Final Verification Testing Engineer

American Battery Solutions Inc.; Michigan; On-site; USD 90,000 - 120,000; Full time

Job summary

American Battery Solutions seeks a Final Verification Testing Engineer to lead hands-on verification of EV/hybrid battery packs. You will collaborate with Hardware & Software teams to design and build testing equipment, develop EOL scripts on AVL Lynx, and ensure manufacturing processes and PFMEA are aligned with specifications.

The role requires strong experience in battery testing, CAN communications, PLCs, and data analysis, with safety-conscious handling of high voltage systems within a

Qualifications

• Bachelor’s degree in Electrical, Mechanical, Computer, or Systems Engineering.
• Minimum of five years of battery testing and validation experience.
• Knowledge of CAN communication and centralized/distributed servers.
• Experience with three-phase systems and power electronics.
• Strong communicator of technical data to customers and teams.
• Ability to lead multiple programs concurrently.
• Data processing and statistical analysis of lithium-ion data.
• Experience with low/high-voltage Li-ion systems.
• Familiarity with Li-ion cell/module/pack tests.
• Ability to handle large battery packs safely.

Responsibilities

• Lead end-of-line (EOL) verification for EV/hybrid battery packs.
• Develop EOL test specs with Systems, Electronics, and Software teams.
• Implement EOL test scripts on AVL Lynx against specs.
• Work with battery pack cyclers; handle DC/AC power flow.
• Create MES process profiles and ensure data capture.
• Write work instructions for assembly, EOL, and post-EOL QA.
• Contribute to PFMEA with manufacturing, systems, and quality teams.
• Troubleshoot using CANalyzer and OEM software.
• Design EOL test flows for high voltage safety.
• Audit supplier test software for robustness and integrity.
• Adhere to regulations and company policies.
• Maintain predictable attendance.

Skills

Battery testing

Data analysis

CAN communication

PLC programming

Software debugging

HMI design

Education

Bachelor’s degree in Electrical, Mechanical, Computer, or Systems Engineering

Tools

AVL Lynx

RSLogix

RSLogix 500

RSLogix 5000

SoftLogix 5800

RSLogix Emulate 500

Allen-Bradley PLC-5

SLC 500

ControlLogix 5000

OPC servers

MS SQL Server

FactoryTalk View

Job description

Job Description

Job Summary

The Final Verification Testing Engineer (FVT) is a highly technical, but very hands-on role that needs high competence in battery technology, validation, and software experience, as well as database and automation controls. The Final Verification Testing Engineer will work closely with Hardware & Software engineering to comprehend the workings of the battery as well as design and build testing equipment independently.

Responsibilities

• End of Line (EOL) Manufacturing/Validation Engineer for electric vehicle and hybrid vehicle batteries.
• EOL test specification for Lithium-ion battery systems in collaboration with Systems, Electronics, and Software Engineering teams.
• Development and implementation of EOL Test scripts on AVL Lynx to test battery performance according to specification.
• Proficient in the use of battery pack cyclers and knowledgeable in Direct Current (DC) power flow and Alternating Current (AC) power flow.
• Work on EOL test specification for production to ensure the product is tested according to the specification while meeting takt time.
• Create process profiles for all manufacturing stations in Manufacturing Execution System (MES), ensure all data is recorded and the process is followed.
• Create work instructions for battery pack assembly, EOL station, and post EOL verification.
• Work on Process Failure Mode and Effects Analysis (PFMEA) in collaboration with manufacturing, systems, and quality teams.
• Troubleshoot and debug issues using CANalyzer and Original Equipment Manufacturer (OEM) software.
• Knowledge of 3-phase systems, complex power flow, energy conversion via switch-mode power electronic circuits: DC/DC converters, DC/AC converters, electromechanical energy conversion, Operating principles of Direct Current (DC) Machines, Synchronous Machines, and Induction Machines.
• Allen-Bradley PLC-5, SLC 500, and ControlLogix 5000 with RSLogix (5, 500, and 5000), SoftLogix 5800, 1734-Point I/O, and RSLogix Emulate 500 software.
• Write and debug Programmable Logic Controller (PLC) ladder logic and create Human Machine Interface (HMI) using factory talk view studio.
• Use Object-Oriented Programming languages (C++/Java) to design, code, and maintain software applications with emphasis on writing code that is organized, structured, modular, and documented.
• Software applications to automate manufacturing operations including but not limited to:
  • communicate with MS SQL server and process traceability data
  • communicate, control, and query test equipment using RS232
  • communicate and process data from Open Platform Communications (OPC) servers
• Design EOL test flow for high voltage batteries while ensuring operator safety.
• Use software development, test specification, etc. knowledge to audit supplier’s test software and equipment to provide input in increasing software robustness and integrity of EOL systems in Production.
• Adhere to federal and state regulations.
• Adhere to all company policies, processes, and procedures.
• Performs other duties as requested, directed, or assigned.
• Predictable and reliable attendance.

Position Qualifications

• Bachelor’s degree in Electrical, Mechanical, Computer, or Systems Engineering, or a related technical field.
• Minimum of five (5) years of previous experience working with battery testing and validation.
• Knowledge of centralized and distributed servers, proficient in the use of open-source code and libraries, working knowledge of Controller Area Network (CAN) communication.
• Knowledge of 3-phase systems, complex power flow, energy conversion via switch-mode power electronic circuits: DC/DC converters, DC/AC converters, electromechanical energy conversion, Operating principles of Direct Current (DC) Machines, Synchronous Machines, and Induction Machines.
• Effective communicator, capable of concisely presenting highly technical test data to internal and external customers, and cross-functional teams.
• Capable of leading multiple programs.
• Adept in data processing and statistical analysis; particularly with lithium-ion test data.
• Experienced with the handling of both low and high-voltage lithium-ion battery systems.
• Educated on common lithium-ion cell, module, and battery pack test certifications.
• Capable of carefully maneuvering large battery packs with the proper safety standards and support.
• Skilled with Microsoft Office products including Excel, PowerPoint, Outlook, OneNote, and Project.
• Self-motivated problem solver, pays attention to the details, challenges the status quo,