EDU Thermal System Engineer

At Tata Technologies we make product development dreams a reality by designing, engineering and validating the products of tomorrow for the world’s leading manufacturers. Due to our continued growth we are now recruiting for a EDU Thermal System Engineer to be based at our customer’s site in Coventry

 Our Engineering Research and Development department (ER&D) is a fast growing function within Tata Technologies Limited that is assembled to work on exciting projects globally for multiple customers. It comprises highly specialized engineers across Automotive, Aerospace and Industrial Heavy Machinery. 

The Role:

We are seeking a supplier-provided EDU Thermal System Engineer to lead the design, development, calibration, and verification & validation (V&V) of the Electric Drive Unit (EDU) cooling and lubrication system for our Battery Electric Vehicle (BEV) programs. The role spans requirements authoring, system architecture, modelling & sizing, continuous and peak thermal testing (including transient events and off-road duty cycles), hydraulic function limit assessment, calibration, and integration with vehicle thermal systems. You will ensure the EDU’s thermal and hydraulic performance meets targets across E-machine, inverter, and gearbox, delivering robust protection strategies, efficient cooling, and reliable lubrication under all use cases.

Area of Responsibility  

Systems Engineering & Requirements

·        Define and maintain system and subsystem requirements for EDU cooling & lubrication (pumps, heat exchangers, filters, sensors, fluid properties, pipework/manifolds).

·        Develop system architecture, operating states, control strategies, and calibration maps with end-to-end traceability.

·        Author clear, testable requirements and acceptance criteria; contribute to DFMEA and functional safety inputs (ISO 26262 awareness).

Modelling, Sizing & Optimisation

·        Build and maintain 1D/0D thermal-hydraulic models (e.g., AMESim, GT-SUITE, Simulink) to size pumps, heat exchangers, lines, sensors, and set pressure–flow–temperature margins.

·        Quantify continuous and peak operating points, thermal balance, derating triggers, and transient responses (start-up, load steps, hot-soak).

·        Execute trade-off and sensitivity studies (thermal capacity, pressure drop, durability, efficiency, NVH) and recommend design/calibration updates.

Test Planning & Execution (Subsystem → System → Vehicle)

·        Plan and conduct continuous performance thermal tests, both steady-state and transient (cold start, rapid load steps, etc).

·        Lead off-road duty cycle testing: rock crawl (low-speed/high torque), sand/mud (high rolling resistance), prolonged slip, trailer-tow grade, altitude and ambient extremes; consider wading/water ingress impacts on hydraulic integrity.

·       

·        Define instrumentation plans, sensor calibration methods, data quality criteria, and safe test procedures; supervise rig/dyno/vehicle execution.

Data Analysis, Correlation & Calibration

·        Post-process data to compute heat flows, pressure–flow characteristics, and thermal transients; correlate models to test results and iterate.

·        Define, optimise, and release derating/protection logic, limp-home thresholds, and calibration datasets with clear rationale and version control.

·        Document findings, residual risks, and recommendations with concise, decision-ready reporting.

Integration, Release & Handover

·        Integrate the EDU thermal system with vehicle cooling architecture; support packaging, hose routing, bleed/fill procedures, serviceability, and contamination control.

·        Prepare release evidence: requirement coverage, test reports, calibration releases, and change notes; support manufacturing readiness (bleed/flush/EOL checks).

·        Ensure deliverables are version-controlled, reproducible, and handed over with models, data, scripts, and calibration files.

Knowledge / Experience

(Essential)

·                  Strong experience in Thermal Systems Engineering for electrified powertrain (EDU, inverter, E-machine, battery).

·                  Deep understanding of cooling & lubrication systems, component behaviour (pump, heat exchanger, filter), sensor selection/placement, and control strategies.

·                  Proven track record across system definition, architecture, requirements writing, design/performance modelling, systems integration, system assessment, and acceptance criteria.

·                  Hands-on with continuous and peak performance thermal testing, transient events, off-road duty cycles, and hydraulic function limits (cavitation, aeration, viscosity, pressure pulsation).

·                  Competent in calibration and function definition (derating, protections, limp-home); experienced in optimisation and system sizing.

·                  Strong analytical and problem-solving skills; clear verbal and written communication; effective cross-functional collaboration.

·                  Requirements management proficiency (e.g., IBM Rational DOORS or equivalent).

·                  Relevant engineering degree (Mechanical, Automotive, Mechatronics, Thermal/Fluids or similar).

 (Desirable)

·                  PhD or equivalent industrial research in thermal/fluids or systems engineering.

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·                  Structured problem-solving (DFMEA, 8D, DMAIC).

·                  Awareness of FUSA, ISO 26262 and environmental standards (e.g., ISO 16750/IEC 60068) as they pertain to system interfaces and testing.

·                  Experience with IBM Rational DOORS (Classic/Next) and ALM toolchains.

In return for bringing your expertise to our business we offer a competitive salary along with excellent benefits including:

·        Pension Scheme – We match employee contribution up to 5% of salary

·        25 Days’ Holiday

·        Private Health Care

·        Tata Jaguar Land Rover Privilege Scheme - up to 20% off new JLR vehicles

·        Group Income Protection

·        Health Assured – Employee Assistance Program

·        Group Life Assurance

·        Health Shield – Private Health Cash Plan

If you are passionate about bringing innovation to the projects you work on and want to join a global company, then this is the place for you.

Tata Technologies: Engineering a better world.