BMS Validation Engineer

Ford; Dearborn (MI); Hybrid; USD 99,000 - 166,000; Full time

Benefits offered by this job

Medical, dental, vision coverage

Flexible family care days

Tuition assistance

Vehicle discount program

Job summary

Ford is seeking a Battery Management Validation Engineer in the United States to validate high-voltage battery management hardware, software, and integrated systems. You will conduct software regression on simulation and hardware-in-the-loop benches and energised pack testing, ensuring traceability and robust evidence across domains.

The role emphasizes bench automation or energized HV testing, with a preference for expertise in both areas.

Qualifications

• Bachelor's degree in engineering required.
• 4+ years validating embedded control systems or high-voltage equipment.
• Demonstrated test plan authorship traceable to requirements.
• Strong instrumentation skills and test documentation.

Responsibilities

• Translate requirements into verification plans, test cases, and acceptance criteria with traceability.
• Execute validation campaigns across software releases and document results.
• Perform fault insertion and negative testing on sensors and communications.
• Verify diagnostics, protection behavior, safe state entries and annunciations.
• Root-cause failures and verify fixes with regression tracking.
• Review supplier verification reports for method conformance.
• Contribute evidence to safety, cybersecurity, and product safety docs.
• Build cross-coverage across validation domains and maintain test benches.

Skills

DV plan & test case authorship

Requirements traceability

HIL & SIL bench development

Test automation & CI gating

Fault insertion & negative testing

High-voltage energized testing

Measurement verification

Environmental/durability testing

Instrumentation & data acquisition

Python scripting & data analysis

Failure analysis & regression mgmt

Education

Bachelors in Electrical/ electronics/ computer/ mechanical/ mechatronics engineering

Tools

Oscilloscopes

Data acquisition hardware

Power supplies

Electronic loads

Communication analyzers

Job description

In this position...

The Battery Management Validation Engineer proves that high-voltage battery management hardware, software, and integrated systems do what they are required to do — from automated software regression on simulation and hardware-in-the-loop benches through energized pack and system-level testing.

Assignments may include software-focused validation on simulation and hardware-in-the-loop benches or system-focused validation on energized hardware and installed systems, and may shift across the product architecture over the life of the program.

The ideal candidate is disciplined about traceability and evidence, capable with instrumentation, and able to script and automate. Strength in either bench automation or energized high-voltage testing is required; strength in both is strongly preferred.

What you'll do...

• Translate system requirements and architect-authored design verification methods into design verification plans, executable test cases, and acceptance criteria with full traceability.
• Execute validation campaigns across sample phases and software release cycles; document results, defects, and evidence to audit standard.
• Perform fault insertion and negative testing, including sensor faults, communication loss, isolation degradation, contactor faults, overvoltage, overtemperature, and thermal event response.
• Verify diagnostic and protection behavior, safe state entry, and annunciation to external systems.
• Root-cause failures with hardware, software, and algorithm engineers; verify fixes and manage regression.
• Witness and technically review supplier verification reports for method conformance and sufficiency.
• Contribute evidence to functional safety, cybersecurity, and product safety documentation packages.
• Build and maintain working competence across both validation domains over time to provide cross-coverage.
• Software-Focused Validation
  • Build and maintain software-in-the-loop and hardware-in-the-loop benches with simulated cells, sensors, contactors, and loads.
  • Develop and maintain automated regression suites integrated into continuous integration; own the pass/fail gate for software releases.
  • Verify base software behavior including bootloader, software update and rollback, secure boot and flashing, communication stacks, and diagnostic services.
  • Verify control logic and estimation behavior against models and requirements, including timing and communication performance.
  • Maintain plant models and test scripts as the design evolves.
• System-Focused Validation
  • Plan and execute validation on energized modules, packs, and full systems using cyclers, environmental chambers, and instrumented test setups.
  • Verify measurement accuracy and end-to-end sensing chains, balancing effectiveness, thermal behavior, and high-voltage sequencing on real hardware.
  • Verify interoperability with surrounding electrical, thermal, and control systems.
  • Define end-of-line and production test content, methods, and acceptance limits.
  • Support commissioning, field troubleshooting, and returned-unit analysis.
• Technical Skills
  • Design verification plan and test case authorship
  • Requirements-to-test traceability
  • Hardware-in-the-loop and software-in-the-loop bench development
  • Test automation and continuous integration gating
  • Fault insertion and negative testing
  • High-voltage energized test execution
  • Measurement accuracy and sensing chain verification
  • Environmental, durability, and EMC test support
  • Instrumentation and data acquisition
  • Python scripting and data analysis
  • Failure analysis and regression management

You’ll have...

• Bachelor's degree in Electrical, Electronics, Computer, Mechanical, or Mechatronics Engineering.
• 4+ years validating embedded electronic control systems, battery systems, or high-voltage electrical equipment.
• Demonstrated test plan authorship traceable to requirements, with disciplined test documentation.
• Practical instrumentation skill: oscilloscopes, data acquisition, power supplies, electronic loads, and communication analyzers.
• Scripting capability in Python or equivalent for test automation or data analysis.
• Either hardware-in-the-loop and test automation experience, or high-voltage laboratory and energized test experience.
• Strong written and verbal communication skills.
• Ability and willingness to travel occasionally.

Even better, you may have...

• Master's degree in a related engineering discipline.
• High-voltage safety qualification, or readiness to certify immediately upon hire.
• Hardware-in-the-loop platform experience and cell or battery emulation.
• Battery cycler operation and long-duration test campaign management.
• Environmental, durability, and electromagnetic compatibility test experience.
• Familiarity with product safety, functional safety, and cybersecurity verification evidence requirements.
• Production and end-of-line test definition experience.

As an established global company, we offer the benefit of choice. You can choose what your Ford future will look like: will your story span the globe, or keep you close to home? Will your career be a deep dive into what you love, or a series of new teams and new skills? Will you be a leader, a changemaker, a technical expert, a culture builder…or all of the above? No matter what you choose, we offer a work life that works for you, including:

• Immediate medical, dental, vision and prescription drug coverage
• Flexible family care days, paid parental leave, new parent ramp-up programs, subsidized back‑up child care and more
• Family building benefits including adoption and surrogacy expense reimbursement, fertility treatments, and more
• Vehicle discount program for employees and family members and management leases
• Tuition assistance
• Established and active employee resource groups
• Paid time off for individual and team community service
• A generous schedule of paid holidays, including the week between Christmas and New Year’s Day
• Paid time off and the option to purchase additional vacation time.

This position is a salary grade 8 and ranges from $99,100-$166,200.

Final determination of salary grade will be based on candidate's skills and experience, and base salary will be set within the applicable range according to job scope, responsibility and competitive market value.

Internal applicants: moving into this role may result in an adjustment to your current compensation based on the posted pay range for this role, taking into consideration your qualifications and other relevant factors.

Visa sponsorship is not available for this position.

Candidates for positions with Ford Motor Company must be legally authorized to work in the United States. Verification of employment eligibility will be required at the time of hire.

We are an Equal Opportunity Employer. All qualified applicants will receive consideration for employment without regard to race, religion, color, age, sex, national origin, sexual orientation, gender identity, disability status or protected veteran status. In the United States, if you need a reasonable accommodation for the online application process due to a disability, please call 1-888-336-0660.

This position is hybrid with a requirement to be onsite four or more days per week.