Test Validation Engineer

Wall Street Consulting Services LLC; Raleigh (NC); On-site; USD 90,000 - 130,000; Full time

Job summary

Wall Street Consulting Services LLC in Raleigh, NC seeks a hands-on Hardware-in-the-Loop engineer to design and validate power converter controllers. You will develop HIL test setups for UPS and converter platforms using OPAL-RT and MATLAB/Simulink.

You will integrate hardware with HIL environments, create real-time models, analyze test results, and collaborate with Control, Firmware, and System Engineering teams to drive robust validation and fault-injection testing.

Qualifications

• Hands-on HIL testing experience is required.
• Experience with MATLAB/Simulink and Stateflow model development.
• Strong understanding of power electronics and UPS/DC-DC/AC-DC converters.
• Experience with real-time simulation and model-based design.
• Ability to debug hardware-software integration issues in real-time environments.
• Cross-functional collaboration with control, firmware and system teams.
• Exposure to firmware validation and embedded system testing.

Responsibilities

• Design and develop breakout/interface boards for integrating power converter controllers with HIL platforms.
• Configure and establish HIL test setups using OPAL-RT for UPS, DC-DC, AC-DC, and inverters.
• Develop and maintain real-time HIL models for power circuits and interfaces using MATLAB/Simulink and Stateflow.
• Integrate power converter control hardware with HIL, including signal conditioning, pin mapping, I/O configuration, and communication setup.
• Execute validation activities per DVT plans from Control Engineering teams.
• Analyze test results, document observations, and generate validation reports.
• Diagnose and troubleshoot issues during HIL testing and collaborate to resolve with Control, Firmware, and System Engineering.
• Support controller algorithm verification, fault-injection testing, and system-level validation.

Skills

HIL testing

Power electronics

Control algorithms

Real-time simulation

Embedded controllers

Debugging hardware-software

Cross-functional teamwork

Signal mapping

I/O configuration

Tools

OPAL-RT

MATLAB/Simulink

Stateflow

Job description

• 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:
  • UPS systems
  • 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.