Manager - Drivetrain Integration

19 hours ago

Bengaluru, Karnataka, India Mahindra & Mahindra Limited Full time ₹ 12,00,000 - ₹ 36,00,000 per year

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.

Core Responsibilities:

  1. Define gearbox architecture (parallel axis, coaxial, dual-stage reduction gearbox, synchronizer or dog clutch shifting concepts) based on vehicle performance targets.
  2. Gear design using Romax/Kisssoft: Macro & micro geometry optimization as per Loaded tooth contact analysis (LTCA), Gear whine & sideband noise evaluation, Profile/lead modification for NVH & efficiency
  3. Derive duty cycles from VDS or Road load data, customer-usage data, and regulatory drive cycles (MIDC) for torque, speed, and thermal load cases
  4. Bearing and shaft system durability analysis including tilt stiffness evaluation, bearing preload strategies, and service life estimation per ISO/ARB standards
  5. Drivetrain torsional vibration modeling and resonance avoidance through system-level eigenvalue analysis
  6. Thermal & lubrication network development: oil jet targeting, churning losses, lubrication flow paths, and thermal soak considerations
  7. Electro-mechanical integration analysis for high-speed e-drives
  8. Rotor dynamic influence on gearbox NVH, Coupling stiffness & misalignment tolerance
  9. Housing FE validation: gear mesh induced vibro-acoustics, stiffness enhancement for NVH, casting/forging manufacturability
  10. Drive control collaboration: MATLAB/Simulink model interfacing for shift strategy calibration, efficiency mapping, and torque handover tuning
  11. CFT activities: Cross- functional Collaboration Support for complete design, development & validation product lifecycle with different internal & external stakeholders like Program, Development, VI, Manufacturing, Validation for DVP&R,  DFMEA, Rig & vehicle level validation technical inputs, durability test correlation, and failure mode root-cause analysis and resolution
  12. Vendor and manufacturing support: DFM feasibility check with heat treatment specification,  gear finishing process selection (honing/shaving/ grinding), GD&T release with full PPAP documentation and technical signoff

Skills & Technical Competencies:

  1. Expert-level proficiency in: Romax, Kisssoft, Catia V5/V6, MATLAB/Simulink, Ansys
  2. Strong grounding in: Gear, bearing, Spline design & selection as per AGMA, DIN, ISO
  3. Transmission NVH metrics/ Behaviour optimisation (PPTE, STE, meshing excitation)
  4. Surface engineering & tribology for high torque density EV gears
  5. Thermal-efficiency trade-offs: churning losses, bearing, and gear mesh losses
  6. Experience designing for: 48V–300V e-axle systems, High rpm motors up to rpm
  7. Commercial duty cycles: high load factor, Fatigue & overload durability

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