12V Power Supply Application Engineer

Ford Motor Company•Dearborn, MI

47d

About The Position

We are the movers of the world and the makers of the future. We get up every day, roll up our sleeves and build a better world -- together. At Ford, we're all a part of something bigger than ourselves. Are you ready to change the way the world moves? In this position... The Power Supply Application Engineer is responsible for sizing, packaging, validating, and releasing the starting/charging system for ICE (Internal Combustion Engine) and EV (Electric Vehicle) applications. This includes several key components: Alternator, Starter, Battery, ASIL (Automotive Safety Integrity Level) rated redundant Power supply components including additional Batteries, Ultra Capacitors, and Battery Management Sensors (BMS). The Power Supply Application Engineer is responsible for sizing, packaging, validating, and releasing the starting/charging system for ICE (Internal Combustion Engine) and EV (Electric Vehicle) applications. This includes several key components: Alternator, Starter, Battery, ASIL (Automotive Safety Integrity Level) rated redundant Power supply components including additional Batteries, Ultra Capacitors, and Battery Management Sensors (BMS).

Responsibilities

Perform Charge Margin analysis with time average, transient, and ASIL sizing models
Interface with program team to package all components in a suitable location
Interact with Powertrain FEAD (Front End Accessory Drive) to ensure proper belt loading and mounting structure for the alternator
Interact with Powertrain to ensure proper interface for the starter motor
Interact with Powertrain calibrators to establish and confirm charging system related calibration values such as electrical idle kickers to support charge margins
Work with suppliers to develop design concepts and define the costs that support the application both electrically and mechanically. Lead To4 (Team of Four) meetings.
Gain approval from the program for all tooling, piece costs, and ED&T (Engineering Design & Testing) associated with power supply components
Work with VO (Vehicle Assembly Operations) to ensure component package meets assembly and ergonomic targets
Work with VO and supplier to develop proper dunnage
Work with FCSD (Ford Customer Service Division) to ensure proper serviceability of power supply components
FEDEBOM (Bill of Materials) / WERS (Worldwide Engineering Release System) release final designs for all power supply components (Alternator, Battery, Battery Labels, Battery Blankets, Starter, Starter Fasteners/Torque specs, Solenoid caps, BMS Sensors, ASIL Ultra capacitors and Energy Modules, etc…)
Complete component FMA (Failure Mode Analysis) documentation including CPAs (Change Point Analysis) and SCCAFs (Special Characteristics Communication and Agreement Form)
Signoff for all vehicle builds (TDC, DCV, TT, PP) at multiple locations
Establish required SDS (System Design Specifications) testing through FEDEDVP (Design Validation Plan) for each program and upload test results
Support VEV (Vehicle Evaluation & Verification) Wind tunnel testing to validate sizing and component temperatures on each application
Conduct cold crank testing to verify battery CCA (Cold Cranking Amps) sizing for powertrain cold crank RPM target
Support/Conduct Garage test to verify Static loads, Key Off Loads, Volt drops, Idle up, and failure diagnostics
Interact with EDS (Electrical Distribution System) team to ensure proper wire size and connections to interface with our components and to meet system volt drop
Lead TDRs (Technical Design Reviews) prior to key program milestone events (TDJ, FDJ, PEC)
Interact with Purchasing and Suppliers to complete ESOW's (Engineering Statement of Work) and Supplier Sourcing Contracts / Supplier on Board Agreements (SOBA)…Handled via Tof4 meetings
Review, edit, and signoff Owner and Workshop manuals for Power Supply content
Monitor AIMs (Automated Issues Management) and DURIS (Durability Information System) and react to any issues and follow to closure.
Monitor and react as needed to warranty trends
React to Voice of the Customer Fleet issues and follow to closure.
Support Fuel Economy team with development and certification testing as related to BMS.
Support TVM (Team Value Management) efforts to implement agreed cost reduction changes