Architecture, EE, Software, Quality and Project teams
Final pass/fail decision authority — accountable for test campaign outcomes reported to management
AI-driven workflow automation using N8N, Claude, Gemini, Supabase vector DB, RAG pipelines for test data management
Standards: ECE R100, UN38.3, ISO 16750, UL2580, IEC 62619, ISO 23285, ISO 26262, ISO 13849, EU Battery Regulation 2023/1542, EMC EN ISO 13766, KS C IEC 62619

LFP 450VRFI / SpecDVP Owner JamaJira3DEXPERIENCE N8N · Claude · RAGConstruction Machinery

Jul 2024 – Apr 2025📍 Munich, Germany

Test Engineer — eVTOL Battery Systems

Lilium Aerospace GmbH · Electric Air Mobility

Core contributor to the world's first 900V / 260kWh all-electric regional jet propulsion battery — highest voltage aviation battery taken to DVP and proto certification
Proto build support — mechanical assembly verification, HV harness routing, cell stack integration, full instrumentation setup (thermocouples, voltage taps, current shunts)
DVP planning to DO-311A & DO-106 aerospace standards — translated aircraft safety requirements into cell, module and pack test specifications covering performance, abuse, environmental and safety domains
Authored detailed test specifications for external aerospace-certified test houses across Europe — vibration (DO-160), thermal shock, altitude, fire resistance and electrical performance
Coordinated multi-site test execution — managing external lab interfaces, schedule adherence, data collection and anomaly investigation across concurrent campaigns
BMS functional verification at pack level: contactor sequencing, pre-charge logic, cell voltage/temperature monitoring accuracy, fault detection and safe-state transitions
Thermal runaway containment validation — single cell trigger tests to verify propagation prevention per DO-311A requirements
Managed test data analysis and engineering reports — failure mode documentation, pass/fail assessment, deviation management, certification evidence packages
Maintained programme technical integrity and certification artefacts through Lilium's insolvency
Standards: DO-311A, DO-106, DO-160G, UN38.3 (air transport), Lilium ATP, EASA CS-E / CS-23 framework

900V · 260kWhDO-311A · DO-106 DO-160GThermal Runaway eVTOL · AerospaceEASA Framework

Jan 2023 – Jan 2024📍 Chennai, India

Senior Engineer — Battery Development & Systems

Renault Nissan Technology & Business Centre India (RNTBCI)

Proof-of-concept for Affordable BEV for India — full feasibility study from blank sheet: energy requirement analysis, cell chemistry shortlisting (LFP vs NMC), pack topology definition, cost modelling
Cell selection and benchmarking — evaluated prismatic, cylindrical and pouch formats across energy density, cost, cycle life, thermal behaviour, supply chain maturity; full selection matrix and recommendation report
Vehicle & battery simulation using Siemens Amesim and MATLAB Simulink — drive cycle energy modelling (WLTP, MIDC), range prediction, regenerative braking efficiency, thermal load estimation, pack sizing optimisation
Developed 3 distinct concept proposals for Renault Kiger EV — differentiated by voltage (350V, 400V), energy (30–50kWh) and architecture; 1 concept developed to management approval stage
Defined pack architecture and component sizing: cells-in-series/parallel config, contactor & fuse sizing, BMS generation selection, thermal management approach
Filed patent (Feb 2023): User-driven Depth-of-Discharge optimisation and battery degradation system — adaptive algorithm allowing customers to trade off range vs longevity, reducing unnecessary cycle ageing
Led team of 3 engineers — task allocation, technical mentoring, supplier interface management and deliverable tracking
Supplier negotiations on pack sizing, cell pricing and development partnerships with Tier-1 battery suppliers and cell manufacturers
Standards: AIS-038 Rev.2, AIS-156, UN38.3, IEC 62660, CMVR for Indian market homologation planning

Patent Filed 2023Renault Kiger EV PoC Amesim · SimulinkCell Selection Pack ArchitectureAIS-038Team Lead · 3

Nov 2021 – Dec 2022📍 Bengaluru, India

Assistant Manager — Cell Validation & Proto Pack Build

Ola Electric Ltd · 2-Wheeler EV (S1 / S1 Pro)

