ideaForge
Website:
ideaforgetech.com
Job details:
About Us
ideaForge Technology Limited is an Indian aerospace and unmanned aerial systems (UAS) technology company focused on the design, development, integration, testing, and production of advanced drone platforms for defence, security, and industrial applications.
Our engineering teams work across aircraft systems, avionics, electrical systems, propulsion, flight controls, communication, payloads, software, manufacturing, and flight testing. We are looking for a hands-on
Senior Engineer – Electrical Systems & Integration to take ownership of platform-level electrical architecture and lead electrical integration activities from concept and design through ground testing and flight trials.
Role Overview
The
Senior Engineer – Electrical Systems & Integration will be responsible for the architecture, design, integration, verification, and troubleshooting of electrical systems for UAV/aerospace platforms.
The role will involve close interaction with
Avionics, Flight Controls, Propulsion, Battery/BMS, Mechanical, Structures, Manufacturing, Quality and Supply Chain teams.
The candidate will own electrical interfaces, power distribution, harness architecture, grounding and bonding, connector selection, electrical budgets, EMI/EMC considerations, system-level testing, and electrical issue resolution.
Qualification
- Bachelor’s or Master’s degree in Electrical Engineering, Electronics Engineering, Avionics, Aerospace Engineering, Mechatronics, or a related discipline.
- Strong fundamentals in electrical and electronic systems, power distribution, wiring, harness development, signal integrity, grounding, and electrical integration.
Experience
8–12 years of relevant experience in electrical/electronic system integration, preferably in
UAV, aerospace, defence, aviation, automotive, or other safety-critical electromechanical systems.
Candidates should have demonstrated experience taking ownership of an electrical subsystem or platform from
architecture and design through integration, testing, troubleshooting, and qualification.
Location
Navi Mumbai, Maharashtra, India
Key Responsibilities
- Electrical Architecture & System Integration
- Own and develop the drone-level electrical architecture for UAV/aerospace systems.
- Develop and maintain the overall electrical power tree, including power sources, power distribution, conversion, protection, and loads.
- Define electrical interfaces between:
- Avionics
- Flight control systems
- Propulsion systems
- Battery/BMS
- Payloads
- Communication systems
- Navigation systems
- Ground-support equipment
- Other aircraft subsystems
- Develop and maintain Interface Control Documents (ICDs), electrical interface specifications, wiring diagrams, and system architecture documents.
- Define and review grounding, bonding, shielding, and return-current strategies.
- Evaluate electrical architecture for redundancy, fault tolerance, fail-safe operation, and single-point failures.
- Participate in system-level design reviews and provide technical recommendations on electrical architecture and integration.
- Ensure electrical design decisions are aligned with aircraft-level requirements, safety requirements, performance, weight, reliability, and maintainability.
- Electrical Power Systems
- Develop and maintain the aircraft electrical power budget covering different operating and flight phases.
- Define power requirements for avionics, propulsion, payloads, communication systems, sensors, actuators, and other electrical loads.
- Analyse steady-state and transient power requirements, including startup current, inrush current, brownout, over-voltage, under-voltage, and load-shedding conditions.
- Ensure adequate electrical power supply margins are maintained throughout the aircraft operating envelope.
- Wiring Harness & EWIS
- Own the electrical harness architecture and overall Electrical Wiring Interconnection System (EWIS).
- Define wire and cable selection based on:
- Current carrying capacity
- Voltage rating
- Temperature
- Weight
- Environmental conditions
- Voltage drop
- EMI/EMC requirements
- Mechanical requirements
- Review harness routing for weight optimisation, bend radius, chafe protection, maintainability, accessibility, and EMI segregation.
- Define separation requirements between:
- High-voltage and low-voltage wiring
- Power and signal wiring
- High-current and sensitive signal circuits
5RF and electrical systems
- Review harness drawings, wiring diagrams, connector pinouts, wire lists, BOMs, and manufacturing documentation.
- Support harness build, installation, inspection, continuity testing, and aircraft integration.
