Engine Controls Engineer IV

generac; Waukesha (WI); On-site; USD 120,000 - 155,000; Full time

Benefits offered by this job

Health, Dental, Vision

401(k) with company match

Career growth opportunities

Job summary

Generac in Wisconsin seeks an Engine Controls Engineer IV to advance the design and performance of internal combustion engines through engine development, data-driven analysis, engine controls system development, and design of system components. This role employs ATI Vision and data acquisition tools to optimize engine behavior and reliability.

The candidate will collaborate with manufacturing partners, contract manufacturers, and product specialists, support development plans, mentor junior

Qualifications

• Bachelor's degree in Mechanical or Electrical Engineering required.
• 7+ years of relevant work experience required.
• Experience in automotive development and calibration or related engineering discipline.
• Hands-on experience with engine and engine component development.
• Experience with engine-control software and data acquisition tools.

Responsibilities

• Designs, validates, and brings new engine controls to market.
• Specifies precise engine design requirements and validates components.
• Develops and tests engine-control components and analyzes cost, reliability, and safety.
• Designs and executes testing, product specs, and process validation plans.
• Creates BOMs and collaborates with manufacturing partners for manufacturability.
• Mentors less experienced engineers and supports product development plans.
• Travels to other Generac facilities as necessary.
• Performs duties as assigned.

Skills

Engine design

Control systems

Data analytics

ATI Vision

Powertrain calibration

Python

MATLAB/Simulink

SAP

Team collaboration

Mentorship

Education

Bachelor of Science in Mechanical or Electrical Engineering

Tools

ATI Vision

MATLAB/Simulink

Python

LabVIEW

SAP

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 market

• Specifies precise new engine design requirements

• Develops, tests, and integrates complex engine control components and evaluates overall effectiveness, cost (including cost/benefit analysis), reliability (risk analysis), and safety

• Designs, develops, executes, and evaluates testing, product specifications, and process validation plans

• Creates and reviews material part specifications and bills of materials

• Collaborates with internal manufacturing partners, contract manufacturers, designers, and product specialists to optimize complex and advanced component and system designs for manufacturability

• Supporting product development plans (schedule, product cost, meeting design inputs)

• Acts as a resource to mentor and teach less experienced engineers

• Travel to other Generac facilities as necessary

• Other duties as assigned

Minimum Qualifications:

• Bachelor of Science Degree in Mechanical or Electrical Engineering or related discipline

• 7+ years of relevant work experience

Knowledge, 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 testing

• Develops, tests, and integrates complex system components and evaluates overall effectiveness, cost (including cost/benefit analysis), reliability (risk analysis), and safety

• Designs, develops, executes, and evaluates testing, product specifications, and process validation plans

• Ability to perform detail‑oriented work with a high degree of accuracy on multiple projects

• Expert with internal combustion engine performance development and specification

• Strong 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 study

• Advanced hands‑on experience in IC engines and engine system development

• Advanced experience using ATI Vision in the use for calibration development for internal combustion engines

• Advanced experience in applying MATLAB/Simulink and Python in internal combustion engine development

• Comprehensive knowledge of internal combustion engines and effective engine test methods

• Experience with MATLAB/Simulink, Python, Labview, Vision, Concerto or similar to modify embedded control software

• Extensive experience with internal combustion engine performance development and specification

• Understanding of thermodynamics and fluid dynamics.

• Understanding of internal combustion engine thermodynamic cycles.

• Demonstrated written communication and presentation skills

• Previous experience with SAP or equivalent ERP

• Ability to easily apply engineering knowledge and experience to improve products, services and processes

• Ability to translate technical information to all audiences.

• Substantial data analysis and control/diagnostic feature creation skills

• Ample familiarity with systems engineering based problem solving

• Proven ability to work well with others as part of a diverse global team

Benefits:

• We are an inclusive company that celebrates differences and keeps equity and respect at the forefront.

• Competitive Benefits: Health, Dental, Vision, & 401k

• 401 (k) retirement savings plans with company match

• Medical support programs: Maternity, Diabetes, Treatment Decision Support and more

• Work‑life benefits: PTO and Holidays

Physical 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 occasionallylift upto 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.”