BMS Validation Engineer

Ford Motor Company • Dearborn, MI

8h • $99,100 - $166,200 • Hybrid

About The Position

The Battery Management Validation Engineer proves that high-voltage battery management hardware, software, and integrated systems do what they are required to do — from automated software regression on simulation and hardware-in-the-loop benches through energized pack and system-level testing. Assignments may include software-focused validation on simulation and hardware-in-the-loop benches or system-focused validation on energized hardware and installed systems, and may shift across the product architecture over the life of the program. The ideal candidate is disciplined about traceability and evidence, capable with instrumentation, and able to script and automate. Strength in either bench automation or energized high-voltage testing is required; strength in both is strongly preferred.

Requirements

• Bachelor's degree in Electrical, Electronics, Computer, Mechanical, or Mechatronics Engineering.
• 4+ years validating embedded electronic control systems, battery systems, or high-voltage electrical equipment.
• Demonstrated test plan authorship traceable to requirements, with disciplined test documentation.
• Practical instrumentation skill: oscilloscopes, data acquisition, power supplies, electronic loads, and communication analyzers.
• Scripting capability in Python or equivalent for test automation or data analysis.
• Either hardware-in-the-loop and test automation experience, or high-voltage laboratory and energized test experience.
• Strong written and verbal communication skills.
• Ability and willingness to travel occasionally.

Nice To Haves

• Master's degree in a related engineering discipline.
• High-voltage safety qualification, or readiness to certify immediately upon hire.
• Hardware-in-the-loop platform experience and cell or battery emulation.
• Battery cycler operation and long-duration test campaign management.
• Environmental, durability, and electromagnetic compatibility test experience.
• Familiarity with product safety, functional safety, and cybersecurity verification evidence requirements.
• Production and end-of-line test definition experience.

Responsibilities

• Translate system requirements and architect-authored design verification methods into design verification plans, executable test cases, and acceptance criteria with full traceability.
• Execute validation campaigns across sample phases and software release cycles; document results, defects, and evidence to audit standard.
• Perform fault insertion and negative testing, including sensor faults, communication loss, isolation degradation, contactor faults, overvoltage, overtemperature, and thermal event response.
• Verify diagnostic and protection behavior, safe state entry, and annunciation to external systems.
• Root-cause failures with hardware, software, and algorithm engineers; verify fixes and manage regression.
• Witness and technically review supplier verification reports for method conformance and sufficiency.
• Contribute evidence to functional safety, cybersecurity, and product safety documentation packages.
• Build and maintain working competence across both validation domains over time to provide cross-coverage.
• Build and maintain software-in-the-loop and hardware-in-the-loop benches with simulated cells, sensors, contactors, and loads.
• Develop and maintain automated regression suites integrated into continuous integration; own the pass/fail gate for software releases.
• Verify base software behavior including bootloader, software update and rollback, secure boot and flashing, communication stacks, and diagnostic services.
• Verify control logic and estimation behavior against models and requirements, including timing and communication performance.
• Maintain plant models and test scripts as the design evolves.
• Plan and execute validation on energized modules, packs, and full systems using cyclers, environmental chambers, and instrumented test setups.
• Verify measurement accuracy and end-to-end sensing chains, balancing effectiveness, thermal behavior, and high-voltage sequencing on real hardware.
• Verify interoperability with surrounding electrical, thermal, and control systems.
• Define end-of-line and production test content, methods, and acceptance limits.
• Support commissioning, field troubleshooting, and returned-unit analysis.

Benefits

• Immediate medical, dental, vision and prescription drug coverage
• Flexible family care days, paid parental leave, new parent ramp-up programs, subsidized back-up child care and more
• Family building benefits including adoption and surrogacy expense reimbursement, fertility treatments, and more
• Vehicle discount program for employees and family members and management leases
• Tuition assistance
• Established and active employee resource groups
• Paid time off for individual and team community service
• A generous schedule of paid holidays, including the week between Christmas and New Year’s Day
• Paid time off and the option to purchase additional vacation time.

What This Job Offers

• Job Type: Full-time
• Career Level: Mid Level