Hardware-In-Test-Loop (HITL) Engineer

Hardware-In-Test-Loop (HITL) Engineer
Experience Level
3-5 Years
Location
Erie, PA, USA
Department
Drives Control & Power Electronics
Role Overview
The HITL Design & Maintenance Engineer plays a crucial role in supporting the development and ongoing maintenance of real-time simulation environments intended for validating control software within power electronic systems. The primary focus of this position is on systems that utilise Insulated Gate Bipolar Transistors (IGBTs), Silicon Controlled Rectifiers (SCRs), and the latest Silicon Carbide (SiC) technologies, particularly in inverter and converter applications. Alongside designing Hardware-In-Loop systems, the engineer is tasked with testing and validating inverter controller software, ensuring that all deliverables meet robust performance standards and comply with specified system requirements.
Key Responsibilities
* Architect and maintain HIL systems to support validation of embedded controllers.
* Develop plant models using MATLAB/Simulink that accurately represent various power converter topologies.
* Integrate developed models with real-time simulation platforms such as Opal-RT, Speedgoat, or dSPACE.
* Ensure reliable hardware interfaces, including implementation of signal conditioning and mapping of input/output signals.
* Collaborate effectively with cross-functional teams to ensure HIL setups are aligned with control and software requirements.
* Diagnose and resolve issues related to real-time execution and the fidelity of simulation models.
* Maintain comprehensive documentation for system configurations and update procedures as needed.
* Design and execute detailed test plans for inverter controller software, leveraging HIL platforms for thorough validation.
* Analyse test results and provide support for debugging control algorithms and embedded code.
* Ensure complete traceability between software requirements and HIL test coverage.
Qualifications
* Bachelor's or Master's degree in Electrical, Electronics, Mechatronics, or a related STEM discipline.
* 3-5 years of experience working on HIL system design and real-time simulation.
* Strong proficiency in MATLAB/Simulink for model-based development tasks.
* Hands-on experience with Opal-RT or comparable real-time simulation platforms.
* Solid understanding of inverter and converter control, particularly with IGBT, SCR, and SiC device technologies.
* Familiarity with industrial communication protocols, including CAN, SPI, UART, and Ethernet.
* Experience in testing embedded software within power electronics applications.
Desirable Skills
* Experience working with Simulink Real-Time or RT-LAB environments.
* Knowledge in sensor and actuator emulation techniques.
* Background in Locomotive Drives, Locomotive electrical controls, industrial drives, automotive systems, or renewable energy domains.
* Familiarity with software testing frameworks and version control systems.