Led team of 6 engineers — in-house cell and pack validation programme delivery, resource planning, DVP test closure coordination
Cell lifecycle testing & characterisation — BOL performance (capacity, OCV, DCIR), cycle life ageing (1C-1C, 0.5C-0.5C, custom Ola drive cycles), calendar ageing, temperature performance mapping
Capacity fade and resistance growth analysis — tracked degradation trajectories across 100s of cells; built statistical models to predict 80% SOH crossover for warranty return conditions
Inline manufacturing measurement correlation — analysed how electrode thickness deviation, electrolyte fill weight variance and formation curve anomalies correlated with early-life capacity fade; findings fed directly to Ola's gigafactory cell manufacturing team
Cell-to-cell variability grading system — developed incoming cell sorting methodology using OCV spread, DCIR map and formation CE fingerprints to quarantine outlier cells before pack assembly
Built in-house testing capability from scratch — procured, installed and commissioned Chroma and Newere battery cyclers, set up thermal chambers, configured test automation, established SOPs
6-Axis Robot abuse testing — designed and executed nail penetration, crush, drop and shock protocols using robotic force-controlled systems — one of the most advanced cell abuse setups in Indian EV industry at the time
BOL inline vision system integration — correlated inline camera inspection data (tab alignment, electrode overhang) with post-formation electrical performance to build a predictive quality gate
Standards: AIS-038 Rev.2, AIS-156, UN38.3, IEC 62660-1/2/3, IS 16046, ECE R136

Team Lead · 6Cell CharacterisationProto Pack Build 6-Axis Robot AbuseInline Meas. Correlation Chroma · NewereGigafactory Interface

Oct 2015 – Nov 2021📍 Chennai, India

Battery Test Engineer → Senior Battery Test Engineer

Mahindra & Mahindra Ltd · EV & Hybrid Vehicles

Delivered end-to-end type certification for 3 full battery programmes: 11kWh (e2o Plus / eVerito), 30kWh and 40kWh — DVP definition through regulatory sign-off
DVP plan ownership — full test scope: electrical performance, thermal, abuse (nail, crush, overcharge, overdischarge, short circuit), environmental (salt spray, humidity, thermal shock, vibration), functional safety
AVL Lynx test bench programming — developed automated test sequences for battery cycling, HPPC, drive cycle simulation and aging protocols; standardised reusable sequence libraries
BMS calibration using ETAS INCA — calibrated SOC/SOH estimation parameters, DCIR tables, temperature derating maps, current limits (SOP), and protection thresholds (OVP, UVP, OTP, OCP)
CAN communication verification — validated BMS signal accuracy (cell voltages, temperatures, pack current, SOC, SOH, fault flags) using CANalyzer and CANdb++; interface testing with VCU and charger
Thermal runaway testing — nail penetration and external heater trigger tests at module and pack level; instrumented with thermocouples, gas detectors and high-speed cameras; propagation analysis
Competitive benchmarking — 59kWh & 79kWh: systematic teardown and performance characterisation of BYD and Tesla battery packs; analysed cell format, chemistry, thermal architecture, BMS design and energy density — direct input into M&M's next-gen EV strategy
Lifecycle reliability modelling — Arrhenius model for thermal acceleration in HTOE tests; Coffin-Manson model for mechanical fatigue in thermal cycling and vibration tests
Test lab management — thermal chambers (–40°C to +85°C), shaker tables, salt spray cabinets, nail/crush rigs, battery cyclers (AVL, Bitrode, Arbin) — calibration schedules and safety protocols
External lab management — coordinated with ARAI, NATRIP and third-party labs for regulatory homologation; prepared test plans, witnessed critical tests, reviewed official lab reports
Grew from Engineer to Senior Battery Test Engineer over 6 years — expanded from test execution to full DVP ownership and cross-functional coordination
Standards: AIS-038 Rev.2, AIS-048, UN38.3, IEC 62660-1/2/3, ISO 12405-3/4, ISO 16750-3/4/5, SAE J2929, SAE J2464, SAE J1772, LV 124, ECE R100

3 Full Certifications6 Years · Senior AVL LynxETAS INCA BYD · Tesla BenchmarkARAI / NATRIPArrhenius · Coffin-Manson

Regulatory Expertise

Battery Testing Standards Mastery

Across 10 years and 5 industries, Viji has executed, managed or overseen battery testing to 30+ international standards — spanning ECE, UN, ISO, IEC, SAE, UL, GB/T, AIS, DO and EU Regulations. This is one of the broadest multi-domain standards portfolios held by any individual battery engineer in Europe.

