Final Verification Testing Engineer

Job Description

Job Summary

The Final Verification Testing Engineer (FVT) is a highly technical, but very hands-on role that needs high competence in battery technology, validation, and software experience, as well as database and automation controls. The Final Verification Testing Engineer will work closely with Hardware & Software engineering to comprehend the workings of the battery as well as design and build testing equipment independently.

Responsibilities

• End of Line (EOL) Manufacturing/Validation Engineer for electric vehicle and hybrid vehicle batteries.
• EOL test specification for Lithium-ion battery systems in collaboration with Systems, Electronics, and Software Engineering teams.
• Development and implementation of EOL Test scripts on AVL Lynx to test battery performance according to specification.
• Proficient in the use of battery pack cyclers and knowledgeable in Direct Current (DC) power flow and Alternating Current (AC) power flow.
• Work on EOL test specification for production to ensure the product is tested according to the specification while meeting takt time.
• Create process profiles for all manufacturing stations in Manufacturing Execution System (MES), ensure all data is recorded and the process is followed.
• Create work instructions for battery pack assembly, EOL station, and post EOL verification.
• Work on Process Failure Mode and Effects Analysis (PFMEA) in collaboration with manufacturing, systems, and quality teams.
• Troubleshoot and debug issues using CANalyzer and Original Equipment Manufacturer (OEM) software.
• Knowledge of 3-phase systems, complex power flow, energy conversion via switch-mode power electronic circuits: DC/DC converters, DC/AC converters, electromechanical energy conversion, Operating principles of Direct Current (DC) Machines, Synchronous Machines, and Induction Machines.
• Allen-Bradley PLC-5, SLC 500, and Control Logix 5000 with RSLogix (5, 500, and 5000), Soft Logix 5800, 1734-Point I/O, and RSLogix Emulate 500 software.
• Write and debug Programmable Logic Controller (PLC) ladder logic and create Human Machine Interface (HMI) using factory talk view studio.
• Use Object-Oriented Programming languages (C++/Java) to design, code, and maintain software applications with emphasis on writing code that is organized, structured, modular, and documented.
• Software applications to automate manufacturing operations including but not limited to:
  • communicate with MS SQL server and process traceability data
  • communicate, control, and query test equipment using RS232
  • communicate and process data from Open Platform Communications (OPC) servers

• Design EOL test flow for high voltage batteries while ensuring operator safety.
• Use software development, test specification, etc. knowledge to audit supplier’s test software and equipment to provide input in increasing software robustness and integrity of EOL systems in Production.
• Adhere to federal and state regulations.
• Adhere to all company policies, processes, and procedures.
• Performs other duties as requested, directed, or assigned.
• Predictable and reliable attendance.

Position Qualifications

• Bachelor’s degree in Electrical, Mechanical, Computer, or Systems Engineering, or a related technical field.
• Minimum of five (5) years of previous experience working with battery testing and validation.
• Knowledge of centralized and distributed servers, proficient in the use of open-source code and libraries, working knowledge of Controller Area Network (CAN) communication.
• Knowledge of 3-phase systems, complex power flow, energy conversion via switch-mode power electronic circuits: DC/DC converters, DC/AC converters, electromechanical energy conversion, Operating principles of Direct Current (DC) Machines, Synchronous Machines, and Induction Machines.
• Effective communicator, capable of concisely presenting highly technical test data to internal and external customers, and cross-functional teams.
• Capable of leading multiple programs.
• Adept in data processing and statistical analysis; particularly with lithium-ion test data.
• Experienced with the handling of both low and high-voltage lithium-ion battery systems.
• Educated on common lithium-ion cell, module,…