Sushank Sachan
Senior Hardware Engineer
Munich
Summary
Results-oriented Power Electronics Engineer with expertise in SMPS, gate driver design, and semiconductor device selection for high-voltage applications (400V to 1200V).
Proven track record in hardware development, circuit design, worst-case analysis, and testing for EV and fuel cell applications. Hands-on experience in developing DC/DC (400V-12V/24V, 850V-12V/24V) and AC/DC converters, including a 3kW onboard charger for electric autos.
Skilled in schematic design using Altium.
Controller design (PI, ACCM, PCCM), and inverter systems for PMSM and IM motors.
Proficient in simulation and design tools like LTspice, eADM, and customer requirement management using DOORS. Experienced with Agile methodologies, Scrum practices, and ticketing systems such as JIRA and KOLA.
Strong background as an Application Engineer supporting OEMs and suppliers with technical solutions in semiconductor device integration.
Adept in cross-functional team collaboration, project planning (Asana, Microsoft Office), and stakeholder management. Certified in Google Project Management with expertise in traditional and Agile project management frameworks.
Engineering experience at Infineon, Bosch, Volvo, and Panasonic.
M.Tech in Power Systems.
Overview
10
10
years of professional experience
1
1
Certification
Work History
Hardware System Engineer
Da Vinci Engineering GmbH
10.2024 - 06.2025
- Requirement Management in DOORS for the Combined charger Unit 11kW for EV application
- Customer Queries support through JIRA ticketing tool
- Field claims analysis at system and hardware level.
- Level 1 system engineering for CCU and Next generation products
- Managing Change Request from customer for field and under development charger and communicating the same with corresponding stakeholder.
- Client – Panasonic Automotive System Europe, Munich June 2025
- Client – Panasonic Automotive System Europe, Munich J
Consultant
MCA Sweden
11.2023 - 08.2024
- Scrum Master Activities for the product electric vehicle air compressor
- Taking care of the work creating and assigning task for the individual PI planning for the team members.
- Currently working as a Global Component Owner for the Product Electric Vehicle Compressor (EVAC) used in Volvo Electric Trucks.
- Following AGILE working methodology
- Reviewing the test results and test plan shared by the supplier
- Taking care of V cycle development and time plan.
- Field failure analysis, FMEA system level, 8D
- Creating task for supplier in JIRA tool related to product quality issue
- Day to day working with PIL (product issue log) listed in Agile board and product KANBAN board.
- Leading the team of function owners which include Software, purchase, quality, supplier for the series product.
- Responsible for SW and DCN release in KOLA tool.
- Review of wirings and connectors diagram.
- Next Generation EVAC owner – collecting and simplifying requirements from various departments and communicating with Supplier.
- Creating Product change request (PCR) on software requirements changes during after market phase.
- worked at Client location from Feb 2024 – Volvo GTT, Gothenburg
Technical Lead Hardware Engineer
Garrett Advancing Motion
01.2023 - 07.2023
- Design of 30kW Inverter for Fuel cell Compressor
- Hardware design which includes inverter, sensor, logic design, Aux power supply, component selection, hardware debugging, worst case calculation, simulation.
- Functional safety implementation as per ISO262626
- Implementation design of SBC and its integration with microcontroller.
- Interacting with customer, supplier, system team, software team, mechanical team.
- Mechanical integration of the board, component and connector placement.
- Schematic design and layout review and guidelines in ALTIUM, Gerber, BOM, layout, fabrication & assembly drawings
- FMEDA for hardware design
- Troubleshoot and diagnose electrical issues in test benches
Senior Application Engineer
Infineon Technologies
04.2022 - 12.2022
- Providing Technical Solutions to the customer.
- Debugging issues faced by the customer in the Evaluation board and semiconductor ICs.
- Providing the best Infineon products to the customer based on the requirements.
- Defining strategy for the promotion of Infineon technical community forum and increasing the user base
- Design and development of coolest flyback converter which includes, analog circuit design,schematic preparation, PCB layout and testing.
