Range & Fuel Efficiency Engineer
Novi, Michigan
Full Time
Job Description:
Focused on maximizing range and energy efficiency for electric and hybrid vehicles, this role involves setting efficiency targets, conducting simulations, and collaborating with cross-functional teams to integrate energy-saving features. The Range and Efficiency Engineer ensures optimal vehicle performance by improving aerodynamics, rolling resistance, and powertrain efficiency and proper selection of EV components.
1D simulation of Electric vehicle powertrain and vehicle dynamics
Set and track range and efficiency target specific to electric/hybrid powertrains, aligning performance with product requirements and customer expectations.
Define physics and behavior of Electric vehicle under different operating scenarios to decide RPM and Torque of Motor, Gear box ratios for given vehicle specifications operating under different drive cycles
understand working, specifications and physics of different EV components like Battery, Electrical machines, inverter, DC-DC Converter, BMS, Controllers to create 1D mathematical model in different software like Matlab-Simulink, Stateflow, Sim-scape, GT suite.
The candidate should have extensive experience in 1D simulation of EV powertrain and vehicle dynamics to not only simulate but improve the existing models, optimize specifications and characteristics of different EV components for different operating scenarios and ambient conditions.
Define and execute test cases based on customer feedback and model development. Collaborate with aerodynamics, thermal, and powertrain engineering teams to integrate energy-efficient technologies and design optimizations/ modifications, including lightweight materials, aerodynamics enhancements, regenerative braking systems, and power management strategies to give recommendations to maximize range and minimize power consumption.
Conduct detailed simulations to optimize vehicle aerodynamics, rolling resistance, powertrain efficiency under different ambient and operating conditions. Correlate simulation results with real-world on-road data, refining models to improve predictive accuracy and ensure efficient performance under varying driving conditions.
Conduct vehicle range tests in various environmental conditions, including different temperatures, terrains, and load scenarios, to assess the impact on battery efficiency and overall vehicle performance.
Document findings and recommendations for range and efficiency improvements, providing actionable insights and design feedback for future product iterations.
The candidate should have experience of MIL, SIL testing and to validate and calibrate the 1D model.
Candidate should have coordinated with battery/motor/thermal/vehicle testing team to collect laboratory/on-road data. Tuned/calibrated parameters and validated/correlated test data with simulation outputs such as vehicle speed, battery SOC, power.
Candidate should have comprehensive vehicle propulsion system-level knowledge, ability to read and understand drawings. Ability to do co-simulation, make changes in in Simulink and or integrate S-function/FMU functionality into other simulation environments
Qualification:
Bachelor’s Degree
Software skills:
Experience with Plant modelling, Controller modelling and Simulation tools like MATLAB/Simulink, Stateflow, Sim-scape, GT-SUITE, AVL Cruise etc.
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