Hybrid Senior Thermal Systems Test Engineer

at Ford Motor Company

• Job title: Senior Thermal Systems Test Engineer
• Job type: Full Time
• Experience level: Senior
• Salary: Not specified
• Degree requirement: Bachelor's Degree
• Tech skills: Python
• Location requirements: Hybrid, Long Beach, United States

About the role

• Senior Thermal Systems Test Engineer focusing on testing and improving thermal systems for electric vehicles at Ford. Collaborating across engineering teams to innovate and deliver high-quality automotive solutions.

Responsibilities

• Design and build thermal test assets spanning a range of size, scope and complexity: this could range from a simple coolant bench test to characterize a valve, to a partially completed refrigeration system with coolant and air loops, to a fully instrumented vehicle.
• Automate / script HIL testers that can replicate boundary conditions, loads etc. felt by a thermal system across a wide range of possible scenarios.
• Work with modeling engineers to validate predictions – propose tests based on prediction weaknesses, learn how to run the models themselves.
• Collaborate closely with controls engineers to validate the SW and propose improvements.
• Work closely with test and integration engineers to debug control algorithms at the bench and vehicle level.
• Lead engineering test fleets – these may consist of bucks and/or vehicles.
• Plan critical test campaigns – both at the wind tunnel and in the field.

Requirements

• B.S. in Mechanical Engineering or a related field.
• Foundational background in thermal systems (heat transfer, thermodynamics, fluid dynamics).
• 4+ years of experience using modeling tools of various scales (GT, Python, MATLAB/Simulink, Dymola, TAITherm or similar).
• Experience with basic programming best practices (e.g., readable, re-usable code).
• Experience working with high voltage powertrain and thermal systems
• Experience diagnosing and repairing HVAC components and systems
• Safe management of glycol, AC refrigerant, and oil-based liquids and gases
• Knowledge of thermal and fluid measurement sensor installation and calibration
• Experience with data acquisition systems and related sensors
• Can interpret and create wiring diagrams for test fixture construction
• Even better, you may have...
• Graduate Degree in Mechanical Engineering with a focus on thermal engineering or energy systems.
• Real-world product development experience using tests to design, validate and continuously improve a thermal system used by customers every day.
• Deep experience with refrigeration systems (compressors, heat exchangers, valves, sensors, charge and oil management) applied to automotive products.
• Deep experience with HVAC design (hardware, control strategies, energy flows within the cabin, glass properties).
• Experience modeling non-linear flow/energy circuits with first principles.
• Familiarity with battery, motor/inverter and electronics thermal/electrical models.
• Familiarity using 3D CAD software collaboratively (NX, Catia, 3DX).
• Proficiency using collaborative work tracking tools such as JIRA, Confluence and GitHub
• Testing/laboratory experience with refrigeration loops, coolant and air circuits.
• An eagerness to work cross-functionally in a dynamic environment where you are part of a high performing team.
• A system approach to design and development with the desire and curiosity to strive for exceptional delivery execution and continuous improvement.
• Experience with controls methods for automotive thermal systems

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.