Staff High Voltage System Design and Simulation Engineer

About the role

The Staff. HV System Design and Simulation Engineer will contribute to the advanced development of the High Voltage (HV) system architecture in Ford’s Universal EV (UEV) platform. In this role, you will be using advanced system simulation and analytical tools to model and characterize HV system performance. The developed model will also be used to check for HV and LV system interoperability by characterizing HV voltage ripple, HV isolation, HV interference on LV system, system EMC performance, etc.

Responsibilities

• HV and LV system interoperability characterization through system modeling using system simulation tools such as MATLAB-SIMULINK, PLECS, and PSIM
• Perform HV powertrain system simulation and/or co-simulation incorporating HV battery, drive unit, and other relevant components to characterize and optimize system efficiency
• Use simulation tools to model and predict HV system behavior, perform feasibility studies and provide guidance to cross functional teams
• Utilize HV system fault modeling techniques to diagnose and root cause HV system issues
• Develop HV system control algorithms using MATLAB-SIMULINK
• System simulation to characterize EMC performance of HV modules in electrical system architectures
• Perform HV system Worst Case Circuit Analysis (WCCA) using proper tools such as MATHCAD
• Define, document, and maintain HV system architecture and interface diagrams
• Review HV system architecture including wiring diagrams and propose design changes to improve system performance
• Support HV system development and component selection to optimize system performance and safety
• Collaborate with cross functional teams including SW, mechanical packaging, vehicle integration, and EPA range to characterize system behaviors and optimize performance
• Perform high voltage distribution system design and optimization
• Develop required HV system protection strategies such as response to loss of isolation to maximize system safety
• Provide guidance on HV system components selection (including HV fuse, contactor, etc.) to meet system performance targets
• Use analytical and experimental methods to ensure HV system design meets safety and regulatory standards
• Help resolve technical issues associated with integration of new HV components into HV system

Requirements

• B.S in Electrical, or Computer Engineering, or equivalent combination of relevant education and experience.
• 8+ years of experience in HV powertrain system simulation using advanced simulation tools such as MATLAB-SIMULINK, ANSYS, PSIM, PLECS, LTSpice, etc.
• 8+ years of Power Electronics HW development experience including schematic and layout design, board bring up, and bench testing
• 3+ years of experience with performing WCCA analysis on HV systems using MATHCAD or similar tools
• Deep technical knowledge on power converter topologies including isolated and non-isolated
• Extensive knowledge and experience with HV powertrain system design and development including HV traction inverters and electric motors
• Fundamental knowledge of various electric motor technologies such as IM, PMSM, SRM, etc.
• Expert in switching devices principle of operation, advanced technologies such as Wide Band Gap (WBG), and their trade offs
• Hands-on experience in performing root cause analysis of HV system issues
• Experience and working knowledge of electric vehicle’s electrical architecture
• Strong understanding of electrical engineering fundamentals and ability to apply them to automotive concepts
• Strong written and verbal communication skills
• An eagerness to work cross-functionally in a dynamic environment where you are part of a high performing team
• A systems approach to design and development with the desire and curiosity to strive for exceptional delivery execution and continuous improvement

Qualifications

• Master’s or PhD degree in Power Electronics
• 5+ years of combined Power Electronics HW design and HV system modeling experience
• Extensive experience with using system simulation tools such as PSIM, MATLAB-SIMULINK, ANSYS, and PLECS
• 5+ years of WCCA experience using MATHCAD
• Strong knowledge of power electronics system design
• Experienced with advanced problem-solving tools such as fish-bone diagram, Design For Six Sigma (DFSS), FA report, 8D documentation, etc.
• Having deep semiconductor level knowledge is a big plus