Dynamometer Test Development Engineer

BorgWarner PowerDrive Systems is currently looking for “dynamic, results driven” individual to join as a DYNAMOMETER TEST DEVELOPMENT ENGINEER specializing in automotive testing and test equipment procurement and development at our Propulsion Technical Center (PTC) in Auburn Hills, Michigan.

In this role, and under direct supervision of the Engineering Operations Manager, the Test Development Engineer will be responsible for the planning and proper execution of tests defined by the Design Validation Plans (DVPs) to test components, sub-systems, and integrated electric propulsion systems for Hybrid and Electric Vehicle applications. The system level validation includes rotating electric machines, power electronics, software, and driveline systems. This also includes the identification of testing capability gaps and championing resolution of those gaps via the procurement of testing equipment. This is 100% onsite and is not a remote or hybrid work position.

Key Responsibilities

• Identify capability and equipment needs based on test demands and advise on the overall test strategy at PTC. This includes current and near-term programs, as well as working with the advanced engineering group on future testing needs.
• Work with the team to establish requirements for new equipment, improvements to existing equipment, and acceptance criteria for both build and test.
• Work with the facilities team and champion any facility work to accommodate build and test equipment.
• Provide concepts, budget and timing estimates for new equipment and improvements.
• Work with purchasing to develop RFQs and identify equipment providers for the new equipment and improvements.
• Provide technical expertise during new equipment and improvement quote evaluation and supplier selection.
• Develop Appropriation Requests to justify and receive approval to procure new equipment and improvements.
• Provide new equipment and improvement project management, which includes managing suppliers, internal and external project timelines, open issue lists, shipment and installation, and run-off/acceptance, and providing professional updates to the team on the progress of projects.
• Be the technical expert on the operation and design of build and test equipment, including the refinement and in-house development of the equipment controls and software, author instructions for build and test equipment, and provide support and training to the team.
• Coordinate and Support calibration of build and test equipment.
• Provide troubleshooting, including data analysis, and root cause identification on build and test equipment and lead implementation of solutions.
• Be the technical liaison to others to provide requested technical information about build and test equipment.
• Assist the Validation Engineering and other Engineering teams to create and perform test procedures, ensure Device Under Test (DUT) operates properly, and diagnose and resolve any issues related to the test equipment and the interface to the DUT by assisting with test result analysis for data integrity/accuracy.
• Establish, document, implement, and share equipment best practices.
• Review DVP provided by the Validation Engineers and other Engineers, support discussions with product development team, and provide test execution timing and cost estimates.
• Identify required equipment resources to support DVP. Ensure best cost/performance/timing options for test execution.
• Develop software and hardware requirements for new technology define equipment required to test current and future products, along with innovation to improve standard work regarding the equipment.
• Integrate, troubleshoot, and commission electric propulsion systems including control systems, inverters, rotating electric machines, and automotive driveline components to properly execute validation testing.
• Define and manage critical path timing issues of tests in order to ensure on-time test completion.
• Define and implement testing standards to meet defined targets in the intended product environment.
• Follow execution of tests to completion.
• Analyse test data to ensure testing was executed properly, meets acceptance criteria, and learnings are communicated to the Validation engineering team including documentation of non-compliance triggering 8Ds for test execution.
• Support Validation engineering, and other Engineering, on root cause analysis of product failures.
• Develop test strategies to align with product roadmap and ensure test technologies are aligned with both present and future product line needs.
• Provide technical expertise on DVP testing and advise the Validation Engineering team on best practices and efficient execution of work.
  
  

What We’re Looking For

• B.S. Mechanical/Electrical/Systems/Mechatronics Engineering required 
• 3 years of engineering experience in Electric Vehicle Propulsion systems required
• Prior Test & Validation experience in a laboratory/test environment required
• Experience in integrating, troubleshooting, and commissioning electrified powertrain applications, including inverters, controls, drivelines, and rotating electric machines preferred, preference given to automotive experience
• Understanding of vehicle communications protocols that interface with inverter and electric motor systems CAN, CAN open, CANoe, CAN FD, FlexRay
• Statistical analysis and strong analytical experience preferred
• Demonstrates on the job professional and technical competence
• Strong written and verbal communication skills in English required
• Proficient in Microsoft Office suite of software
• Ability to routinely work in a hands-on manner required
• Ability to work flexible hours to support multi-shift operation if necessary
• Ability to travel domestically and internationally up to 10%
• Ability to work under limited supervision (self-driven / self-starter)
• Customer focused, with strong teamwork and collaboration skills required
• Likes challenging problems with strong problem-solving skills
• Must be highly aware and adhere to high voltage safety standards and procedures, or willing to learn and be certified
• Experience with National Instruments controls type software (LabVIEW, VariStand, TestStand, etc.) and hardware preferred
  
  

Internal Use Only Salary

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