Senior Thermal Systems Test Engineer

We are the movers of the world and the makers of the future. We get up every day, roll up our sleeves and build a better world -- together. At Ford, we’re all a part of something bigger than ourselves. Are you ready to change the way the world moves?

Ford’s Electric Vehicles, Digital and Design (EVDD) team is charged with delivering the company’s vision of a fully electric transportation future. EVDD is customer-obsessed, entrepreneurial, and data-driven and is dedicated to delivering industry-leading customer experience for electric vehicle buyers and owners. You’ll join an agile team of doers pioneering our EV future by working collaboratively, staying focused on only what matters, and delivering excellence day in and day out. Join us to make positive change by helping build a better world where every person is free to move and pursue their dreams.

In this position...
Thermal systems spans a diverse range of critical customer-facing attributes, hardware, and software domains. For example, our work keeps occupants comfortable, enables full vehicle powertrain capability, and empowers battery fast charging – in all weather conditions. We strive to balance heating/cooling performance, energy consumption, cost, reliability, NVH and packaging trade-offs through physics-driven, cross-functional engineering collaboration. We work closely with mechanical engineers, aerodynamicists, battery and powertrain experts, electrical engineers, embedded/controls engineers, and more through all phases of vehicle development. Your role: build and apply world-class engineering buck and vehicle testing tools to shape next generation thermal systems for electric vehicles. Deeply integrate testing into our design process; this is not a downstream check the box role. Use your domain knowledge to propose product and/or controls improvements.
 

What you'll do...
● 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.

You'll have...
● 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 f