- Working on GaN Mosfet and driver IC, CoolMos, CoolSic devices.
Hardware Engineer
Robert Bosch Engineering and business Solution
08.2018 - 03.2022
- Technical Lead (GEN3 project owner) – 3kW DC/DC converters for EV and hybrid EV application in series production (BMW, VW, Ferrari).
- Front end Hardware design support for the team in Budapest. Providing Worst case calculation, component selection designs, Test plan preparation, Test results reviewing, Lt spice simulation, Review of Requirements from OEMs and analyzing them to include in the old platform.
- First point of contact for Teams in Europe and leading a team of 4 people in India.
- Managing the Cost Saving project for GEN 3 DC/DC converter which includes proposing and evaluating cost saving idea, finalizing the total cost saving with proposed changes of semiconductor components onboard level, total cost saved 0.9 euros – Spot awardee
- Handling PCN/PTN – review of change from the semiconductor supplier side and assessing the impact on the existing design.
- Field failure analysis - 5 why's, Fish bone analysis, cause, and effect analysis, 8D's
- Module Developer – GEN3 EVO 3kW DC/DC Converter (VW)
- Module developer for Reverse power operation of DC/DC converter from 12V to 450V for inverter DC link capacitor charging. (MEB, MQB platform).
- Design of module based on the flyback coupled inductor topology and creating the system requirement for the module.
- Performing FMEA at the module level and component change impact analysis.
- Design of software requirements for the module implemented in the TC27X MDG1 32bit microcontroller IC.
- Software calibration – changing the values of the coefficients for desired operation of the module.
- Design of onboard diagnostic function for the module which is the combination of hardware and software.
- Performing module reliability testing, module verification testing
- Layout support.
- Module thermal behavior study using data from MATLAB scripting and modifying the script as per the requirement.
- Requirement management tools - DOORS, and components management tools – EADM
- Knowledge of Communication Protocols SPI, CAN, LIN
- Bronze Awardee for saving 0.75 euro per DC/DC converter
- Module developer – 11kW AC/DC Converter (Honda)
- Design of secondary side H bridge based on Sic Mosfet 750V.
- Design of gate driver for SiC Mosfets
- Design of Auxiliary power supply 65W with multiple outputs.
- Schematic design using OrCAD and Zuken , footprint adding, BOM, netlist creation.
- PCB Layout design using Altium, foot print adding, components placement, routing, gerber file creating and viewing
- Project developer – Fuel cell 850V to 24V DC/DC (Volvo)
- Redesigning the platform as per the OEM requirements (such as change in voltage level, power level, operation mode, derating, system requirements)
- Hardware components selection such as gate driver, Mosfet, IGBT, BJT, capacitor, controller IC, Amplifier ICs, Comparator etc.
- Sensor design for HV and LV voltage, HV and LV current.
- Integrator – Gen3 Inverter (100kW) – Internal
- IGBT selection and design for 800V system
- Gate driver design and simulation
- Motor electrical performance testing
- Integration of Inverter modules.
- Miscellaneous – all projects
- Mathcad, Lt Spice simulation and Worst-case calculation, of Sensor circuits, PSFB, LLC, auxiliary power supply, gate driver design, Analog circuits.
- DC/DC Converter high voltage Testing and Debugging using INCA/CANOE.
- DC/DC Converter design - PSFB, LLC, Flyback, push pull, buck, boost, SEPIC converter.
- Magnetics simulation in tools such as ANSYS and CST studios
- Magnetics characteristics validation of Choke, CT, transformer using DPG10 and Bode100
- Operating Unichiller for coolant flow to the converter, working with Lecroy & Tektronix Oscilloscope
- PCB layout verification using Visecad
Project Trainee
Robert Bosch Engineering and business Solution
09.2017 - 06.2018
- Design of EV charger 1.5kW, closed loop AC/DC/DC for 48V system
- Design of closed loop AC/DC converter implementing average current control method and DC/DC converter implementing PI control
- Study of various international standards related to EV charging
- Design of control algorithm for the prevention of Grid overloading against bulk EV charging
- Designed temperature sensing current controller in Matlab Simulink to change the EV charging current based on battery temperature to prevent the battery Age reduction.
