Drivetrain Integration Engineer

6 days 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.

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.

 

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