Goldi Solar Vehicle Test Engineer Interview: Rounds, Questions and Preparation

What the job involves

A Vehicle Test Engineer in the EV and cleantech sector plans and runs tests on electric vehicles, batteries, motors, and controllers to verify performance, safety, and reliability. Day to day work includes setting up test rigs, running bench and on-road tests, logging data, analysing results, and reporting issues to design teams. At fast-growing companies like Goldi Solar, you may also support solar-powered or hybrid mobility prototypes and validate components against Indian and international standards.

Role and Sector Knowledge

1. 1

   What does a Vehicle Test Engineer do in an EV company, and how is it different from a design engineer?

   Explain that test engineers validate designs through experiments, while design engineers create them. Mention test planning, instrumentation, data logging, and failure reporting.

2. 2

   Why are you interested in the EV and cleantech sector, especially at a growing company like Goldi Solar?

   Connect personal motivation to India's EV transition and solar integration. Show awareness of the company's work in solar and clean energy without claiming inside knowledge of their processes.

3. 3

   What are the key differences between testing an IC engine vehicle and an electric vehicle?

   Focus on battery pack, BMS, electric motor, regenerative braking, high-voltage safety, and the absence of exhaust and transmission. Mention different test parameters like state of charge and thermal behaviour.

4. 4

   What safety precautions must be followed when testing a high-voltage EV battery pack?

   Cover PPE, insulated tools, lockout-tagout, voltage verification, working in pairs, and following AIS-038 or equivalent safety standards. Mention emergency response for thermal runaway.

Technical Concepts and Testing Methods

1. 5

   How would you test a lithium-ion battery pack for capacity, internal resistance, and thermal performance?

   Describe charge-discharge cycling at different C-rates, measuring voltage and current, using a battery cycler, and recording temperature with thermocouples. Mention comparing results to datasheet values.

2. 6

   What is CAN bus, and how is it used in vehicle testing?

   Explain that CAN is a communication protocol for ECUs. In testing, you log CAN messages to monitor motor RPM, battery voltage, temperature, and fault codes using tools like CANalyzer or a Raspberry Pi with a CAN shield.

3. 7

   What sensors and data acquisition equipment would you use to test an electric motor's performance?

   List torque and speed sensors, current and voltage probes, thermocouples, and a DAQ system. Mention sampling rate, calibration, and synchronising data with CAN logs.

4. 8

   How do you calculate the range of an electric vehicle from test data?

   Use energy consumption per km from logged battery voltage and current over a drive cycle, then divide usable battery capacity by that consumption. Mention factors like temperature, load, and driving style.

Practical Scenarios and Problem Solving

1. 9

   During a road test, the battery temperature rises faster than expected. What steps would you take?

   Stop the test safely, check cooling system operation, review current draw and ambient conditions, inspect for blocked airflow or sensor errors, and report findings with logged data to the design team.

2. 10

   You notice a sudden drop in motor power during a bench test. How would you troubleshoot?

   Check connections, controller fault codes, throttle signal, battery voltage sag, and motor phase resistance. Isolate variables one by one and document each check.

3. 11

   How would you plan a test schedule for validating a new battery pack within a tight deadline?

   Prioritise critical safety and performance tests, use parallel test rigs where possible, define clear pass-fail criteria, and communicate risks early. Mention documenting assumptions and limitations.

4. 12

   A test result does not match simulation data. What do you do?

   Verify sensor calibration, test setup, and boundary conditions. Re-run the test, compare with simulation inputs, and check for modelling errors. Report the discrepancy with evidence rather than guessing.

Behavioural and HR Questions

1. 13

   Tell us about a time you worked in a team to complete a project under pressure.

   Use the STAR method. Highlight your specific role, how you coordinated with others, and the outcome. Keep it relevant to a college project, internship, or competition.

2. 14

   Describe a situation where you made a mistake during an experiment or project. What did you learn?

   Choose a real but low-stakes example. Show ownership, the corrective action you took, and how you improved your process afterwards.

3. 15

   Are you willing to relocate or travel frequently for test assignments at sites or proving grounds?

   Answer honestly and positively if you are open to it. Mention that hands-on field testing is valuable for learning and that you are flexible.

4. 16

   Where do you see yourself in three years as a Vehicle Test Engineer?

   Show a growth path: from executing tests to designing test plans, leading a small team, or specialising in battery or powertrain validation. Align your goal with the company's growth in clean mobility.