Weare seeking a supplier-provided EDU Thermal System Engineer to lead the design, development, calibration, and verification & validation (V&V) of the Electric Drive Unit (EDU) cooling and lubrication system for our Battery Electric Vehicle (BEV) programs. The role spans requirements authoring, system architecture, modelling & sizing, continuous and peak thermal testing (including transient events and off-road duty cycles), hydraulic function limit assessment, calibration, and integration with vehicle thermal systems. You will ensure the EDU’s thermal and hydraulic performance meets targets across E-machine, inverter, and gearbox, delivering robust protection strategies, efficient cooling, and reliable lubrication under all use cases.
Area of Responsibility
* Define and maintain system and subsystem requirements for EDU cooling & lubrication (pumps, heat exchangers, filters, sensors, fluid properties, pipework/manifolds).
* Develop system architecture, operating states, control strategies, and calibration maps with end-to-end traceability.
* Author clear, testable requirements and acceptance criteria; contribute to DFMEA and functional safety inputs (ISO 26262 awareness).
* Build and maintain 1D/0D thermal-hydraulic models (e.g., AMESim, GT-SUITE, Simulink) to size pumps, heat exchangers, lines, sensors and set pressure–flow–temperature margins.
* Quantify continuous and peak operating points, thermal balance, derating triggers, and transient responses (start-up, load steps, hot-soak).
* Execute trade‑off and sensitivity studies (thermal capacity, pressure drop, durability, efficiency, NVH) and recommend design/calibration updates.
* Plan and conduct continuous performance thermal tests, both steady‑state and transient (cold start, rapid load steps, etc).
* Lead off‑road duty cycle testing: rock crawl (low‑speed/high torque), sand/mud (high rolling resistance), prolonged slip, trailer‑tow grade, altitude and ambient extremes; consider wading/water ingress impacts on hydraulic integrity.
* Determine hydraulic function limits: cavitation margin (NPSH), aeration risk, cold‑viscosity operation, filter loading, pressure pulsation, flow stability, and component protection strategies.
* Define instrumentation plans, sensor calibration methods, data quality criteria, and safe test procedures; supervise rig/dyno/vehicle execution.
Data Analysis, Correlation & Calibration
* Post‑process data to compute heat flows, pressure–flow characteristics, and thermal transients; correlate models to test results and iterate.
* Define, optimise, and release derating/protection logic, limp‑home thresholds, and calibration datasets with clear rationale and version control.
* Document findings, residual risks, and recommendations with concise, decision‑ready reporting.
Integration, Release & Handover
* Integrate the EDU thermal system with vehicle cooling architecture; support packaging, hose routing, bleed/fill procedures, serviceability, and contamination control.
* Prepare release evidence: requirement coverage, test reports, calibration releases, and change notes; support manufacturing readiness (bleed/flush/EOL checks).
* Ensure deliverables are version‑controlled, reproducible, and handed over with models, data, scripts, and calibration files.
Knowledge / Experience
* Strong experience in Thermal Systems Engineering for electrified powertrain (EDU, inverter, E‑machine, battery).
* Deep understanding of cooling & lubrication systems, component behaviour (pump, heat exchanger, filter), sensor selection/placement, and control strategies.
* Proven track record across system definition, architecture, requirements writing, design/performance modelling, systems integration, system assessment, and acceptance criteria.
* Hands‑on with continuous and peak performance thermal testing, transient events, off‑road duty cycles, and hydraulic function limits (cavitation, aeration, viscosity, pressure pulsation).
* Competent in calibration and function definition (derating, protections, limp‑home); experienced in optimisation and system sizing.
* Strong analytical and problem‑solving skills; clear verbal and written communication; effective cross‑functional collaboration.
* Requirements management proficiency (e.g., IBM Rational DOORS or equivalent).
* Relevant engineeringdegree (Mechanical, Automotive, Mechatronics, Thermal/Fluids or similar).
* PhD or equivalent industrial research in thermal/fluids or systems engineering.
* Experience with CAE/MBE tools and methods: Simulink, AMESim, GT‑SUITE; exposure to CFD (STAR‑CCM+, Fluent, OpenFOAM).
* Structured problem‑solving (DFMEA, 8D, DMAIC).
* Awareness of FUSA, ISO 26262 and environmental standards (e.g., ISO 16750/IEC 60068) as they pertain to system interfaces and testing.
* Experience with IBM Rational DOORS (Classic/Next) and ALM toolchains.
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