Power Supply Application Engineer

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The Power Supply Application Engineer is responsible for sizing, packaging, validating, and releasing the starting/charging system for ICE (Internal Combustion Engine) and EV (Electric Vehicle) applications. This includes several key components:
Alternator, Starter, Battery, ASIL (Automotive Safety Integrity Level) rated redundant Power supply components including additional Batteries, Ultra Capacitors, and Battery Management Sensors (BMS).

• Perform Charge Margin analysis with time average, transient, and ASIL sizing models
• Interface with program team to package all components in a suitable location
• Interact with Powertrain FEAD (Front End Accessory Drive) to ensure proper belt loading and mounting structure for the alternator
• Interact with Powertrain to ensure proper interface for the starter motor
• Interact with Powertrain calibrators to establish and confirm charging system related calibration values such as electrical idle kickers to support charge margins
• Work with suppliers to develop design concepts and define the costs that support the application both electrically and mechanically. Lead To4 (Team of Four) meetings.
• Gain approval from the program for all tooling, piece costs, and ED&T (Engineering Design & Testing) associated with power supply components
• Work with VO (Vehicle Assembly Operations) to ensure component package meets assembly and ergonomic targets
• Work with VO and supplier to develop proper dunnage
• Work with FCSD (Ford Customer Service Division) to ensure proper serviceability of power supply components
• FEDEBOM (Bill of Materials) / WERS (Worldwide Engineering Release System) release final designs for all power supply components (Alternator, Battery, Battery Labels, Battery Blankets, Starter, Starter Fasteners/Torque specs, Solenoid caps, BMS Sensors, ASIL Ultra capacitors and Energy Modules, etc…)
• Complete component FMA (Failure Mode Analysis) documentation including CPAs (Change Point Analysis) and SCCAFs (Special Characteristics Communication and Agreement Form)
• Signoff for all vehicle builds (TDC, DCV, TT, PP) at multiple locations
• Establish required SDS (System Design Specifications) testing through FEDEDVP (Design Validation Plan) for each program and upload test results
• Support VEV (Vehicle Evaluation & Verification) Wind tunnel testing to validate sizing and component temperatures on each application
• Conduct cold crank testing to verify battery CCA (Cold Cranking Amps) sizing for powertrain cold crank RPM target
• Support/Conduct Garage test to verify Static loads, Key Off Loads, Volt drops, Idle up, and failure diagnostics
• Interact with EDS (Electrical Distribution System) team to ensure proper wire size and connections to interface with our components and to meet system volt drop
• Lead TDRs (Technical Design Reviews) prior to key program milestone events (TDJ, FDJ, PEC)
• Interact with Purchasing and Suppliers to complete ESOW's (Engineering Statement of Work) and Supplier Sourcing Contracts / Supplier on Board Agreements (SOBA)…Handled via Tof4 meetings
• Review, edit, and signoff Owner and Workshop manuals for Power Supply content
• Monitor AIMs (Automated Issues Management) and DURIS (Durability Information System) and react to any issues and follow to closure.
• Monitor and react as needed to warranty trends
• React to Voice of the Customer Fleet issues and follow to closure.
• Support Fuel Economy team with development and certification testing as related to BMS.
• Support TVM (Team Value Management) efforts to implement agreed cost reduction changes

• Bachelor’s degree in Electrical Engineering or Mechanical Engineering.
• Fundamental understanding of electrical architectures and electrical systems (circuit analysis, power distribution principles).
• Profi…