Job Description
In this position...
The Power Supply Application Engineer is responsible for sizing, packaging, validating, and releasing the starting/charging system for ICE (Internal Combustion Engine) and EV (Electric Vehicle) applications. This includes several key components: Alternator, Starter, Battery, ASIL (Automotive Safety Integrity Level) rated redundant Power supply components including additional Batteries, Ultra Capacitors, and Battery Management Sensors (BMS).
Responsibilities
What you'll do...
- Perform Charge Margin analysis with time average, transient, and ASIL sizing models
- Interface with program team to package all components in a suitable location
- Interact with Powertrain FEAD (Front End Accessory Drive) to ensure proper belt loading and mounting structure for the alternator
- Interact with Powertrain to ensure proper interface for the starter motor
- Interact with Powertrain calibrators to establish and confirm charging system related calibration values such as electrical idle kickers to support charge margins
- Work with suppliers to develop design concepts and define the costs that support the application both electrically and mechanically. Lead To4 (Team of Four) meetings.
- Gain approval from the program for all tooling, piece costs, and ED&T (Engineering Design & Testing) associated with power supply components
- Work with VO (Vehicle Assembly Operations) to ensure component package meets assembly and ergonomic targets
- Work with VO and supplier to develop proper dunnage
- Work with FCSD (Ford Customer Service Division) to ensure proper serviceability of power supply components
- FEDEBOM (Bill of Materials) / WERS (Worldwide Engineering Release System) release final designs for all power supply components (Alternator, Battery, Battery Labels, Battery Blankets, Starter, Starter Fasteners/Torque specs, Solenoid caps, BMS Sensors, ASIL Ultra capacitors and Energy Modules, etc…)
- Complete component FMA (Failure Mode Analysis) documentation including CPAs (Change Point Analysis) and SCCAFs (Special Characteristics Communication and Agreement Form)
- Signoff for all vehicle builds (TDC, DCV, TT, PP) at multiple locations
- Establish required SDS (System Design Specifications) testing through FEDEDVP (Design Validation Plan) for each program and upload test results
- Support VEV (Vehicle Evaluation & Verification) Wind tunnel testing to validate sizing and component temperatures on each application
- Conduct cold crank testing to verify battery CCA (Cold Cranking Amps) sizing for powertrain cold crank RPM target
- Support/Conduct Garage test to verify Static loads, Key Off Loads, Volt drops, Idle up, and failure diagnostics
- Interact with EDS (Electrical Distribution System) team to ensure proper wire size and connections to interface with our components and to meet system volt drop
- Lead TDRs (Technical Design Reviews) prior to key program milestone events (TDJ, FDJ, PEC)
- Interact with Purchasing and Suppliers to complete ESOW's (Engineering Statement of Work) and Supplier Sourcing Contracts / Supplier on Board Agreements (SOBA)…Handled via Tof4 meetings
- Review, edit, and signoff Owner and Workshop manuals for Power Supply content
- Monitor AIMs (Automated Issues Management) and DURIS (Durability Information System) and react to any issues and follow to closure.
- Monitor and react as needed to warranty trends
- React to Voice of the Customer Fleet issues and follow to closure.
- Support Fuel Economy team with development and certification testing as related to BMS.
- Support TVM (Team Value Management) efforts to implement agreed cost reduction changes
Qualifications
You'll have...
- Bachelor’s degree in Electrical Engineering or Mechanical Engineering.
- Fundamental understanding of electrical architectures and electrical systems (circuit analysis, power distribution principles).
- Proficient in Microsoft Office Suite (Excel, Project, Word, PowerPoint).
- Full professional command of the English language (written and verbal).
- Ability to work effectively within a diverse team environment to accomplish the goals of FORD+ (interfacing with program teams, suppliers, and cross-functional departments).
- Ability to perform engineering analysis (such as sizing models or load calculations) and problem-solving.
Even better, you may have...
- Advanced degree (Master’s or PhD) in Engineering.
- Familiarity with Ford internal processes and tools, including:
- WERS, FEDEBOM, GPDS.
- FEDEDVP, GPIRS, AIMs, DURIS.
- DOCMAN (2D Drawings), ESOWs.
- Experience with Network Communication tools such as CANalyzer, PTDiag, and Vehicle Spy (Vspy).
- Knowledge of Team Center Enterprise (TCe), CATIA/3Dx data structures, or Digital Pre-Assembly (DPA).
- Familiarity with Vehicle Operations (VO) and Customer Service (FCSD) requirements.
- Understanding of Powertrain FEAD (Front End Accessory Drive) or High Voltage/48V systems.
- Exposure to ASIL (Automotive Safety Integrity Level) standards.
- Prior experience leading projects or people is a plus.