Consultant – Technical Project Manager
Flair Charge – Electric Trucks
08.2015 - 06.2016
- Helping the Client in identifying the best Electric Truck Segment that best fit the market through Market Research
- Project timeline creation and planning various stages of the product development
- Developing V model for the project and implementation of it through the project
- Gathering system requirements, Creating the work package where each work package contains individual modules
- Creating the technical specs for each engineering modules
- Creating teams and assigning the work package based on the competency
- Weekly meeting setup and tracking the work progress
- Developing the System level Architecture for the electric powertrain
Education
Master of technology - Power System
National Institute of Technology Calicut
Calicut, Kerala01.2018
Bachelor of Engineering - BE - Electrical and Electronics Engineering
Rajiv Gandhi Prodyogiki Vishwavidyalaya
Bhopal, MP01.2015
Skills
- MATLAB programming / Simulink,
- Lt-Spice, SABER,
- ANSYS/CST studio Magnetic simulation
- Altium Schematic design
- INCA / CAN analyzer, CANOE, DPG10/BODE100, D-space
- JIRA, KOLA, DOORS
- Project Management
- Power electronics design
- Field failure Analysis, 8D, FMEA, FTA
- Requirement Analysis and Management
- Communication
Accomplishments
1. Was involved in Bosch Ambassador Program for Bosch India to encourage associates to actively participate in the Social media campaign by BOSCH Group
2. BOSCH Spot award for Managing technical complexity systematically and saving 0.75 euro for GEN3DC/DC project per sample.
3. BOSCH Bronze Award for 0.75 Euro savings per sample in development project total savings of 3,50,000 euro and Field failure analysis.
4. Recognition from Elsevier Journal for supporting in Review activities.
5. Recognition under TITAN Technology Innovation Award for EV charger design.
Certification
- Vanderbilt University and Coursera – MATLAB Programming, ID - 7G6XXG3B6Z3G
- TUV Rheinland Certified for working with High Voltage – Cert. No. 090918-TC19760
- Google Project Management with Coursera: https://www.coursera.org/learner/sushank-sachan-6697
Publications
- CC operation of temperature dependent full bridge isolated DC-DC buck converter for battery charging applications, 2018 International Conference on Power, Instrumentation, Control and Computing(PICC) - IEEE Xplore
- Published FEBER Report within Bosch for Overloading protection of Distribution transformer against Residential clustered EV charging.
Involvement and Recognition
- Was involved in Bosch Ambassador Program for Bosch India to encourage associates to actively participate in the Social media campaign by BOSCH Group
- BOSCH Spot award for Managing technical complexity systematically and saving 0.75 euro for GEN3DC/DC project per sample.
- BOSCH Bronze Award for 0.75 Euro savings/sample in development project total savings of 3,50,000 euro and Field failure analysis.
- Recognition from Elsevier Journal for supporting in Review activities.
- Recognition under TITAN Technology Innovation Award for EV charger design.
- Involved as a Voluntary Reviewer in ELSEVIER JOURNAL – roles is to accept and reject the papersfor the publication after thorough review.
Timeline
Hardware System Engineer
Da Vinci Engineering GmbH
10.2024 - 06.2025
Consultant
MCA Sweden
11.2023 - 08.2024
Technical Lead Hardware Engineer
Garrett Advancing Motion
01.2023 - 07.2023
Senior Application Engineer
Infineon Technologies
04.2022 - 12.2022
Hardware Engineer
Robert Bosch Engineering and business Solution
08.2018 - 03.2022
Project Trainee
Robert Bosch Engineering and business Solution
09.2017 - 06.2018
Consultant – Technical Project Manager
Flair Charge – Electric Trucks
08.2015 - 06.2016
Bachelor of Engineering - BE - Electrical and Electronics Engineering
Rajiv Gandhi Prodyogiki Vishwavidyalaya
Master of technology - Power System
National Institute of Technology Calicut
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