Avionics Harness Engineer

Job Title

Avionics Harness Engineer

Location

Bengaluru

Job Type

Full time

Job Summary

The Avionics Harness Engineer owns the design of all electrical harnesses in HyPrix systems. The position holder takes each harness from the interface requirements to a released drawing that a supplier or the assembly team can build without questions. The scope includes the air vehicle, the launcher, ground support equipment, the ground control station and test harnesses. The Avionics Test Engineer runs the harness tests, and the supply chain team buys the harnesses from suppliers.

Responsibilities

• Interface definition. Translate the system interface requirements and ICDs into wiring diagrams, connector pin-outs and signal lists. Agree each interface with the avionics, power, RF and mechanical teams.
• Harness design. Produce 2D schematics, 3D routed harness models and 2D formboard drawings, with branch lengths, bundle diameters, breakouts and all call-outs.
• Component selection. Select wires, connectors, contacts, backshells, shielding and protection materials for each environment. Balance weight, EMC performance, temperature rating, cost and lead time.
• Electrical analysis. Calculate wire gauge, current capacity, voltage drop and derating. Do trade studies for topology, shielding and connector selection.
• EMC design. Apply cable segregation, shield termination, backshell bonding and separation between noisy and sensitive circuits. Design the grounding and bonding scheme with the avionics team, including composite structures.
• Safety-critical circuits. Segregate, shield and protect safety-critical circuits, for example safe-and-arm and initiation circuits, to the applicable standards.
• Routing and installation. Route harnesses in the vehicle with the mechanical team. Control bend radius, chafe protection, clamps, strain relief and access for maintenance.
• Environmental design. Design each harness for vibration, launch shock, temperature, humidity and small volumes.
• Prototypes. Build and test prototype harnesses in the laboratory. Check routing, connector mating, shield continuity and workmanship before supplier release.
• Supplier data package. Prepare complete harness data packages: drawings, BOM, wire lists, test requirements and workmanship class. Check each package before release, and answer supplier questions.
• Manufacture and test support. Write harness assembly instructions and test requirements for the assembly team and suppliers. Support first article inspection, harness tests and fault investigations.
• Integration support. Support harness installation, system integration and field trials. Investigate each harness fault, and update the design.
• Configuration control. Release and control harness data in the PLM system. Keep each harness traceable to its revision and to each platform variant.
• Standards. Set the HyPrix harness design rules, preferred parts list and drawing standards.

Requirements

• Minimum Experience (Years). 4 years of electrical harness design for aerospace, defence, UAV, automotive or other high reliability products. HyPrix prefers this experience, but it is not mandatory. Demonstrated capability is more important than years.

Required Skills

• Harness CAD. Proficiency with SOLIDWORKS Electrical, Siemens Capital, NX Cabling or an equivalent harness design tool.
• Drawings. Experience to produce wiring diagrams, 3D routed harnesses and 2D formboard drawings that a supplier can build without interpretation.
• Interconnect knowledge. Good knowledge of wires, connectors, contacts, backshells, shielding and their environmental ratings.
• Electrical analysis. Ability to calculate wire gauge, current capacity, voltage drop and derating.
• EMC. Knowledge of harness-level EMC: segregation, shield termination, grounding and bonding.
• Standards. Knowledge of IPC/WHMA-A-620 and aerospace wiring standards such as AS50881 or the applicable MIL-STD requirements.
• Bus interfaces. Familiarity with CAN, Ethernet, RS-422/485 and power distribution.
• Hands-on work. Experience to build and test harnesses, and to work with harness manufacturers.
• A bachelors degree in electrical, electronics, aerospace or mechanical engineering.

Advantageous Skills/Qualifications

• Experience with harnesses for missiles, UAVs, launch vehicles or aircraft.
• Experience with Siemens Capital or NX Cabling. HyPrix plans to move to Siemens NX.
• Experience with harness routing in carbon fibre composite airframes.
• Experience with launch shock environments, umbilical connectors or separation connectors.
• Knowledge of MIL-STD-461, MIL-STD-464 and the protection of initiation circuits.
• Experience with harness data in a PLM system, and with configuration control.
• Knowledge of wire and connector standards such as MIL-W-22759, MIL-DTL-38999 or EN 3197.
• Experience with Indian harness suppliers.

Disclaimer: This job posting has been aggregated from external source. Role details, content, and availability are subject to change. Applicants are advised to confirm the latest information directly on the company website before applying.