Vehicle Controls Engineer - Propulsion Controls

Ford Motor • Dearborn, MI

18h • $99,600 - $192,900 • Hybrid

About The Position

Do you have what it takes to make smart vehicles for a smart world? Join the Ford Research and Advanced Engineering team, where you’ll work with a cross-functional team of highly technical engineers to deliver propulsion systems for electrified vehicles of the future. We’re seeking forward-thinking, laser-focused professionals with a passion for bringing innovative, exciting, and sustainable ideas to life. We apply our knowledge of control algorithms, systems engineering methods, modeling and simulation to develop vehicle controls that enable new technologies and functions for future electrified vehicles. Our goal is to continuously improve the capability, robustness and value of our vehicles. As a team, we are relentless about continuous improvement for the entire control system development process. We are seeking a highly technical professional who will develop control systems for our newest powertrain technologies. You will focus 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 for this position 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 propulsion controls and the complex interactions between subsystems. In this position, you will work in Research and Advanced Engineering, meaning you are developing technologies for future vehicle programs, not just fixing legacy code. You will take your designs from pure math and desktop simulation (MIL/SIL) to hardware testing (HIL), and ultimately to calibrating and driving actual prototype vehicles. You will leverage modern software practices, automated CI/CD pipelines, and cutting-edge AI coding assistants like GitHub Copilot to accelerate development. You will harness the power of cloud computing, wireless vehicle data, and AI/ML to develop predictive, self-optimizing energy management systems.

Requirements

• M.S. or equivalent in mechanical, aerospace, electrical, systems engineering or similar field with a control systems focus
• 6+ years of experience in dynamic systems modeling and real-time controls development for automotive or similar complex electromechanical systems
• 6+ years in roles requiring understanding of automotive powertrain (including hybrid electrical vehicle) systems and controls, and vehicle dynamics with fundamental knowledge of general dynamics, hydraulics, electric machines, batteries, internal combustion engines, and mechatronic actuators
• 6+ years in roles demonstrating the ability to develop controls software for embedded targets using C or C++
• 6+ years in roles demonstrating the ability to use Matlab/Simulink or Python for system modeling, simulation, scripting, and data analysis
• 6+ years of experience working in Linux, Unix and Windows environments
• 6+ years of experience with unit testing platforms for tools development (pytest, Google Test, Ceedling)
• 6+ years experience with standard systems engineering tools including boundary diagrams, fault tree analyses, FMEAs, P-diagrams, etc.
• 6+ years in roles demonstrating excellence in problem-solving (with a passion for new technology development)
• 6+ years of experience in roles requiring effective communication, documentation, and interpersonal skills in a team environment and the ability to work well with others as part of a diverse global team

Nice To Haves

• Ph.D. 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 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 using Matlab/Simulink for embedded controls development
• 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, simulate, and implement advanced embedded control algorithms (including feedback controls, state estimation, and Model Predictive Control) to optimize vehicle efficiency, performance, and drivability.
• Leverage Model-in-the-Loop (MIL), Software-in-the-Loop (SIL), and Hardware-in-the-Loop (HIL) environments to rigorously test and validate your designs before they hit the road.
• Utilize physics-based and data-driven CAE models of electric motors, batteries, engines, and mechatronic actuators to analyze complex system interactions and optimize parameters.
• Collaborate with systems engineering and cloud teams to integrate connected vehicle data (traffic, route, weather) and machine learning models for advanced energy prognostics.
• Document and present your research to global engineering partners, facilitating the seamless transfer of advanced technology into production vehicle programs.

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: Senior