Power Electronics Engineer — HIL & Real-Time Validation

Ztek Consulting; Raleigh (NC); On-site; USD 85,000 - 120,000; Full time

Job summary

Ztek Consulting is seeking an experienced HIL engineer to design and validate power converter controllers with real-time simulation. You will develop HIL models in MATLAB/Simulink/Stateflow, interface hardware, and drive full validation across UPS, converters, and inverters.

Collaboration with Control, Firmware, and Systems teams is essential for robust verification. The role emphasizes hands-on hardware integration, signal conditioning, I/O configuration, and fault injection testing in a

Qualifications

• Hands-on experience with Hardware-in-the-Loop (HIL) testing and validation of power converters; OPAL-RT experience preferred.
• Strong experience in MATLAB/Simulink and Stateflow model development.
• Solid understanding of power electronics systems, including UPS systems and AC-DC/DC-DC converters.
• Strong knowledge of power converter control algorithms and state machine implementation.
• Experience in controller-to-HIL interfacing, signal mapping, and I/O configuration.
• Ability to debug and troubleshoot hardware-software integration issues in real-time simulation environments.
• Good understanding of control systems, embedded controllers, and validation methodologies.
• Experience with real-time simulation and model-based design.
• Exposure to firmware validation and embedded system testing.
• Strong analytical and problem-solving skills with the ability to work effectively in cross-functional teams.

Responsibilities

• Design and develop breakout/interface boards for integrating power converter controllers with HIL platforms.
• Configure and establish Hardware-in-the-Loop (HIL) test setups using OPAL-RT for power electronic systems such as UPS, DC-DC converters, AC-DC converters, inverters, and related products.
• Develop and maintain real-time HIL models for power circuits and associated interface circuits using MATLAB/Simulink and Stateflow.
• Integrate power converter control hardware with the HIL environment, including signal conditioning and gain setting, pin mapping and wiring validation, analogue and digital I/O configuration, and communication interface setup.
• Execute validation activities as per Design Verification Test (DVT) plans provided by Control Engineering teams.
• Analyze test results, document observations, and generate validation reports.
• Diagnose and troubleshoot issues identified during HIL testing and collaborate with Control, Firmware, and System Engineering teams to drive resolution.
• Support controller algorithm verification, fault injection testing, and system-level validation activities.

Skills

HIL testing

OPAL-RT familiarity

MATLAB/Simulink

Stateflow modeling

Power electronics

Control algorithms

Hardware interfacing

Embedded systems

Real-time debugging

Cross-functional collaboration

Tools

OPAL-RT

MATLAB/Simulink

Stateflow

Job description

Ztek Consulting is seeking an experienced HIL engineer to design and validate power converter controllers with real-time simulation. You will develop HIL models in MATLAB/Simulink/Stateflow, interface hardware, and drive full validation across UPS, converters, and inverters.

Collaboration with Control, Firmware, and Systems teams is essential for robust verification. The role emphasizes hands-on hardware integration, signal conditioning, I/O configuration, and fault injection testing in a