Test Engineer - Hardware-in-the-Loop (HIL) testing

Wall Street Consulting Services LLC; Raleigh (NC); On-site; USD 110,000 - 150,000; Full time

Job summary

Wall Street Consulting Services LLC in Raleigh, NC seeks an experienced real-time HIL engineer to design and validate power-converter controllers using MATLAB/Simulink and Stateflow.

You will develop breakout boards, configure OPAL-RT HIL setups for UPS and converters, and collaborate across Control, Firmware, and System Engineering teams to ensure robust hardware-software integration.

Qualifications

• Hands-on experience with HIL testing and validation of power converters.
• Proficiency in MATLAB/Simulink and Stateflow model development.
• Solid understanding of power electronics systems, including UPS, AC-DC and 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; Analog and digital I/O configuration; Communication interface setup and verification.
• 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

MATLAB/Simulink

Stateflow

Power electronics

Power converter control

Real-time simulation

Embedded controllers

Control systems

Firmware validation

Cross-functional teamwork

Tools

OPAL-RT

Job description

Location - Raleigh, North Carolina (onsite only)

Years - 7 to 10 years

Job Description:

Mandatory Skills:

• Hands-on experience with Hardware-in-the-Loop (HIL) testing and validation of power converters, with OPAL-RT experience preferred.

• Strong experience in MATLAB/Simulink and Stateflow model development.

• Solid understanding of power electronics systems, including:

o UPS systems

o AC-DC and 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:

o Signal conditioning and gain setting

o Pin mapping and wiring validation

o Analog and digital I/O configuration

o Communication interface setup and verification

• 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.