Sakthivel Thiyagarajan
HIL Design & Validation Engineer
Kidlington
Summary
HIL Design & Validation Engineer with 2 years of experience in EV high-voltage systems, specialising in Battery Management Systems (BMS/BSC) and on-board chargers (OBC). Strong background in system-level ECU validation using Vector HIL platforms, with hands-on expertise in CAN communication, UDS diagnostics (ISO 14229) and XCP measurement. Experienced in requirement-based testing, diagnostic validation and system-level debugging through signal analysis and ECU behaviour verification. Proven ability to identify faults, support root-cause analysis and improve validation efficiency through CAPL-based automation.
Overview
2
2
years of professional experience
Work History
HIL Design & Validation Engineer
Test Base Solutions Ltd., UK
09.2024 - Current
- Performed system-level validation of BMS/BSC ECU on Vector VT-based HIL rigs, covering I/O behaviour, CAN communication, diagnostics and functional safety requirements.
- Developed and executed requirement-based test cases in vTESTstudio with full traceability across 2,000+ system requirements in Polarion.
- Validated UDS diagnostic services (ISO 14229) against system requirements, analysing request/response behaviour, session control and DTC handling using CANoe.
- Executed fault injection scenarios to verify diagnostic robustness, identified inconsistencies in ECU responses, and supported root-cause analysis through log correlation and system-level debugging.
- Diagnosed system-level faults using CANoe log analysis and XCP measurement, identifying issues related to timing, calibration and communication.
- Automated test scenarios and simulation control using CAPL, improving repeatability and reducing manual validation effort.
- Configured VT System hardware including I/O mapping, cell simulation, relay control and signal conditioning for accurate HIL setup.
- Created CANoe panels for real-time monitoring and diagnostics, improving visibility during validation activities.
- Collaborated with software and calibration teams to support debugging, issue resolution and software release validation.
- Performed functional safety–oriented testing, checking FTTI (Fault Tolerant Time Interval), FHTI (Fault Handling Time Interval) and FDTI (Fault Detection Time Interval) behaviour for selected safety-critical requirements in line with ISO 26262.
- Managed test artefacts (logs, reports and evidence) in Polarion, and raised/tracked defects via JIRA, re-testing fixes in subsequent software releases.
- Client: Fortescue WAE, UK
- Project: BMS – Heavy-Duty Electric Truck
HIL Validation Engineer Trainee
Test Base Solutions Ltd., UK
04.2024 - 08.2024
- Started career as a HIL Validation Engineer Trainee, supporting MicroFuzzy’s on-board charger (OBC) platform for 3-phase and single-phase AC charging on a customer EV programme.
- Worked within Automotive SPICE hardware processes (HWE.2 and HWE.4), supporting hardware requirement clarification, interface definition and basic integration/test tasks for the OBC ECU.
- Analysed CANoe log files from HIL and system/vehicle tests for AC charging sessions to identify communication issues, missing/incorrect signals and timing anomalies between the OBC, BMS and vehicle control units.
- Helped investigate defects by reproducing issues in CANoe simulations and correlating log data with ECU behaviour and requirement specifications, feeding findings back to HIL and software teams.
- Performed routine HIL support activities such as configuration checks and simple wiring/patch-panel updates under guidance from senior HIL engineers.
- Recorded issues, observations and change requests in Polarion and JIRA, attaching traces and clear steps to reproduce for efficient debugging by client and internal teams.
- Client: MicroFuzzy, Germany
- Project: On-Board Charger (OBC) Platform
Education
MSc - Embedded Systems
University of Leeds
UK09-2023
BTech - Electrical, Electronics and Communications Engineering
SRM Institute of Science and Technology (SRM IST)
Chennai, India06-2022
Skills
HIL simulation and ECU verification
Requirement-based testing
System-level validation expertise
Experience with software and tools
Vector: CANoe, CANalyzer, CANape, VT System, vTESTstudio, CAPL scripting
Development of plant models and gateway behavior
Version control proficiency with Polarion, JIRA, and Git
Diagnostic analysis
Experience with XCP and SPI protocols
DTC analysis, request/response validation, communication debugging
EV & High-Voltage Domain
BMS/BSC, OBC (AC charging), DC-DC, EV power distribution
Protection logic, operating range, wake-up/shutdown behaviour
Experience with FTTI, FHTI, and FDTI standards
Calibration of measurement instruments
Timeline
HIL Design & Validation Engineer
Test Base Solutions Ltd., UK
09.2024 - Current
HIL Validation Engineer Trainee
Test Base Solutions Ltd., UK
04.2024 - 08.2024
BTech - Electrical, Electronics and Communications Engineering
SRM Institute of Science and Technology (SRM IST)
MSc - Embedded Systems
University of Leeds