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Project Engineer – HV Charging, Conversion and Distribution


Job Purpose:

To be responsible for the on-time delivery of HV Distribution, DCDC converters and on-vehicle charging systems and their integration into vehicle and to the grid on all programmes.

Key Responsibilities & Tasks:

As Project Engineer, HV Distribution, Charging and Conversion, you will be responsible for the following activities:

  • To define, own and deliver HV Distribution, DCDC conversion and on-vehicle charging systems and their integration into vehicle and to the grid from concept through to production, including achieving:
  • Function: Lead generation and delivery of robust technical specifications and timing plans for RFQ, including Functional Safety, Cybersecurity and EMC requirements to ensure compliance
  • Package: Manage CAD engineers to achieve static & dynamic clearance targets, negotiate component change in other AML R&D departments if required to achieve clearances.
  • Quality: Identify & contain potential quality concerns using engineering quality systems (FMEAs, Robustness Studies)
  • Testing & Development: Support the definition of DVP activities and on-time delivery of in-house and supplier tests on rigs and vehicles
  • Cost: Definition of programme cost targets and working with suppliers to deliver system that achieves these targets. Maintain control of tooling, engineering & part costs via Cost Management System (CMS) and predict the spend to the end of the project to ensure that it can be completed within the available budget.
  • Weight: Definition of programme weight targets and managing CAD engineers to design system that achieves targets
  • Main point of contact for HV Distribution, DCDC conversion and on-vehicle charging systems and their integration into vehicle for feasibility, functionality and active resolution of technical issues on given projects
  • Deliver the commodity programme to meet Mission Gateway objectives including leading Final Engineering Sign Off activities
  • Develop and deliver commodity strategy for all HV Distribution, HV DC/DC converters and on-vehicle charging system alongside commodity plans for each programme including design & manufacturing lead-times and key programme deliverables timing.
  • Present status at Gateways and support Powertrain design reviews, Package Meetings & Powertrain PMT meetings.
  • Work cross-functionally with other R&D departments (especially Electrical Circuits and EDS teams) to define HV Distribution, DCDC conversion, on-vehicle charging system and efficient power management strategy balancing characteristics to achieve vehicle requirements for minimum cost
  • Support all Virtual Verification activities, including packaging, 1D & 3D analyses
  • Complete Change Tracking Documents, Engineering Release Notices & Releases to allow engineering changes to be approved.
  • Resolve engineering Concerns (using eCMS) in a timely fashion.
  • Lead FMEAs and input to manufacturing PFMEAs.
  • Acquire and evaluate competitor benchmark information to influence concept creation in early project phases
  • Coordinate system and supplier comparison studies and evaluate RFQ responses to influence management decisions
  • Establish regular design reviews with cross functional teams
  • Support Intellectual Property (IP) team to protect the generated IP
  • Train, coach and present technical information at all levels and share the knowledge throughout the company
  • Develop and record best practices and lead development of all HV Distribution, DCDC conversion and on-vehicle charging system design manuals to handle the Powertrain Electrification requirements of today and the future

Qualification & Experience:

The essential areas of previous experience required to undertake this role include:

  • Delivery of HV Distribution, DCDC converters and on-vehicle charging systems and integration for hybrid and/or electric vehicles
  • Hands on experience of working with LV and HV systems
  • Knowledge of all relevant vehicle legislation and certification requirements for automotive HV Distribution, DCDC converters and on-vehicle charging systems and their integration
  • Successful delivery of systems to automotive Functional Safety, Cybersecurity and EMC requirements
  • Led development of charging strategies and charging profiles
  • Knowledge of project life cycle management from early R&D to series production

Preferred areas of experience include:

  • HV Distribution, DCDC converters and charging system development for high performance hybrid and/or electric vehicles
  • Understanding of hybrid and electric powertrain system functionalities and attributes at vehicle, system and component levels
  • Leadership of technical teams delivering product development projects to production
  • Automotive powertrain electrical, electronic and mechanical integration knowledge
  • Leading engagement with engineering partners working on power management commodities
  • Automotive electrical design and development
  • Vehicle fusing, relays, harness and connectors
  • Design of vehicle power management systems
  • Data analysis of CAN logs to resolve faults
  • Experience of battery load balance requirements
  • Automotive battery technology and requirements including battery protection systems
  • Leading of sub-system DFMEA reviews
  • Leading of design verification plans ensuring timely completion of Final Engineering Sign off
  • Component Releasing and Change Control management
  • Use of test equipment to support electrical and electronic system testing
  • Driving product development issues to a resolution
  • Strong user of MATLAB/Simulink
  • Experience with CAD (NX, CATIA)
  • Responsibility in Formula Student/SAE team

Millbank are an equal opportunities employer and welcome applications from all suitably qualified persons.

Millbank operates as an Employment Agency and Business.