Charging Systems – Technical Specialist

We are seeking a highly experienced and technically proficient Charging System Technical Expert to lead leading defining system requirements, ensuring quality and reliability, and driving technical solutions and calibration development for the charging systems for PowerNet 1.0, PowerNet 2.0, and future architectures across ICE, FHEV, and PHEV vehicle variants.  This role requires deep technical expertise, strong leadership skills, and the ability to drive complex problem-solving, define technical strategy, and ensure system robustness from concept through field performance. The expert will serve as a key technical expert, mentoring engineers and influencing future system designs.

Key Responsibilities:

1. Technical Leadership & Strategy:

• Serve as the primary technical expert for vehicle power supply and charging systems focusing on the powertrain interfaces/controls.
• Lead the development, strategy definition, and global sign-off for Powertrain INALT (Integrated Alternator) / LVSM (Low Voltage System Management) calibration guides and strategies for ICE, FHEV, EV, and PHEV variants.
• Provide technical guidance and leadership on power supply system architecture design from a calibration perspective, influencing both new architectures and existing programs.
• Contribute significantly to the definition of control logic design for new power supply calibrations, offering insights for design improvements and predicting potential issues.
• Lead the formal sign-off process for critical charging system requirements, including fundamental parameters like voltage drop and setpoint voltage.

2. System Development & Validation:

• Author, maintain, and update comprehensive charging system requirements and test methods (DVM - Design Verification Methods) for both in-vehicle and Hardware-in-the-Loop (HIL) validation.
• Develop robust and comprehensive diagnostic strategies for charging systems, covering system-level interactions, component failures, and wiring-related issues.
• Manage and optimize the calibration of key powertrain features that directly impact the electrical system load and charging performance, such as Accessory Torque Manager, Idle Load Response Control, Engine Idle Up Control (Saturation, Snow Plow, Winch), Powertrain Load Shedding (E-Fan), Alternator Engagement and Soft Start, and Thermal Management/Hotspot Mitigation.
• Drive continuous improvement in performance metrics vehicle operational and failure conditions/behavior of the powernet by refining system requirements and supporting Vehicle Evaluation & Verification (VEV), program impact assessments, and R/1000 (Repairs per Thousand) correlation analysis.
• Provide expert technical support for emissions and homologation testing processes and related software enhancements concerning the charging system.
• Collaborate with cross-functional teams (e.g., Chassis) to formalize and execute test methods for voltage quality assessment, including evaluation under challenging conditions like evasive maneuvers or during a failed battery state.

3. Quality, Reliability & Problem Resolution:

• Lead the investigation, root cause analysis, and resolution of significant system quality issues and recalls related to power supply.
• Lead the campaign prevention sign-off process for power supply elements, ensuring robust designs with a strong focus on Functional Safety (FUSA) requirements and maintaining voltage quality to critical safety-related modules (e.g., EPAS, EBB).
• Develop and implement proactive robustness actions to prevent future quality campaigns and warranty issues.
• Develop and maintain comprehensive Failure Mode Avoidance (FMA) documentation for power supply systems in ICE and FHEV vehicles.
• Generate innovative and intuitive technical solutions for complex, real-world challenges, including those arising from component shortages (e.g., addressing the BMS situation on Super Duty) and difficult-to-diagnose field issues.
• Lead warranty issue investigations, designing test plans and providing expert guidance on interpreting test results to determine root causes.
• Address immediate technical needs, such as developing specific diagnostic or monitoring strategies (e.g., Voltage Sensor Rationality Monitoring for PCM related to Carb concerns) and evaluating the impact of strategy changes (e.g., EVAP monitor After Run) on battery life and quality.

4. Documentation, Mentorship & Knowledge Sharing:

• Update, create, and continuously improve existing engineering manuals and technical documentation for Power Supply Calibrations and related systems.
• Provide technical guidance, training, and mentorship to junior engineers,