€100M
BMW customer handover
EE / FIRMWARE / INDUSTRIAL AUTOMATION / RENEWABLES
Mohammad Hamzah Warsi — building the low-level systems that keep high-stakes hardware honest.
Electrical & Electronics Engineer · Firmware · Battery Test Infrastructure · Automation
MEng in Electrical & Electronics Engineering (Nottingham). Direct engineering experience across BMW, Sony, Fraunhofer, Varta and PEC NV — shipping bare-metal and Linux firmware, industrial robotics, and validated test infrastructure in environments where a wiring fault means a safety incident, not a bug ticket.
30%
downtime reduction, Sony
84,000 Ah
cell pallet prototype, 20 cells
2
peer-reviewed publications
Experience
01 / TIMELINE
Electronics Engineer — Firmware & Testing
PEC NV, Belgium
Feb 2025 – Dec 2025
- Developed bare-metal and Linux-based firmware for Integrated Cell Testers (TI MCUs, C) for BMW and Fraunhofer — new docking-controller functions and optimized low-level control logic to reduce test-cycle variability.
- Integrated pressure transducers (±1% accuracy), vacuum systems, safety systems and HMI monitoring for real-time cell control; built 3-way valve and fan control logic for thermal regulation.
- Diagnosed and corrected an overheating safety issue (incorrect wiring) on Varta testers; delivered a probe comparison study for Fraunhofer.
BMW Project — Wackersdorf, Germany
- Prototyped a new cell pallet for 20 cells at an 84,000 Ah charging rate (4.2V max) for BMW's "Neue Klasse" vehicles; refined testing parameters to improve safety margins without compromising throughput.
- Delivered a 1-week rapid intervention resolving wiring faults, overheat risk, sensor placement and a condensation root cause; completed tower RD01 validation, contributing to the €100M customer handover.
Integrated Cell Tester Towers — Firmware Detail
- AI8 modules: firmware calibration update (Keil uVision), refined lookup tables and gain offsets, validated with documented before/after accuracy.
- Safety systems: reformatted alarms for service engineers; added bimetal-flicker and GTS air-pump failure detection; built a DO/DI cross-validation health check and evaporator post-run cooling logic.
- THC cards: calibrated and validated 40 thermal control cards; found and fixed register misconfiguration and offset errors; automated calibration scripts and reduced manual steps.
- Pressure transmitters: real-time monitoring across –1 to 12 bar, ±1% accuracy, live HMI integration with overpressure alerts.
- Type C pallet: contributed to the next-generation pallet deployed at BMW, reducing contact-resistance variability and authoring best-practice test documentation.
Automation Engineer Intern
Sony EMCS, Malaysia
Jun 2022 – Sep 2022
- Deployed and optimized Fanuc and Mitsubishi robots on a live TV production line, achieving a 30% reduction in downtime within 3 months.
- Led control panel and power system troubleshooting to keep production uninterrupted.
- Designed an Excel-based error dashboard enabling faster root-cause analysis.
Machine Learning Engineer
Think Outside, Norway
Feb 2022 – May 2022
- Built time-series forecasting models for electricity prices and water availability, supporting 5-year energy planning for hydropower and wind integration.
- Owned the end-to-end data pipeline — cleaning, preprocessing, feature selection, model tuning — improving forecast accuracy.
- Established reproducible ML workflows with data versioning and experiment tracking.
Featured Projects
02 / APPLIED WORK
Power · Embedded · Simulation
Energy Harnessing System for Smart Highways
Multi-source renewable energy system for Malaysian highways, harvesting wasted vehicle energy to power street utilities. Piezoelectric transducers with a full-wave bridge rectifier converted pulsed mechanical input (~65V) to a regulated 12V output, while a closed-loop DC-DC boost converter stabilized a wind turbine's fluctuating 10–20V output to a constant 24V with under 2mV ripple. Wind turbine simulations (Ansys Fluent) projected up to 350W at highway speeds from a NACA 4412 horizontal-axis design. All sub-systems — piezoelectric, thermoelectric, wind — were integrated onto a single PCB and validated in LTspice, Simulink, and partial physical prototyping.
350W projected output<2mV rippleLTspice / Simulink / Ansys Fluent
Power Electronics
Switch-Mode Power Supply
12V/2A buck converter using a TL494 PWM controller and MOSFET switching at 100kHz, with a custom 4-layer PCB routed in KiCAD. Reduced gate-drive parasitic inductance and added a freewheeling diode after oscilloscope-based waveform troubleshooting.
~85% efficiency150mV rippleKiCAD
Embedded · ML
Edge Coffee Leaf Disease Classification
Trained five deep learning models (MobileNetV2, VGG-16/19, DenseNet121, PentaCNN) on the JmuBen dataset, then deployed and benchmarked the best performer across GPU, TPU and VPU using a Google Coral Developer Board Mini for real-time, on-device inference.
98.9% training accuracy10ms vs 40ms inference
Signal Processing · STM32
Doppler Radar Speed Gun
Continuous-wave Doppler radar speed gun using an HB100 microwave sensor (10.525GHz) and an STM32. Designed an op-amp band-pass signal-conditioning stage and a zero-crossing algorithm to convert Doppler shift to velocity, calibrated against a known moving target.
±5% error vs commercial gun
Robotics · Controls
Hercules 4WD Line-Following Robot
Autonomous 4WD robot on an Arduino Mega with a PID control loop over an 8-sensor IR array, driving four DC geared motors through an L298N driver. Self-etched PCBs for the sensor array and a 3D-printed AutoCAD sensor mount.
PID controlCustom PCB + mount
Publications
03 / RESEARCH
Published
Advances in Energy Harnessing Techniques for Smart Highways: A Review
Consolidates research on highway energy-harvesting technologies — piezoelectric, thermoelectric, pyroelectric, electromagnetic, solar — with a comparative assessment of principles, trade-offs and challenges for researchers, engineers and policymakers.
Published
Real-Time Disease Classification in Coffee Plants with Coral Developer Board Mini
Automated coffee-leaf disease classification on a Coral Developer Board Mini with Edge TPU; MobileNetV2 reached 98.9% training accuracy, with the Coral board outperforming a GPU workstation on inference latency.
In review
Detecting Coffee Leaf Diseases with the Google Coral Developer Board Mini
In review
Wired Highways: Energy Production for Roads
Skills & Tools
04 / STACK
Embedded & Firmware
TI MCUBare-metal CLinux firmware
STM32ArduinoKeil uVision
Power, PCB & Automation
Circuit & PCB DesignKiCADPower Electronics
Cell Testing & ValidationFanuc / Mitsubishi RoboticsWiring Systems
Data, Simulation & Delivery
LTspiceSimulinkAnsys Fluent
Python / MLTroubleshootingCross-functional Delivery
Education & Certifications
05 / CREDENTIALS
MEng, Electrical & Electronics Engineering
Foundation in Engineering
Languages
- English Professional
- Hindi Native
- Urdu Native
- Malay Intermediate
- C Language, Basic to Advance Learnvern, ongoing
- Legacy JavaScript Algorithms & Data Structures freeCodeCamp, 2023
- Data Analysis with Python freeCodeCamp, 2022
- Machine Learning with Python freeCodeCamp, 2022
- Responsive Web Design freeCodeCamp, 2022
- Data Visualisation using Python IBM, 2021
- Big Data 101 IBM, 2021
- Computer Networking — Wired & Wireless Alison, 2021
- Python for Pentesters Alison, 2021