Battery Controls Integration Engineer

Battery Controls Integration Engineer

Santa Clara, CA - Relocation Assistance Provided

The Company

Our client is an innovative aerospace company designing, building, and manufacturing state-of-the-art electric air vehicles capable of transporting passengers. They are rapidly growing their team to successfully deliver next generation transportation systems.

The Job

In the Battery Controls Integration Engineer role, you will be responsible for integrating high voltage battery controls system onto test platforms and verifying BMS safety-critical functionality – enabling the use of electric vertical-takeoff-and-landing aircraft for urban air mobility. Your deliverables will span all phases of the product development life cycle: development, implementation, validation, and continuous improvement.

Core Responsibilities and Development Focus

• Verification and Testing Strategy: Develop and execute verification procedures and test plans across various environments: Simulation, Software-in-the-Loop (SIL), Hardware-in-the-Loop (HIL).
• Integrated Testing Ownership: Own the Battery Management System (BMS) controls hardware/software integrated system functionality testing on safety-critical components, utilizing HIL, SIL, and high-voltage (HV) integrated labs.
• Automation and Infrastructure: Implement updates to automated test cases in synchronization with BMS functionality development for verification and regression testing, specifically using model-based environments.
• Test System Development: Provide commissioning and maintenance support for the complete testing infrastructure required to enable HIL testing of BMS controls, algorithms, and software.
• Process and Infrastructure Improvement: Own the automated testing platform to enhance the efficiency, accuracy, and level of automation for BMS control system verification. Support continuous test infrastructure improvement, including writing and debugging test scripts on HV HIL systems.

Cross-Functional Collaboration and Integration

• Coordination and Liaison: Coordinate all integrated BMS test infrastructure and verification activities across teams. Serve as the verification liaison between the Systems Engineering organization and the High Voltage Power System / BMS's Controls and Software groups.
• Integration Activities: Perform essential integration activities for the BMS in the dedicated battery labs and integrated system labs.
• Feedback and Resolution: Provide feedback on issues and verification gaps discovered during integration to the relevant System/Software teams and collaborate on effective resolution and subsequent verification.
• Lab Stakeholder: Collaborate with lab staff to ensure continuous improvement of process and infrastructure, and assure the continuity of integration learnings into both prototype and production aircraft functional testing.
• Cross-Functional Alignment: Work closely with mechanical, electrical, system architecture, software development, and integration teams to understand new component-level hardware changes and ensure corresponding software support.

Compliance, Reporting, and Safety

• Certification Support: Maintain traceability between requirements and test results, generating all required artifacts to support software certification.
• Data Analysis: Analyze test data and present clear summaries via dashboards and failure reports.
• Failure Analysis: Investigate and lead device failure analysis to determine root cause, driving subsequent product improvements.
• Safety Compliance: Adhere to all safety procedures when operating with and around high voltage systems.
• System Support: Support HIL systems, test systems, dSPACE, python scripting, and hardware setups related to software systems.

What You Need

• Bachelor’s Degree in Electrical Engineering, Aerospace Engineering, Computer Science, or related field
• 3 years of experience with experience in Model-, Software-, Processor-, and Hardware-in-the-Loop testing
• Experience with test platforms such as dSPACE, National Instruments, Speedgoat, etc.
• Proficiency in MATLAB/Simulink design and test workflows
• Proficiency in scripting languages, e.g., Python
• Knowledge of communication protocols such as CAN, SPI, Ethernet, etc.
• Experience with CAN software tools, e.g., Vector CANalyzer
• Experience with requirement management tools
• Experience with new product development in regulated industries (e.g., aviation, medical devices)
• Excellent organization and communication skills
• Self-motivated with the ability to manage and prioritize multiple tasks
• Collaborative mindset, willingness to step in and support where needed
• Passion for learning and problem solving

Bonus Qualifications

• Experience with high voltage battery systems and controls
• Working knowledge of lithium-ion battery electrochemistry and electrothermal models
• Experience with DO-178C software verification and ARP4754 development process
• Experience with eVTOL aircraft and a basic understanding of the role of various aircraft subsystems including an electric powertrain
• Experience executing formal validation and verification activities in a civil aerospace program

Please note that this job description is intended to provide a general overview of the position and does not include an exhaustive list of responsibilities and qualifications.