High Voltage Systems Engineer

methode; Southfield (MI); On-site; USD 120,000 - 160,000; Full time

Job summary

Methode Electronics in Michigan is seeking an experienced Senior HV Power Electronics Engineer to design and optimize 800V DC-DC converters, onboard chargers, and traction inverters for automotive and industrial applications. You will lead cross-functional teams across electrical and mechanical disciplines to deliver robust powertrain solutions.

The role emphasizes planar magnetics, thermal management with liquid cooling, system-level simulations, hardware validation, and adherence to automotive

Qualifications

• Experience with high-voltage systems (60V+; ideally 400–800V).
• Strong knowledge of switching topologies and gate drivers.
• Familiarity with automotive safety standards (ISO 26262, ASIL).
• Proven ability to lead cross-functional engineering projects.
• Hands-on hardware design, testing, and validation.

Responsibilities

• 800V converter design and optimization for automotive/industrial use.
• Planar magnetics integration and high-frequency transformer work.
• Integrate power boards and multi-layer PCB layouts in powertrains.
• Lead thermal solutions including liquid cooling strategies.
• Perform system simulations and EMI/EMC analysis; drive validation.

Skills

Power electronics

Magnetics design

Thermal management

System simulation

Hardware validation

Leadership

Education

Bachelor's or Master's in Electrical Engineering

Tools

MATLAB/Simulink

PLECS

PSpice

ANSYS Maxwell

Job description

About Methode Electronics

We are a leading global provider of innovative automotive and industrial electronic products, including center stacks, switch banks, sensors, high-voltage busbars, Battery Disconnect Units (BDU), Integrated Circuit Boards (ICB), park brake actuators, ambient lights, and Center High-Mount Stop Lights (CHMSL). Our commitment to quality, innovation, and sustainability positions us at the forefront of the industry, delivering high-performance power distribution solutions to customers worldwide.

Key Responsibilities

• 800V Converter Design: Architect, design, and optimize high-efficiency 800V DC-DC converters, onboard chargers, and traction inverters utilizing wide-bandgap semiconductors (SiC/GaN).
• Planar Magnetics Integration: Design and optimize high-frequency planar transformers and inductors to maximize power density and minimize parasitic parameters (leakage inductance and interwinding capacitance).
• Integrate Power Boards: Connect, configure, and optimize multiple high-power distribution boards, multi-layer PCBs, and control circuits within the overall vehicle powertrain or grid system.
• Manage Thermal Solutions: Perform thermal analysis and design active cooling solutions-including liquid-glycol loops, phase-change materials, and advanced thermal interface materials-to manage high heat fluxes in compact planar magnetics and power modules.
• System Simulation & Analysis: Conduct detailed systems analysis, including circuit-level simulations, stress modeling, and electromagnetic Finite Element Analysis (FEA) for magnetic flux optimization.
• Hardware Validation: Lead the physical testing of high-voltage batteries, inverters, converters, and cabling harnesses using specialized laboratory equipment under high-power conditions.
• Lead Teams: Guide, mentor, and align cross-functional technical teams (software, mechanical, layout) to execute complex engineering projects from concept to production.
• Ensure Functional Safety: Follow strict automotive and industrial safety standards, implementing isolation monitoring, interlocks, and creepage/clearance requirements to mitigate hazard risks.
• Solve Hardware Issues: Root-cause complex power flow instabilities, EMI/EMC issues (such as dV/dt noise coupling), AC copper losses (skin and proximity effects), or physical component breakdowns discovered during the validation phase.

Requirements

• Education: Bachelor's or master's degree in electrical engineering, Power Electronics, or a closely related technical field.
• Experience: 5 + years of hands-on experience developing high-voltage systems, specifically dealing with architectures exceeding 60V (ideally 400V to 800V+ systems).
• Power Electronics & Magnetics Expertise: Proven experience with switching topologies, gate driver optimization, and magnetic component design-including deep knowledge of planar transformer construction , multi-layer PCB winding layouts, and ferrite/nanocrystalline core selection.
• Thermal Management: Hands-on experience implementing liquid cooling, forced air systems, or phase-change cooling for high-power-density electronics.
• Hardware & Layout Standards: Deep familiarity with IPC-2221, IPC-9592, and relevant automotive safety compliance frameworks (such as ISO 26262 or ASIL ratings).
• Tools & Simulation: Proficiency with simulation software (MATLAB/Simulink, PLECS, PSpice, or magnetic simulation tools like ANSYS Maxwell) and high-power lab tools (high-voltage power supplies, electronic loads, oscilloscopes, and power analyzers).
• Leadership: Strong communication skills with a track record of managing technical project timelines and guiding junior engineers.

Work Environment:

The work environment characteristics described here are representative of those an employee encounters while performing the essential functions of this job. Reasonable accommodations may be made to enable individuals with disabilities to perform the essential functions of this job.

Physical Demands:

The physical demands described here are representative of those that must be met by an employee to successfully perform the essential functions of this job. Reasonable accommodations may be made to enable individuals with disabilities to perform the essential functions of this job. The employee must occasionally lift and/or move up to 25 pounds. Frequent hand motion and repetitive tasks including using a computer for typing. While performing the duties of this job, the employee will occasio