- Establish and enforce harness workmanship standards based on IPC/WHMA-A-620 and applicable aerospace/military practices.
- Support development of standard practices for crimping, soldering, shielding, splicing, lacing, termination, connector assembly, and inspection.
- Wire harness design for the following systems:
- Avionics systems
- Electrical systems such as motor and ESC.
- Battery and Battery management systems
- Communication systems
- Connector & Interface Management
- Select appropriate connectors, contacts, backshells, terminals, and accessories based on electrical, mechanical, environmental, and reliability requirements.
- Define connector specifications considering:
- Current and voltage rating
- Contact resistance
- Retention force
- Environmental sealing
- Mating cycles
- Vibration
- Temperature
- EMI/EMC requirements
- Establish connector standardisation across the aircraft platform wherever practical.
- Review connector derating, contact loading, pin allocation, keying, and mating requirements.
- Maintain connector pinout and interface documentation and ensure configuration consistency between design, manufacturing, and aircraft installation.
- EMI/EMC Engineering
- Incorporate EMI/EMC considerations from the early design stage.
- Define appropriate practices for:
- Cable segregation
- Shielding
- Grounding
- Bonding
- Filtering
- Termination
- Cable routing
- RF isolation
- Identify potential EMI/EMC coupling paths between propulsion, power electronics, avionics, communication, and sensor systems.
- Support troubleshooting of EMI/EMC issues during laboratory, ground, and flight testing.
- Support EMI/EMC qualification activities in accordance with applicable standards such as MIL-STD-461 and MIL-STD-464.
- Support environmental qualification activities in accordance with applicable requirements such as MIL-STD-810.
- Electrical Testing & Verification
- Develop electrical integration and verification plans based on system requirements.
- Lead and participate in:
- Continuity testing
- Insulation resistance testing
- Dielectric withstand/Hi-Pot testing where applicable
- Ground bonding/continuity testing
- Power-on testing
- Load testing
- Communication interface testing
- Develop test procedures, test checklists, test reports, and verification records.
- Review test results and ensure requirements are objectively verified.
- Documentation & Configuration Management
- Prepare and maintain:
- Electrical architecture documents
- Electrical schematics
- Wiring diagrams
- Harness drawings
- ICDs
- Electrical BOMs
- Wire lists
- Connector pinout documents
- Power budgets
- Electrical interface specifications
- Test procedures
- Test reports
- Troubleshooting reports
- Ensure engineering documentation is properly controlled and updated through the product lifecycle.
- Work closely with configuration management/PLM teams to maintain design baselines and engineering changes.
- Cross-Functional Teams Collaboration
Work closely with Systems Engineering, Avionics, Flight Controls, Propulsion, Mechanical, Structures, Software, Manufacturing, Quality, Supply Chain, and Flight Test teams.
Key Skills
Practical/Hands-on Skills
- Ability to work directly on aircraft, prototypes, test rigs, and production systems.
- Ability to read and interpret electrical schematics, wiring diagrams, connector drawings, and harness drawings.
- Hands-on experience with electrical test and measurement equipment such as CRO, multi meter, micro ohm meter, insulation resistance testers and Etc.
- Strong understanding of aerospace wiring practices and workmanship requirements.
Engineering & Professional Skills
- Strong analytical and problem-solving capability.
- Good understanding of system engineering principles and requirements traceability.
- Ability to make engineering decisions considering safety, reliability, cost, weight, schedule, and maintainability.
- Strong technical documentation and communication skills.
- Ability to lead technical discussions and present solutions to senior management.
- Strong ownership and accountability for assigned systems.
Preferred Skills
- Working knowledge of MIL-STD-461, MIL-STD-464, and MIL-STD-810.
- Exposure to DGQA, CEMILAC, airworthiness, or defence qualification processes.
- Working knowledge of IPC/WHMA-A-620 and aerospace wiring workmanship practices.
- Experience with electrical CAD/harness tools such as Creo Schematics and Altium or equivalent.
- Experience with PLM/document management systems such as Windchill or equivalent.
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