Senior Staff Geartrain Architect

The Geartrain Architect will be responsible for defining, conceptualizing and detail analyzing geartrain systems that deliver as close as optimal system level trades between NVH, efficiency, durability, cost and manufacturability for any given application, you will be responsible for defining macro and micro geometry of any part in the power unit that spins and transmits torque such as splines, gears, bearings, differentials, half-shafts, clutches and axle shafts. You will also be responsible for defining the pathway for future gear train technologies, we are seeking a talented and creative individual who is passionate about Powertrain engineering and development. 

What you’ll be able to do: 

• Closely collaborate with vehicle modeling and Electromagnetic motor design groups to define ideal gear ratios. 
• Gear mesh macro geometry definition based on packaging, NVH, efficiency and durability requirements. 
• Gear mesh micro geometry definition based on bearing, shaft, and cases stiffnesses and deflections. 
• Analyze transmission error under different working conditions and manufacturing tolerances. 
• Perform numerical simulations and NVH analysis of geartrains. 
• Develop gear and bearing contact and bending fatigue models for life prediction and optimization. 
• Balance manufacturing tolerances to guarantee robust gear meshes at reasonable manufacturing costs. 
• Closely collaborate with structures team to define limits for gear meshes and bearings misalignment. 
• Define and analyze bearing attributes such as arrangement, type, size, internal clearances, cross corner tolerances, preload, special heat treatments, etc. 
• Lead problem solving investigations to resolve early development stage NVH and or durability issues. 
• Collaborate closely with the Test engineers and subject matter experts to develop Test rigs and test plans to help validating, characterizing, and refining the analysis performed. 
• Steer geartrain research and lead development of advanced technologies.
• Implement new design processes, methodologies, and analytical tools to further optimize the development process. 
• Develop and maintain comprehensive documentation and reports related to the analysis work. 
• Contribute to design reviews, test plans, and requirements reviews to further optimize the powertrain system cross functionally. 
• Work with suppliers and internal manufacturing teams for process improvements to improve part/assembly quality and attain cost reductions. 
• Device appropriate drive unit and vehicle level NVH test plans for correlation to simulations and drive improvements. 
• Participate in EOL dyno to vehicle correlations and limit setting. 
• Improve reliability, efficiency and NVH models utilized for gears and bearings in vehicle level optimization and trade-off studies. 
• Perform/guide system level NVH simulations for structure borne and air borne noise paths. 
• Guide system level analysis for appropriate bushing positions, orientations, and stiffness for appropriate NVH performance 

The minimum requirements we seek: 

• Master’s Degree in mechanical Engineering or related field. 
• 3+ years of experience designing, developing, validating and releasing electric vehicle batteries, power electronics, or power units 
• 2+ years of experience using Finite element methods for analyzing powertrain components. 
• 5+ years of experience using gear-train analysis tools such Romax, Masta, KissSoft, WindowsLDP or equivalent applications. 
• Strong understanding of gear manufacturing processes. (Hobbing, Skiving, broaching, shaping, honing, etc.) 
• Strong first principles understanding on materials, fatigue, and heat treatment.  
• Strong analytical and problem-solving skills. 
• An eagerness to work cross-functionally in a dynamic environment where you are part of a high performing team. 

Preferred Requirements: 

• Hands-on experience building and launching automotive products and prototyping powertrain systems. •            3+ years of experience using 3D CAD software collaboratively (NX, CATIA, 3DX, Solid Works, etc.) 
• Strong first principles understanding of failure mechanism and heat treatments. 
• Strong first principles understanding of tribology. 
• Experience with Microsoft Office, Confluence, and Jira applications 
• Strong written and verbal communication skills 
• Experience with instrumentation and measurement of powertrain systems in a lab environment. 

What you’ll receive in return: 

As part of the Ford family, you’ll enjoy excellent compensation and a comprehensive benefits package that includes generous PTO, retirement, savings and stock inves