Hardware-in--Loop; HIL Test Engineer

Location

(Remote)

12+ months contract with potential extends or Convert

• Own the Hardware‑in‑the‑Loop (HIL) test platform validating control software for utility‑scale Battery Energy Storage Systems (BESS).
• You’ll develop real‑time plant models in Simulink, run them on Speedgoat at ~1 ms base rates, integrate with power plant controller PLCs over Modbus/TCP and DNP3, and automate requirement‑based test suites with a focus on fast, deterministic controller validation (not microgrid stability studies).

• Build & operate HIL rigs: configure Simulink Real‑Time on Speedgoat, map I/O harness, and manage deterministic scheduling; optimize solver settings for ~1 ms steps.
• Model the plant: create/maintain Simulink/Simscape Electrical models for PCS/inverter, filters/transformer, battery/Client; validate model fidelity against bench/site data.
• HIL simulation: connect Schneider M580 PLC to Speedgoat via Modbus TCP; verify commands, telemetry, time sync, alarms/events, and fail‑safe sequences end‑to‑end.
• Author requirement‑based tests: derive MiL/SiL/HIL cases for power/VAR control, ramp‑rate, freq/volt response, SoC management, thermal derates, ride‑through, startup/shutdown, and fault scenarios.
• Automate regression: implement scripted test suites with pass/fail metrics, waveform capture, and auto‑reports; integrate with Git and CI workflows.
• Defect lifecycle: analyze logs, isolate root causes across controller ↔ PLC ↔ plant model, file issues, verify fixes, and maintain full traceability (requirement → test → result).
• Rig reliability & safety: maintain configs/calibrations/harnesses, implement health checks, and observe lab.

• 3–7+ years in embedded/controls test & validation with HIL.
• Strong MATLAB/Simulink skills (Simulink Test, Simulink Real‑Time; Simscape Electrical).
• General programming/scripting experience (Python, VBA).
• Hands‑on Speedgoat experience at ~1 ms base rates (fixed‑step solvers, rate transitions, task partitioning).
• PLC integration experience;
  Schneider M580 familiarity preferred; understanding of IEC 61131‑3 concepts.
• Protocols:
  Modbus/TCP and DNP3 (command/telemetry, time‑stamped events, buffers).
• Version control with Git; comfort with code reviews and branching strategies.

• Clear communication, root‑cause analysis, and documentation skills.

• B.S./M.S. in Electrical/Controls/Power/Mechatronics or related field.

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