Muhammad Tajammal Hussain
Sr. Automotive Hardware Validation And Diagnostics Engineer
Neuwied,RP
Summary
Dynamic and results-driven engineer with extensive experience at ZF Group, specializing in ECU validation, diagnostics, and automotive electronics development. Proficient in automotive communication protocols (CAN, FlexRay, LIN, Ethernet) and diagnostic tools such as CANoe, CANape, and CANalyzer. Adept at cross-functional collaboration to optimize testing efficiency, troubleshoot complex systems, and enhance ECU performance. Proven expertise in functional safety (ISO 26262), system validation, and failure analysis methodologies (FMEA). Quick to adapt to new technologies, consistently delivering high-quality solutions in fast-paced environments.
Overview
10
10
years of professional experience
3
3
Languages
Work History
Hardware Validation and Diagnostics Engineer
ZF Group
05.2018 - Current
- Familiar with EOL (End-of-Line) testing processes for automotive ECUs, ensuring the functionality and performance of electrical systems during production.
- Flashed and calibrated ECUs with test software and wrote comprehensive flashing/commissioning instructions for test labs, ensuring seamless execution of validation procedures.
- Proficient in automotive communication protocols including CAN, LIN, FlexRay, Ethernet, UDS, UCI, and XCP, ensuring seamless data exchange and diagnostics during validation testing.
- Prepared and configured tools such as CANape and CANoe for signal logging, test maneuvers and analysis during testing.
- Experienced with high-voltage and low-voltage systems commonly found in modern electric vehicles, applying this knowledge during hardware validation to ensure the safety and functionality of vehicle ECU.
- Analyzed ECU test results, identified hardware and software issues, and collaborated with hardware and software teams to implement robust solutions.
- Knowledgeable in FMEA (Failure Mode and Effects Analysis) methodologies, which are used to identify potential failure modes in vehicle systems, prioritize risks, and develop effective mitigation strategies to enhance system reliability and performance.
- Developed and implemented validation test specifications (DV/PV) for automotive ECUs (Electronic Braking Control Units), covering electrical, environmental, and EMC testing in compliance with industry standards (e.g. LV124). Performed and assisted Electrical and EMC tests.
- Supported ECU-level testing during EMC tests at Volkswagen facilities.
- Conducted braking maneuvers tests on test tracks in Sweden (ZF and Volkswagen) and provided real-time insights to enhance ECUs performances.
- Developed expertise in functional safety standards and applied safety principles during validation to ensure compliance with ISO 26262.
- Spearheaded initiatives to improve testing efficiency, including process automation, diagnostics, and fault analysis methodologies.
- Coordinated cross-functional activities, actively engaging with project managers, HW and SW teams, customer and test labs to meet project goals and timelines.
- Passed Driver Qualification 2 (DQ2) training, acquiring advanced skills for dynamic vehicle control and performance testing.
Automotive Electronics Development Engineer
Kautex Textron
10.2017 - 03.2018
- Developed and implemented servo motor control using AVR microcontroller and CAN bus communication for automotive systems.
- Conducted functional testing of fuel tank control units using CANape, ensuring compliant with system requirements.
- Designed and executed comprehensive test plans to validate the performance of electronic control systems.
- Analyzed the test results, identified issues, and collaborated with team members to recommend and implement improvements.
- Conducted patent reviews to ensure innovation compliance and avoid intellectual property conflicts.
- Utilized tools like CANape and CANalyzer for diagnostics, analysis, and system validation during development.
Automotive Hardware Development Engineer
Bosch (via WEBER GmbH)
08.2016 - 08.2017
- Calculated electronic circuit parameters and software-related values to optimize hardware performance.
- Developed a thermal model for MOSFET to ensure efficient heat dissipation and system reliability.
- Conducted worst-case calculations and simulations to validate circuit designs under extreme operating conditions.
- Performed impact analyses and validated circuit components in compliance with ISO 26262 functional safety standards.
- Managed requirements in Rational DOORS and collaborated on tasks related to functional safety and risk mitigation.
- Planned and maintained bill of materials (BOM) to support hardware development processes.
Master Thesis: Automotive ECU Validation Methods
ETAS GmbH (Bosch Subsidary)
04.2015 - 10.2015
- Investigated erros and uncertainties in the modeling of automotive systems to improve reliability.
- Examined ambiguity in the parameterization of simulation models for enhanced accuracy.
- Developed methods to replay validated vehicle data in the Hardware-in-the-Loop (HiL) Simulations.
- Tested electric automotive Battery Management System (BMS) and Fuel Cell ECUs in Model-in-the-Loop (MiL) simulations to validate the use of real vehicle data for simulation models.
Intern: EV Battery Testing and Laboratory Support
Deutsche ACCUmotive GmbH & Co. KG (Daimler AG)
09.2014 - 02.2015
- Designed printed circuit boards (PCBs) for laboratory testing setups using Eagle and Target 3001! software.
- Supported electric vehicle battery testing processes, ensuring compliance with performance and safety standards.
- Developed a graphical user interface (GUI) to enhance testing efficiency and control.
- Programmed diagnostic processes using CAPL.
- Constructed a breakout box to facilitate electric vehicle (EV) battery testing and diagnostics.
- Performed harness assembly, soldering, and mechanical tasks to prepare test setups.
Education
Master of Science - Electrical Power Engineering
Brandenburg Technical University
Cottbus, Germany 04.2001 -
Bachelor of Science - Electrical Engineering
University of Engineering & Technology (UET)
Lahore, Pakistan 04.2001 -
Skills
Technical Skills:
Automotive Communication Protocols: CAN, FlexRay, LIN, Ethernet, UDS, XCP
EOL System and Testing: Knowledge of ECU-EOL testing processes
Testing Tools & Software: CANoe, CANape, CANalyzer, LABCAR OPERATOR, MDA
Hardware Development and Validation: PCB design, circuit/schematic analysis, and validation processes
Simulation and Modeling: Model-in-the-Loop (MiL), LTspice, PSpice, Proteus, PSIM, ETAP, Matlab, Simulink
Programming and Scripting: C, C, Python, CAPL
Functional Safety: ISO 26262 compliance and impact analysis
Verification and Validation: Hands-on-experience with ECU verification and validation methods before SOP
Failure Analysis and Methodologies: Knowledge of FMEA, root cause analysis
Microsoft Office: Excel, PowerPoint, Word, Outlook
Soft Skills:
Collaboration and Teamwork: Proven ability to work effectively in cross-functional teams
Problem Solving: Strong analytical and troubleshooting skills
Multitasking: Efficient in managing multiple tasks and projects without compromising quality
Adaptability and Fast Learner: Quick to acquire new skills and adapt to changing technologies and environment
Hobbies
- Sport
- Cooking
- Socializing and spending time with friends
Timeline
Hardware Validation and Diagnostics Engineer
ZF Group
05.2018 - Current
Automotive Electronics Development Engineer
Kautex Textron
10.2017 - 03.2018
Automotive Hardware Development Engineer
Bosch (via WEBER GmbH)
08.2016 - 08.2017
Master Thesis: Automotive ECU Validation Methods
ETAS GmbH (Bosch Subsidary)
04.2015 - 10.2015
Intern: EV Battery Testing and Laboratory Support
Deutsche ACCUmotive GmbH & Co. KG (Daimler AG)
09.2014 - 02.2015
Master of Science - Electrical Power Engineering
Brandenburg Technical University
04.2001 -
Bachelor of Science - Electrical Engineering
University of Engineering & Technology (UET)
04.2001 -