ECE / UNECEAutomotive · Regulatory

ECE R100 Rev.3Battery electric vehicle safety — performance, abuse, environmental. Applied across M&M, Ola, YanmarExpert

ECE R136L-category (2/3-wheeler) EV safety — relevant to Ola Electric 2W platformAdvanced

UN / DOTTransport · Global

UN38.3Li-ion cell & pack transport safety — altitude, thermal, vibration, shock, overcharge, short circuit. All programmesExpert

UN3480 / PI965Lithium-ion battery shipping classification and packaging instructionsAdvanced

ADR / RID / ADNEU road / rail / inland waterway dangerous goods transport (2008/68/EC)Working

ISOAutomotive · Reliability · Safety

ISO 12405-3 / -4Li-ion traction battery pack — performance and lifecycle testing. Mahindra programme deliveryExpert

ISO 16750-3 / -4 / -5Road vehicle environmental conditions — mechanical, climate, chemical loads. Yanmar & M&MExpert

ISO 26262Road vehicle functional safety — ASIL determination, DFMEA, safety goals. Active DFMEA at YanmarAdvanced

ISO 13849 / ISO 19014Functional safety for machinery (PLc/PLd) — construction equipment at YanmarAdvanced

ISO 23285Safety for battery systems in agricultural and construction vehiclesAdvanced

ISO 6469-1 / -3EV safety — on-board energy storage, protection against electrical hazardsAdvanced

IECElectrotechnical · Performance

IEC 62619:2022Safety requirements for stationary and industrial Li-ion batteries. YanmarExpert

IEC 62660-1 / -2 / -3Li-ion cell performance, reliability and abuse testing. M&M and Ola cell characterisationExpert

IEC 62620Li-ion cell performance specification and marking for industrial applicationsAdvanced

IEC 60068-2-52Salt mist (cyclic) environmental testing — corrosion resistance validationAdvanced

IEC 61000-4-2ESD immunity testing — battery system electronics hardeningWorking

SAEAutomotive · North America

SAE J2464EV & HEV rechargeable energy storage abuse testing. M&M and Yanmar US marketExpert

SAE J2929EV battery safety — performance and abuse for HV battery packsExpert

SAE J1772EV charging connector and interface standard — charging compatibility at pack levelAdvanced

SAE J1939CAN-based communication for commercial vehicles and off-highway machinesAdvanced

ULNorth America · Certification

UL 2580Batteries for use in EVs — abuse, performance, environmental. Yanmar US market & M&M exportExpert

UL 1642Lithium cell safety — cell-level abuse and performance. Cell qualification at Ola & M&MAdvanced

UL 9540AThermal runaway fire propagation testing for battery energy storage systemsWorking

GB/T (China)China National Standards

GB/T 31485Safety requirements and test methods for traction battery cells and packsAdvanced

GB/T 31486Electrical performance requirements and test methods for traction batteryAdvanced

GB/T 38031EV traction battery safety requirements — updated China EV battery safety standardWorking

AIS / BIS (India)India Homologation

AIS-038 Rev.2Battery operated vehicle battery safety — India homologation. M&M & Ola programme deliveryExpert

AIS-048Electric power train safety for L-category (2/3-wheelers). Ola ElectricExpert

AIS-156Li-ion cell and battery pack performance and safety for EVs in IndiaAdvanced

IS 16046Indian standard for secondary Li-ion cells — portable and EV applicationsAdvanced

DO / RTCAAerospace · Aviation

DO-311AMinimum operational performance standards for rechargeable Li batteries in aviation. Lilium eVTOLAdvanced

DO-106Guidance for Li-ion battery certification in civil aircraft applications. LiliumAdvanced

DO-160GEnvironmental conditions and test procedures for airborne equipment — vibration, thermal, altitudeAdvanced

EU Regulations & LVEurope · Compliance

EU Battery Regulation 2023/1542Battery passport, carbon footprint, due diligence requirements. Active at YanmarAdvanced

LV 124German OEM electrical component testing for 12V/48V/HV vehicle networks. M&M exportExpert

EN ISO 13766-1 / -2EMC for earth-moving machinery — Yanmar construction platform complianceAdvanced

KS C IEC 62619 (Korea)Korean adoption of IEC 62619 battery safety — Yanmar Korea market requirementWorking

Expert — led full test campaigns, authored reports, regulatory sign-off

Advanced — executed tests, reviewed results, coordinated with labs

Working Knowledge — applied in project context, familiar with requirements

VIJIVENKATESAN

VIJI
VENKATESAN