Automotive HIL Engineer — CarMaker & Embedded Controls

TechDigital Group; Dearborn (MI); On-site; USD 85,000 - 125,000; Full time

Job summary

TechDigital Group seeks an HiL Engineer to develop test procedures and implement tests using HiL equipment, with deep CarMaker expertise and close collaboration with global teams.

Responsibilities include model-based control development, CAE analysis, and documentation across the product lifecycle, ensuring traceability and quality in automotive systems.

Qualifications

• BS or MS in electrical, mechanical, aerospace or related field with control emphasis.
• Experience with CarMaker and Python for dynamic system modeling.
• Knowledge of ISO26262 and functional safety processes.
• Experience with MIL/SIL/HIL testing and CI tools.
• 3+ years in distributed systems engineering and requirements management.

Responsibilities

• Develop chassis control algorithms for brakes, steering, suspension; verify via MIL/SIL/HIL and vehicle tests.
• Analyze CAE models to support design decisions, optimization and validation.
• Define and review physical system tests to validate models.
• Implement control algorithms on embedded controllers.
• Support quality process workstreams (FMEAs, P-diagrams, functional safety).
• Create documentation for system models, use cases, requirements, and tests.
• Leverage connected vehicle tech to improve controls and prognostics.

Skills

Problem solving

Communication

Team collaboration

Multiple task management

Education

Bachelor's in Electrical/Mechanical/Aerospace Eng

Master's degree preferred

Tools

CarMaker

Python

Matlab/Simulink

SysML

CAN/LIN/Ethernet

Job description

Job Description:

• Required Degree: BS or MS in Electrical Engineering or Computer Engineering, Mechanical Engineering, or equivalent

Job Requirements:
The Hardware-in-the-Loop (HiL) Engineer supports the product development and system integration processes by developing test procedures for automated execution, implementing tests using Hardware-in-the-Loop equipment, documenting and reviewing execution reports, reporting incidents, and tracking software updates to fix issues. This role requires depth with CarMaker. The HiL Engineer develops expertise in software test design and has advanced knowledge in vehicle functional partitioning, electrical and communication architectures, Ford's embedded software processes, and the Global Product Development System. This role requires close collaboration with feature owners, engineering, and suppliers to develop a strong understanding of the vehicle functions and implement appropriate test design strategies for early identification of defects and to provide evidence of defect elimination.
Responsibilities
• Develop chassis (brakes, steering, suspension) control algorithms for advanced chassis systems to deliver vehicle attributes, including control architecture selection, algorithm simulation, implementation, and verification and validation via leveraging a combination of model-in-the-loop (MIL), software-in-the-loop (SIL), hardware-in-the-loop (HIL) and vehicle test environment.
• Leverage, subsystem- and component-level CAE models to analyze dynamic systems and complex system interactions, and to support concept analysis and verification, parameter optimization, and controls/design verification and validation.
• Define and review physical system testing and characterization to validate CAE models and guide vehicle and control system design.
• Control algorithm implementation on embedded controllers.
• Support the quality process workstreams (P-diagrams, FMEAs, requirements development, functional safety - ISO26262).
• Create and maintain comprehensive documentation to support global engineering and quality processes, and to facilitate technology transfer: system models, use cases, requirements, design validation tests, and methods
• Leverage connected vehicle technologies (wireless communication, location and route data, cloud-computing resources, AI/ML techniques, etc.) to improve customer experience with enhanced controls and prognostics
Qualifications Required:
• Bachelor's Degree in electrical engineering, mechanical engineering, aerospace engineering or a related field with emphasis on control systems
• Experience with data analysis, scripting, and modeling & simulation of dynamic systems using CarMaker and Python
• Experience with standard systems engineering tools including boundary diagrams, fault tree analyses, FMEAs, P-diagrams, etc.
• Knowledge of the ISO26262 Automotive Functional Safety standard
• Familiarity with AUTOSAR standards and tools for automotive software development
• Problem-solving skills with a passion for new technology development
• Demonstrated effective communication, documentation, and interpersonal skills in a team environment
• Demonstrated ability to manage and balance multiple tasks and timelines
• Proven ability to work well with others as part of a diverse global team
• 1+ years experience in dynamic systems and embedded real-time controls development for automotive or similarly complex electromechanical systems, including C or C++
• Subject matter expertise in chassis (brakes, steering, suspension) system hardware and control
• Understanding of automotive powertrain systems and controls (including hybrids), with fundamental knowledge of dynamics, hydraulics, electric machines, batteries, and mechatronics
Qualifications Preferred
• Master's Degree in mechanical, aerospace, electrical, systems engineering or similar field
• Familiarity with industry-standard systems engineering tools, including SysML
• Familiarity with ISO26262 engineering tools, including Hazard Analysis, Functional Safety Concept, Safety Requirements Specification, Functional Safety Requirements, Technical Safety Requirements
• Hands-on experience with distributed system prototyping, troubleshooting, and commissioning
• Experience using Matlab/Simulink for embedded controls development
• Experience with standard version control and collaboration systems (ClearCase, AccuRev, GitHub)
• Experience applying CAE (MIL/SIL/HIL, virtual system/plant models, regression testing) concepts and CI (Jenkins, GitHub, Gradle) tools in robust system controls development
• Knowledge of CAN/LIN/Ethernet communication protocols and development tools for automotive applications
• Familiarity with Ford development processes, GTDS, and GPDS
• Familiarity with Ford systems engineering systems and tools, including VSEM, FEDE, Stages, FRD, HLF
• 3+ years of experience in distributed systems engineering, including requirements management, function decomposition and allocation, failure mode avoidance, robustness analysis, and system validation and verification
• Experience with longitudinal controls for xEV systems (series hybrid, parallel hybrid, mild hybrid, battery electric, fuel cell)

Keywords: Automotive, HIL, CarMaker