RAE Controls Engineer

Ford Motor • Dearborn, MI

1d • Hybrid

About The Position

In this position, you will work with a cross-functional team of highly technical engineers to deliver chassis (steering, brakes and suspension) and driveline systems for conventional and electrified vehicles of the future. You will apply knowledge of control algorithms, systems engineering methods, modeling and simulation to develop vehicle controls that enable new technologies and functions for future conventional and electrified vehicles. The goal is to continuously improve the capability, robustness and value of our vehicles. You will develop control systems for our newest technologies, focusing on analyzing customer needs and defining required architecture and functionality early in the development cycle, modeling and simulating propulsion system operation, designing and implementing control algorithms, and validating designs in desktop simulation, hardware benches, test stands and prototype vehicles. Successful candidates will possess a track record of strong independent thinking, effective communication, self-motivation, complex system troubleshooting, and thrive in an environment where they need to understand the complete workings of controls and the complex interactions between subsystems.

Requirements

• B.S. or equivalent in mechanical, aerospace, electrical, systems engineering or similar field with a control systems focus
• 3+ years of experience in dynamic systems modeling and real-time controls development for automotive or similar complex electromechanical systems
• 3+ years in xEV (Motor, Inverter, High Voltage) vehicle controls development
• Understanding of automotive systems and controls, and vehicle dynamics with fundamental knowledge of general dynamics, hydraulics, electric machines, batteries, internal combustion engines, and mechatronic actuators
• Understanding and ability to apply advanced control theory including filtering techniques, state estimation, feedback controls, Model Predictive Control, etc.
• Demonstrated ability to develop embedded controls software and supporting analysis tools in Model-based and hand-code environments using a combination of MATLAB/Simulink, C/C++ and Python
• Experience with standard systems engineering tools including boundary diagrams, fault tree analyses, FMEAs, P-diagrams, etc.
• Demonstrated excellence in problem-solving (with a passion for technology development)
• Demonstrated effective communication, documentation, and interpersonal skills in a team environment.
• Proven ability to work well with others as part of a diverse global team

Nice To Haves

• M.S. or equivalent in mechanical, aerospace, electrical, systems engineering or similar field
• 3+ years of experience in distributed systems engineering including requirements management, function decomposition and allocation, failure mode avoidance, robustness analysis, and system validation and verification
• Experience using AI Assistants such as GitHub Copilot for efficient software development
• Experience working in Linux, Unix, and Windows environments
• Experience with unit testing platforms for tools development (pytest, Google Test, Ceedling)
• Experience with modern build systems (Bazel, Gradle) and continuous integration and continuous delivery systems (Jenkins, GitHub Actions)
• Experience with longitudinal controls for xEV systems (series hybrid, parallel hybrid, mild hybrid, battery electric, fuel cell)
• Familiarity with ISO26262 engineering tools including Hazard Analysis, Functional Safety Concept, Safety Requirements Specification, Functional Safety Requirements, Technical Safety Requirements
• Hands-on experience with distributed system prototyping, troubleshooting, and commissioning
• Experience with standard version control and collaboration systems (ClearCase, AccuRev, git, GitHub)
• Experience applying CAE (MIL/SIL/HIL, virtual system/plant models, regression testing) concepts and CI (Jenkins, GitHub, Gradle) tools in robust system controls development
• Knowledge of automotive communication protocols (CAN, LIN) and experience with analysis tools including CANalyzer, CANape, CANLab, etc.
• Familiarity with Ford development processes GTDS and GPDS
• Familiarity with Ford systems engineering systems and tools including VSEM, FEDE, Stages, FRD, HLF

Responsibilities

• Develop control algorithms for advanced systems to deliver vehicle attributes, including control architecture selection, algorithm simulation, implementation, and verification and validation via leveraging a combination of model-in-the-loop (MIL), software-in-the-loop (SIL), hardware-in-the-loop (HIL) and vehicle test environments
• Leverage, subsystem and component-level CAE models to analyze dynamic systems and complex system interactions, and to support concept analysis and verification, parameter optimization, and controls/design verification and validation
• Define and review physical system testing and characterization to validate CAE models and guide control system design
• Provide controls and software support to Systems Engineering and Functional Safety work partners
• Create and maintain comprehensive documentation to support global engineering and quality processes, and to facilitate technology transfer: system models, use cases, requirements, design validation tests, and methods
• Support and present research on the application of advanced controls and methods for advanced chassis and driveline systems
• Leverage connected vehicle technologies (wireless communication, location and route data, cloud-compute resources, AI/ML techniques, etc.) to improve customer experience with enhanced controls and prognostics

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