Senior HIL / Controls Engineer — Lead

Zealogics.com; San Diego (CA); On-site; USD 140,000 - 200,000; Full time

Job summary

Zealogics.com seeks a Senior HIL Controls Engineer in San Diego to lead real-time bench architecture, target selection, and safety interlocks. You will integrate the bench with client hardware and run closed-loop tests toward client sign-off.

Lead distributed teams, manage export-controlled data, and align MATLAB/Simulink models with production firmware and hardware prototypes. Strong communication with client leadership is essential.

Qualifications

• 8+ years in controls, test or systems engineering in high-power environments.
• 3+ years hands-on OPAL-RT HIL development or similar.
• Proficient in MATLAB/Simulink, C/C++, real-time systems; FPGA I/O familiarity.

Responsibilities

• Define the HIL bench architecture including target selection, I/O mapping, and safety interlocks.
• Develop and validate plant models in MATLAB/Simulink and OPAL-RT; validate with real hardware.
• Lead offshore teams; drive defect triage, progress reporting, and client sign-off.

Skills

HIL development

Real-time systems

MATLAB/Simulink

C/C++

FPGA I/O

Team leadership

Client communication

Education

BS/MS in Electrical/Mechatronics/Controls

Tools

OPAL-RT

dSPACE

Speedgoat

NI VeriStand

Job description

• Define the HIL bench architecture: real-time target selection, I/O mapping, signal conditioning, safety interlocks, and fidelity targets
• Develop and validate plant and power-electronics models in OPAL-RT (RT-LAB / HYPERSIM) and MATLAB/Simulink
• Integrate the bench with the client's hardware and software build targets; run closed-loop tests and lead defect triage
• Own the acceptance specification and drive it to sign-off with client engineering
• Direct the offshore controls, test and software engineers: work breakdown, reviews, weekly progress reporting to the client
• Act as custodian for export-controlled technical data; ensure only cleared individuals access controlled material

What you bring

• 8+ years in controls, test or systems engineering for high-power electronics, plasma, laser, or precision motion systems
• 3+ years hands-on with OPAL-RT (or dSPACE / Speedgoat / NI VeriStand) HIL development
• Strong MATLAB/Simulink, C/C++, real-time systems, and FPGA I/O familiarity
• Experience integrating HIL benches with production firmware and hardware prototypes
• Proven ability to lead distributed teams and communicate with client engineering leadership
• BS/MS in Electrical, Mechatronics or Controls Engineering

Nice to have:

semiconductor capital equipment or EUV/DUV source exposure; Python test automation; SECS/GEM or EtherCAT; prior work in ITAR/EAR environment