Thermal Systems Simulation Integration Engineer

GM•Warren, MI

1d•Hybrid

About The Position

This role involves participating in virtual engineering by developing and executing the integration of full-vehicle cross-functional co-simulation packages. The engineer will develop and integrate co-simulation packages for various vehicle systems including Battery, Driveline, Vehicle Dynamics, Powertrain Cooling, HVAC/Cabin, Energy and Drive Quality, and Electric Drive Unit (DU) models with virtual controllers, software, and calibration. The position requires conducting vehicle-level virtual simulations for powertrain cooling, HVAC cooling, battery pack cooling, electric motors, high voltage power electronics components, and thermal protection. Additionally, the engineer will perform vehicle-level energy consumption simulations, implement energy and thermal control strategies to meet performance attributes and EPA fuel economy drive cycles, and work on BEV programs with a focus on process efficiency and innovation. The role also includes developing and performing 1D and thermal control simulations for new programs, ensuring the validity of CFD and 1D models, and aligning with software release and calibration milestones. Collaboration with other engineering teams, communication of simulation results, and acting as a point of contact for co-simulation users are key aspects of this position. The engineer will also advocate for virtual methods, define innovation opportunities, participate in product design reviews, and assist in the development of standard analysis procedures and tools. Ensuring co-simulation packages meet defined standards and representing thermal systems needs among peers are also responsibilities. The role involves making design changes to demonstrate benefits, performing 'what if' studies, and taking ownership of simulation activities to guide the design team. Preparation of management summaries and reports is also required.

Requirements

Bachelor’s degree in Mechanical Engineering, Electrical Engineering, Software Engineering, Computer Science, or related field of study
Two (2) years of experience as a Thermal Systems Simulation Engineer, Electrical Engineer, CFD Engineer, or related role.
Two (2) years of experience with simulation data management (SDM) systems including Teamcenter and RTC.
Two (2) years of experience with CFD tools including STAR-CCM+, FLUENT, and SIMERICS.
Two (2) years of experience characterizing thermal systems using 3D tools including CFD.
Two (2) years of experience creating and implementing 1D plant models of the underlying components and subsystems.
Two (2) years of experience with system tools or controls integration CAE tools including GT Power, AMESIM, Carsim, Carmarker, MATLAB, Simulink and other similar CAE tools.

Responsibilities

Participate in virtual engineering by developing and executing the integration of full-vehicle cross-functional co-simulation packages.
Develop and integrate co-simulation packages by including Battery, Driveline, Vehicle Dynamics, Powertrain Cooling, HVAC/Cabin, Energy and Drive Quality, Electric Drive Unit (DU), and Driver models with virtual controllers, software, and calibration.
Conduct vehicle-level virtual simulations for powertrain cooling, HVAC cooling, battery pack cooling, electric motors, high voltage power electronics components, and thermal protection.
Perform vehicle-level energy consumption simulations and implement suitable energy and thermal control strategies to meet vehicle performance attributes and EPA fuel economy drive cycles.
Work on BEV programs with a focus on process efficiency and innovation.
Develop and perform 1D and thermal control simulations for new programs based on vehicle content and functional objectives.
Ensure the validity of Computational Fluid Dynamics (CFD) and 1D models, including input data such as geometry data from Product Lifecycle Management Systems like Teamcenter and RTC.
Perform simulations using tools such as STAR-CCM+, FLUENT, SIMERICS, MATLAB, Simulink, AMESIM, Kuli, GT-SUITE, and AVL-CRUISE.
Align with software release and calibration milestones to keep the virtual vehicle co-simulation package current.
Collaborate with aero and thermal engineers, release groups, and design studios to communicate simulation results and implement design improvements.
Prepare presentations to communicate simulation results and design recommendations to various groups.
Act as a single point of contact for co-simulation users for thermal systems to resolve concerns on usage.
Perform resolution of program issues by rallying co-simulation partners to meet the demands of the problem.
Advocate for the adoption of virtual methods for vehicle design, development, and validation.
Define strategic opportunities for innovating processes and methods.
Participate in product design and development team reviews and regularly present analysis results to product engineering peers and management using the latest visualization tools.
Assist in the development and enhancement of standard analysis procedures and tools to improve fidelity and execution speed.
Ensure co-simulation packages meet standards as defined by the Simulation Integration Engineering governance team, including model management for documentation and deployment using version control systems such as Git, SVN, and TFS.
Represent the needs of thermal systems among Simulation Integration Engineering peers from other disciplines.
Make design changes to demonstrate benefits and perform multiple “what if” studies to guide the design process.
Engage in vehicle development activities and take ownership of simulation activities to best guide the design team.
Prepare management summaries and reports that meet the needs of Directors and Chief Engineers.