Motor Controller Engineer

Role Description

• "Accountability: End-to-End Technical Ownership of the Motor Controller

Tasks:

- Own the component requirement specification (electrical, functional, thermal, mechanical, EMC, safety, diagnostic) derived from the powertrain system requirements and maintain full traceability.

- Own the component design maturity through concept and series release gates; manage design reviews and drive open-point closure.

- Own the component DFMEA, interface control documents, DVP&R and the release documentation required.

- Act as the single technical interface for the inverter towards the powertrain system, vehicle integration, validation, quality, purchasing and the supplier.

- Creation, updation and maintenance of Design Guidelines and TVS Specification for Motor controllers. "                                                                  

"Accountability: Power Electronics Design and Integration

Tasks:

- Review the internal power stage design: IGBT / SiC MOSFET module selection, switching and conduction loss budget, gate driver design, short-circuit and safe-state protections.

- Specify and verify DC link capacitor sizing, busbar layout, ripple current, creepage/clearance implementations and HV isolation requirements.

- Own the thermal design and derating strategy: create a thermal model correlation, continuous and peak power capability over the operating envelope and digital twin creation.

- Review control board, sensing (current, voltage, temperature, position) accuracy and power supply design; drive design changes with the electronics design and supplier teams."                                                                              

"Accountability: Motor Control Algorithm and Calibration Ownership

Tasks:

- Own the motor control implementation: torque/current control loop, SVPWM, dead-time compensation, MTPA and field-weakening strategies.

- Own position and speed feedback handling (resolver, encoder, hall), sensorless strategoes and limp-home strategies, including plausibility and fault handling.

- Own machine parameter identification, flux/current look-up table generation, efficiency map creation and torque accuracy calibration on dyno.

- Define and validate the torque and power capability curves, derating maps and the controller behaviour at different voltage, thermal and current limits."                                                                           

"Accountability: Validation, Component Dyno and Vehicle-Level Performance Verification

Tasks:

- Define and drive the component validation plan: functional, performance, environmental, mechanical, thermal, electrical and endurance testing.

- Correlate dyno-measured efficiency, torque accuracy, thermal behaviour and derating against simulation and specification, drive corrective actions on deviations.

- Support vehicle-level testing, drive-quality and NVH investigations related to the inverter and the machine-inverter integration.

- Analyse test and field failures, lead root-cause analysis and implement countermeasures."                                                                              

"Accountability: Supplier, Change and Cross-functional Management

Tasks:

- Drive technical evaluation and benchmarking of inverter suppliers and topologies, support sourcing decisions with technical evaluation and analysis.

- Manage supplier technical reviews, deliverable tracking, sample builds, engineering change requests for the component.

- Track and drive component cost, weight and packaging targets (development and VAVE).

- Maintain lessons learned, design guidelines and reusable building blocks for future controller programmes."                                                               

"Accountability: Functional Safety, EMC and Regulatory Compliance

Tasks:

- Derive the component safety requirements from the powertrain safety concept: own the technical safety concept, safe states (active short circuit / freewheeling).

- Own EMC compliance of the inverter: conducted and radiated emission and immunity, filter and shielding definition, and closure of EMC test findings.

- Ensure compliance with applicable regulations and standards for HV electrical safety, insulation resistance, isolation monitoring and IP protection.

- Own component-level diagnostics, DTC definition and the failure reaction matrix agreed with the functional integration team."