Mechanical Structural Engineer – E+ES (Battery and Power systems)

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Job Description:

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Mechanical Structural Engineer – E+ES (Battery and Power systems)

Role Overview
Mechanical Structural Engineer responsible for design, analysis, and product realization of battery systems and power electronics for energy and power applications. The role focuses on ensuring structural integrity, electrical packaging compliance, vibration robustness, and manufacturable designs under defined loading conditions, thermal environments, and boundary constraints.

Key Responsibilities
Structural Design & Analysis:

• Define load cases and boundary conditions based on vibration inputs, shock events, G-loads, and operating conditions
• Perform linear and nonlinear FEA: static, modal, random vibration (PSD), fatigue, thermo-mechanical, and drop impact analysis
• Evaluate handling scenarios including lifting and transportation loads as per standards
• Design sheet metal, Casting and Extrusion based structures
• Execute weld design considering fatigue strength, HAZ effects, and distortion
• Perform bolted joint analysis (preload, clamp retention, fatigue, sealing compression)
• Develop isolation mount (iso-mount) models for vibration isolation and resonance control
• Incorporate thermal solutions including Coolant pipes, HV -LV harnessing and auxiliary systems in the design keeping serviceability in mind
• Packaging & Electrical Integration:
• Develop 3D packaging layouts considering space claim, clearances, and serviceability
• Define creepage and clearance distances for high-voltage systems in compliance with applicable standards
• Ensure compliance with electrical insulation, dielectric spacing, and safety requirements (IEC/UL/ISO)
• Incorporate EMI/EMC considerations, sealing (IP ratings), and thermal paths in packaging
• Caterpillar: Confidential Green
• Work with electrical teams with intermediate-level exposure to harness design including routing constraints, bend radii, connector interfaces, and protection requirements
• Optimize packaging for thermal dissipation and structural support

Design Definition & Controls:

• Apply GD&T (ASME Y14.5) and perform tolerance stack-up analysis
• Select materials based on mechanical, thermal, electrical insulation, and corrosion properties (e.g., Galvanic corrosion
• Manufacturing Integration:
• Implement DFM/DFA for manufacturability and assembly robustness and process selection (sheet metal forming, welding, casting, molding)
• Address variation, distortion, and residual stress
• Support DV/PV builds and CAE correlation
• Quality & Product Development:
• Execute DFMEA/PFMEA with structured risk mitigation
• Drive APQP deliverables across development phases
• Manage PPAP requirements
• Supplier Technical Engagement:
• Evaluate supplier capability in part quality, fabrication, welding, and dimensional control
• Validate tooling and process capability
• Lead technical reviews and issue resolution
• Failure Analysis & Optimization:
• Perform root cause analysis (stress correlation, fracture, test vs CAE)
• Correlate strain, vibration, and thermal data with simulation
• Optimize designs for fatigue life, stiffness efficiency, and cost

Required Qualifications:

• Bachelor’s/master is in mechanical, aerospace engineering or similar
• more than 3 years’ experience in battery systems, power electronics, or energy & power applications
• Experience with Teamcenter PLM for product data management, BOM management, and design release processes

Additional Information: This job required 5days working from office.

Posting Dates:

Caterpillar is an Equal Opportunity Employer. Qualified applicants of any age are encouraged to apply

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