Ford Motor Company

Engineer serves as a key technical resource responsible for the end-to-end process of design, building, and maintaining Hardware-in-the-Loop (HiL) test environments ensuring accuracy, robustness, and functionality throughout the entire validation lifecycle, including implementing necessary design changes or proposing solutions to enhance test coverage, facilitate comprehensive system validation and enable test automation.

• Setting up the Host PC and test tool: Install, configure, and maintain operating systems, drivers, and a suite of necessary validation, simulation, measurement, and diagnostic software tools on Host PCs. Ensure network configurations and tool compatibility are correctly established to support various testing environments and activities.
• Test specification analysis: Analyze Test/Feature documentation (boundary diagrams and interface specifications) to understand signal definitions, pin assignments, power requirements, and communication protocols required to define the interactions between the Devices Under Test and the simulation environment.
• Design of benches for end-to-end HIL testing: Develop and deliver a detailed document that clearly defines the mapping of signals and interfaces from the test specifications (boundary diagrams, interface sheets) to specific physical connections (connector pins, breakout boxes) on the HiL breadboard and corresponding logical points within the simulation environment.
• Test benches build request: Coordinate with dedicated hardware build team to initiate and oversee the physical construction of the HiL test bench/breadboard. Provide the detailed allocation map, necessary design documentation, clarify technical requirements, and manage the progress and quality of the build.
• Request environment modeling: Collaborate with the modeling team to request, develop and/or adapt the simulation models (variables models, sensor/actuator models) that accurately represent the real-world components interacting with the devices under test. Use the allocation map to ensure the models' interfaces align correctly with the breadboard's physical connections and the simulation environment's requirements.
• Performing stimulus testing on the model: Conduct testing of the simulation models independently and integrated with basic hardware setups.
• Stimulus testing wiring: Conduct testing of the wiring connections on the test bench to ensure proper functionality of physical interfaces between devices under test, testing tools and test bench control equipment.
• Commissioning Electronic Computer Units: Execute initial basic tests on the integrated HiL system (Program HW, Wiring, Peripherals, Communication Channels, tools and model) to ensure fundamental power-up, communication, and core functionality are operational based on test specifications.
• Continuous maintenance on the HiL test environment: Provide ongoing maintenance for the HiL breadboard, which includes identifying and repairing faulty connections or components, updating hardware as needed, performing calibrations, and ensuring the overall reliability and stability of the test setup for continuous use over the life cycle of the test project.
• Providing technical assistance to validation engineers: Support includes troubleshooting issues related to the test setup, assisting with the proper use of validation tools, breadboard connections and configurations, and helping to diagnose hardware/software conflicts within the HiL environment.
• Build and integration of test solutions: Receive and process test solution requirements, lead the plan for build and integrate required test solutions (end to end feature testing and automation solutions) into test environment. Build and commission electromechanical solutions to enable automation.
• Test bench decommissioning and material management: Dismantling the test bench removing ECUs and wiring, management of decommissioned components, material and tools. Complete scrap process documentation to dispose correctly no longer needed material.
• Manage environment test data: Test usage measurement and Equipment/Part/Material inventory.
• Bachelor's degree in Engineering (Mechanical, Mechatronics, Electrical, or Industrial Engineering).
• Experience with dSPACE SCALEXIO systems, including board mapping and ControlDesk software.
• Proficiency with Vector tools for CAN and LIN communication.
• Advanced proficiency with Diagnostic Engineering Tools.
• Troubleshooting electrical integrations.
• Ability to interpret automotive electrical diagrams.
• 5+ years of experience in the automotive industry.
• Experience with feature testing.