HiL Plant Modeling & Configuration Engineer

GM Performance Power Units•Concord, NC

2d•Onsite

About The Position

GM Performance Power Units is seeking a highly motivated HiL Plant Modeling & Configuration Engineer to own development of the real-time power-unit plant models used to support testing and validation of Formula 1 control software. Based in Concord, North Carolina, this role offers a unique opportunity to contribute to a foundational area of our F1 program and join a world-class Electronics & Controls team. The HiL Plant Modeling & Configuration Engineer will develop, integrate, correlate, and maintain the dynamic plant models required to operate the TAG-700 SECU in a closed-loop HiL environment. The primary scope covers the Formula 1 power unit, including the internal combustion engine, air path, fuel system, turbocharger, energy recovery system, hydraulics, gearbox, differential, electrical network, thermal systems, sensors, and actuators. Vehicle-side models will be integrated from the responsible simulation teams. A key responsibility will be selecting model fidelity against the targeted control functions, required dynamic bandwidth, correlation accuracy, and real-time execution budget. The objective is a balanced simulation that captures the interactions needed to support closed-loop controls validation without unnecessary complexity.

Requirements

Bachelor’s or Master’s degree in Mechanical, Electrical, Controls, Automotive, Aerospace, Mechatronics, or a related engineering discipline.
Four or more years of experience developing and integrating dynamic-system models for closed-loop control applications.
Experience with fixed-step real-time simulation is preferred; deployment of plant models to HiL platforms is highly desirable.
Strong proficiency with MATLAB and Simulink for dynamic-system modeling, simulation, data analysis, and model integration.
Experience developing and integrating multi-domain plant models for closed-loop control applications, with the ability to adapt models for fixed-step real-time execution.
Practical understanding of fixed-step simulation, solver selection, task scheduling, model execution rates, numerical stability, state initialization, and deterministic real-time execution.
Familiarity with dSPACE, Speedgoat, or a comparable real-time simulation platform.
Working knowledge of internal combustion engines, hybrid powertrains, electric machines, driveline systems, sensors, actuators, and embedded controller interfaces.
Experience using test data or higher-fidelity simulation results for model parameterization, correlation, and validation.
Strong systems-level thinking, technical communication, problem-solving, and cross-functional collaboration skills.

Nice To Haves

Hands-on experience deploying and commissioning real-time plant models on HiL platforms for Formula 1, motorsport, hybrid powertrains, advanced automotive controls, aerospace propulsion, or another performance-critical system.
Hands-on model-development experience in several power-unit domains, such as engine-speed dynamics, combustion torque, gas exchange, turbochargers, electric machines, inverters, batteries, thermal systems, hydraulics, or gearbox and driveline dynamics.
Experience with Functional Mock-up Interface, Functional Mock-up Units, co-simulation, reduced-order modeling, surrogate modeling, or model exchange between simulation environments.
Experience enabling automated test frameworks, fault injection, regression testing, and requirements-based validation through configurable HiL environments.
Familiarity with Formula 1 power-unit architecture, TAG-700 hardware, motorsport data systems, and dyno or trackside development environments.

Responsibilities

Own development, integration, correlation, and maintenance of the real-time power-unit plant models required to operate the TAG-700 SECU in a closed-loop HiL environment.
Work with simulation teams from GMPPU, GM Motorsports, and Cadillac F1 to create a modular representation of the ICE, air path, fuel system, turbocharger, ERS, electrical and thermal systems, gearbox, differential, sensors, actuators, and supporting interfaces, while integrating vehicle-side models from the responsible teams.
Work with simulation teams from GMPPU, GM Motorsports, Cadillac F1, and subsystem subject-matter experts to select fidelity based on targeted control functions, required bandwidth, correlation accuracy, available data, and real-time execution budget.
Convert detailed engineering models into efficient real-time representations, applying fidelity where it creates measurable controls-validation value.
Validate plant models through correlation against dyno, component, track, and higher-fidelity simulation data.
Define correlation criteria and document model assumptions, operating ranges, limitations, parameter sources, intended use cases, and validated operating envelope.
Work with electrical engineers to specify, configure, commission, and optimize the SECU HiL platform.
Develop detailed supplier requirements covering real-time processors, I/O, signal conditioning, actuator loads, communication interfaces, electrical fault insertion, controller power sequencing, and crankshaft and camshaft signal generation.
Monitor processor loading, execution timing, communication performance, and model stability to ensure efficient, deterministic, and reliable operation of the HiL environment.
Provide a representative and repeatable environment for controls and validation engineers to test TAG-700 software under normal operation, transients, operating limits, degraded modes, and sensor, actuator, electrical, or communication faults.
Support reproduction of relevant dyno and track conditions; ownership of control-validation testing remains with the validation teams.
Support automated testing by making plant parameters, operating conditions, faults, and measurement channels configurable within the HiL environment.
Maintain plant models, parameters, I/O configurations, hardware mappings, and supporting utilities under structured version and configuration control.