Powertrain Controls Simulation Model Developer - Plant Modeling

Ford Motor • Dearborn, MI

2d • Hybrid

About The Position

The Core Modeling and Simulation team supports powertrain controls developers and calibrators with an ecosystem of advanced simulation tools used to validate modern control systems. The Core Modeling and Simulation Team is responsible for creating, maintaining, and scaling the virtual vehicle ecosystem. Their primary mission is to eliminate the dependency on physical prototypes during the software development cycle. This is not a traditional mechanical engineering team, nor is it a pure software team. It is a hybrid group of multi-disciplinary experts. The team operates like a modern software development house, applying software engineering best practices to physical modeling. Joining this team means having a massive lever of influence; your models will directly impact the development and safety of almost every vehicle in the Ford lineup. Our Mission: We build Ford's "digital twins" to eliminate dependency on physical prototypes during the software development cycle. We create the virtual playground where embedded software controls and calibration teams can safely test, break, and perfect vehicle code. Our Culture & Dynamics: We are a hybrid group of multi-disciplinary experts—combining physical systems modeling (thermodynamics, electromagnetics, fluid dynamics) with modern software engineering. We pride ourselves on a culture of mentorship, collaborative code reviews, and cross-functional learning. Our Technical Ecosystem: We operate like a modern software development house. We manage our codebase using Git, track our work in Jira, and utilize an automated Continuous Integration (CI) pipeline to run unit, system, and full-vehicle validation maneuvers. Our Reach: We are a highly visible hub within Ford, collaborating daily with Physical Component Design Teams, Embedded Controls Teams, and Calibration/ADAS teams to distribute our plant models as Functional Mock-up Units (FMUs). In this role, you will focus on Plant Modeling; building the high-fidelity virtual representations of the physical vehicle hardware (the "plant," such as engines, electrical networks, and transmissions) that we use to test and validate our control software. By creating these virtual environments, you enable our teams to run comprehensive Model-in-the-Loop (MIL), Software-in-the-Loop (SIL), and Hardware-in-the-Loop (HIL) testing scenarios long before physical prototypes are built.

Requirements

• B.S. in Mechanical Engineering, Electrical Engineering, Systems Engineering, or a related technical field.
• 3+ years of experience designing, building, and validating simulation models of automotive powertrain or vehicle systems.
• 3+ years of hands-on experience using MATLAB, Simulink, and Simscape.

Nice To Haves

• M.S. in Mechanical Engineering, Electrical Engineering, or a related technical field.
• Direct experience testing and validating ECU control strategies in Model-in-the-Loop (MIL), Software-in-the-Loop (SIL), and Hardware-in-the-Loop (HIL) environments.
• Experience with scripting languages (Python, MATLAB m-scripting) to automate simulation execution and data analysis.
• Familiarity with Agile workflows and project management tools like Jira.
• Experience with code-base version control systems like Git.
• Experience developing models within an established software ecosystem, adhering to strict interface standards (e.g., using S-functions, reference models, variant subsystems, or Functional Mock-up Units/FMUs).
• Experience leveraging AI-assisted engineering tools (such as GitHub Copilot and Model Context Protocol/MCP extensions) to accelerate model development, debugging, and testing.

Responsibilities

• Architect & Design Plant Models: Define system architectures, subsystem interfaces, and component models in Simulink and Simscape. Ensure models are detailed enough to validate control systems but fast enough to run in real-time (or faster) on HIL and SIL simulators.
• Lead Whitespace Projects: Own the end-to-end development, integration, and validation of our new Simscape-based diesel engine and electrical system models.
• Develop Parameterization Strategies: Establish strategies for populating and tuning plant models using data sourced from physical component testing, dyno runs, and vehicle calibration activities.
• Integrate with Simulation Infrastructure: Design robust model interfaces, paying special attention to virtual sensors and actuators to ensure seamless integration with our automated MIL/SIL/HIL testing processes.
• Validate & Automate: Apply an iterative development approach. Use our automated Continuous Integration (CI) pipeline to run unit, system, and full-vehicle validation maneuvers, comparing simulation results against physical vehicle data.
• Collaborate Cross-Functionally: Partner with a deeply experienced team of modelers, controls engineers, and ADAS teams. Build an internal network of Ford system experts to align simulation capabilities with future vehicle product cycles. Apply your knowledge and experience with automotive systems to develop models which are appropriately detailed, yet fast enough, to support validation of ECU control systems in real-time or faster.

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