Engine Controls Engineer IV

Generac Power Systems; North Prairie (WI); On-site; USD 105,000 - 145,000; Full time

Benefits offered by this job

Health insurance

Dental plan

Vision plan

401(k)

Job summary

Generac Power Systems Inc. in Wisconsin is seeking an Engine Controls Engineer IV to advance ICE engine control design, calibration, and testing across gaseous fueled applications.

You will lead development, run data-driven analyses, and collaborate with cross-functional teams to improve performance, reliability, and emissions. Responsibilities include designing and validating engine controls, developing test plans, mentoring junior engineers, and coordinating with manufacturing and suppliers.

Qualifications

• Bachelor of Science in Mechanical or Electrical Engineering or related discipline.
• 7+ years of relevant work experience in automotive development or engine controls.
• Hands-on experience with engine development, calibration software, and engine control systems.
• Proficiency in spark control, AFR optimization, durability, and emissions testing.
• Strong analytical and problem-solving skills with clear technical communication.

Responsibilities

• Designs, validates, and brings engine controls to market (throttles, fuel control, ignition).
• Develops testing plans and evaluates product specifications and process validation.
• Mentors junior engineers and collaborates with manufacturing partners and suppliers.
• Performs cost, reliability, and safety analyses for new control components.
• Travels to Generac facilities as needed.

Skills

Engine controls

Calibration

Data analysis

ATI Vision

MATLAB/Simulink

Python

Engine design

Technical communication

Education

Bachelor's in Mechanical or Electrical Engineering

Master's degree (preferred)

Tools

ATI Vision

MATLAB/Simulink

Python

LabVIEW

Vision/Concerto

Job description

We believe power is a promise - a shared commitment to be there for others when it matters most.For more than 65 years, we've turned big ideas into solutions that help protect homes, strengthen businesses and build a more resilient, efficient, sustainable energy future.Ready to Power a Smarter World with us?The Engine Controls Engineer IV plays an important role in advancing the design and performance of internal combustion engines (ICE), through engine development, data-driven analysis, engine controls system development, and design of system components. This position leverages data analytics, ATI Vision, and data acquisition tools to optimize system behavior, improve engine control, improve product reliability, and increase engine performance across a range of gaseous fueled applications.Major Responsibilities:Designs, validates, and brings new engine controls (throttles, mixers, fuel control, ignition systems) to marketSpecifies precise new engine design requirementsDevelops, tests, and integrates complex engine control components and evaluates overall effectiveness, cost (including cost/benefit analysis), reliability (risk analysis), and safetyDesigns, develops, executes, and evaluates testing, product specifications, and process validation plansCreates and reviews material part specifications and bills of materialsCollaborates with internal manufacturing partners, contract manufacturers, designers, and product specialists to optimize complex and advanced component and system designs for manufacturabilitySupporting product development plans (schedule, product cost, meeting design inputs)Acts as a resource to mentor and teach less experienced engineersTravel to other Generac facilities as necessaryOther duties as assignedMinimum Qualifications:Bachelor of Science Degree in Mechanical or Electrical Engineering or related discipline7+ years of relevant work experienceKnowledge, Skills and Abilities:Experience in automotive development and calibration, or a related engineering discipline.Hands-on experience with engine and engine component development.Experience in powertrain calibration software - ATI/CAN or similar.Hands-on experience with ATI Vision as applied to engine control systems.Extensive experience in new IC engine control system design and development.Proficiency in developing internal combustion engines, including understanding of the effects of spark control, adjusting AFR for best performance and emissions, durability, control system components, intake/exhaust system pressure, and emissions testingDevelops, tests, and integrates complex system components and evaluates overall effectiveness, cost (including cost/benefit analysis), reliability (risk analysis), and safetyDesigns, develops, executes, and evaluates testing, product specifications, and process validation plansAbility to perform detail-oriented work with a high degree of accuracy on multiple projectsExpert with internal combustion engine performance development and specificationStrong analytical and problem-solving skills, with a deep understanding of internal combustion engine design, operation, and testing.Strong written and verbal communication skills with the ability to clearly interpret and present complex simulation results to technical and non-technical audiences.Collaborate with internal manufacturing partners, contract manufacturers, designers, and product specialists to optimize complex and advanced designs for performance.Preferred Qualifications:Master’s degree in mechanical engineering, Aerospace Engineering, Computer Science, or a related field of studyAdvanced hands-on experience in IC engines and engine system developmentAdvanced experience using ATI Vision in the use for calibration development for internal combustion enginesAdvanced experience in applying MATLAB/Simulink and Python in internal combustion engine developmentComprehensive knowledge of internal combustion engines and effective engine test methodsExperience with MATLAB/Simulink, Python, Labview, Vision, Concerto or similar to modify embedded control softwareExtensive experience with internal combustion engine performance development and specificationUnderstanding of thermodynamics and fluid dynamics.Understanding of internal combustion engine thermodynamic cycles.Demonstrated written communication and presentation skillsPrevious experience with SAP or equivalent ERPAbility to easily apply engineering knowledge and experience to improve products, services and processesAbility to translate technical information to all audiences.Substantial data analysis and control/diagnostic feature creation skillsAmple familiarity with systems engineering based problem solvingProven ability to work well with others as part of a diverse global teamBenefits:We are an inclusive company that celebrates differences and keeps equity and respect at the forefront.Competitive Benefits: Health, Dental, Vision, & 401k401 (k) retirement savings plans with company matchMedical support programs: Maternity, Diabetes, Treatment Decision Support and moreWork-life benefits: PTO and HolidaysPhysical Demands:While performing the duties of this job, the employee is regularly required to talk and hear; and use hands to manipulate objects or controls. The employee is regularly required to stand and walk. On occasion, the incumbent may be required to stoop, bend, or reach above the shoulders. The employee must occasionally lift up to 25 pounds. Specific conditions of this job are typical of frequent and continuous computer-based work requiring periods of sitting, close vision, and the ability to adjust focus. Occasional travel.“We are an equal opportunity employer and all qualified applicants will receive consideration for employment without regard to race, color, religion, sex, sexual orientation, national origin, disability status, protected veteran status, or any other characteristic protected by law.”