EV Energy Management CAE Engineer at Ford Global Career Site

Dearborn, Michigan, United States -

Full Time

Start Date

Immediate

Expiry Date

18 Mar, 26

Salary

164192.0

Posted On

18 Dec, 25

Experience

5 year(s) or above

Remote Job

Yes

Telecommute

Yes

Sponsor Visa

Skills

Thermal Management, Computer Aided Design, 3D CFD Modeling, Thermal Analysis, Heat Exchanger Optimization, Automotive Powertrain Cooling, Data Analysis, Machine Learning, High-Performance Computing, Vehicle Cabin Thermal Systems, Human Comfort Modeling, Battery Thermal Analysis, Air Flow Analysis, Design Optimization, CFD Simulation, Transient Thermal CAE Models

Industry

Motor Vehicle Manufacturing

Description

Note, this is a hybrid position whereby the employee will work both from home and from the Dearborn office. Hence, the employee must live within a reasonable commuting distance from Dearborn, MI. Collaborate with program team and key work partners in the company to frame the right thermal environment for every under hood/body/cabin. Lead, train and guide CAE team of engineers to support and accommodate customers (thermal program team and key work partners in the company). Lead and perform full vehicle transient thermal CAE models from start to finish (CAD data collection, clean up, meshing, boundary conditions setup and post processing). Continuously innovate and search for CAE process improvement focusing on accuracy, efficiency, capability. Ensure high quality CAE results and solutions throughout the design process. Make technical recommendations on design optimization, issue resolutions and countermeasures, based on engineering judgment and interpretation of CAE results. Interface with Ford global team (global 1D and 3D CAE team, CAD, CAE Integration, PTI, D&R and other attributes). Document all CAE work and results as per the Ford Thermal process to ensure tasks traceability. Perform and support Powertrain Cooling CAE 3D air flow analysis, heat exchanger/fan sizing, heat exchanger arrangement and air flow uniformity. Assist front end opening and grill designs optimization to meet vehicle airflow and performance targets throughout vehicle development phases. Perform and support Traction Battery (High Voltage) 3D CAE thermal analysis by coupling exterior vehicle air flow analysis with complex 3D and /or 1D battery CAE model. Assist vehicle system optimization to meet vehicle airflow and battery performance targets throughout vehicle development phases. Perform BEV coolant and refrigerant system heat loss/gain analysis by coupling analytical vehicle air flow analysis with complex 3D and /or 1D CAE model. Assist vehicle system optimization to meet vehicle energy usage and performance targets throughout vehicle development phases. Perform BEV cabin interior CFD analysis to optimize air flow stratification (with Climate Thermal group), minimize cabin heat loss/gain analysis and human comfort features modeling. Perform Battery Cell Venting and smoke mitigation strategy through CAE. Perform vehicle air flow analysis to understand CVM gas flow and optimize design to prevent high temperature gas from reaching critical safety areas. Develop, design and analyze AGS, ducting and under hood hot air evacuation concept and strategy by working closely with thermal program and D&R engineer. Develop, design and analyze vehicle energy usage. Use CAE insights to eliminate or reduce vehicle energy waste (heat gain or loss). Perform CAE assessment on exterior design proposals from Studio. Support design theme selection process throughout studio design process. Bachelor's degree or foreign equivalent in Mechanical Engineering, Chemical Engineering, Aerospace Engineering or a related field and 5 years of experience in the job offered or a related occupation. 5 years of experience with each of the following skills is required: 1. Using Computer Aided Design (CAD) clean up, components interfaces and meshing parameters to ensure a successful full vehicle model ready for CFD analysis. 2. 3D CFD modeling. 3 years of experience with each of the following skills is required: 1. Performing full vehicle thermal analysis using Computational Fluid Dynamics. Ability to build, setup, analyze and post process a digital twin vehicle model and perform correlation to physical test. 2. Use of automotive powertrain cooling system and developing and optimizing heat exchangers, fan sizing and hydraulic system routing. 3. Performing virtual automotive under hood and body thermal management to ensure vehicle design robustness and occupant safety during failure mode. 2 years of experience with each of the following skills is required: 1. Analyzing and processing large amount of analytical data from CFD simulation and test data. Utilizing machine learning and/or reduced order modeling. 2. Use of high-performance computing system and cloud when dealing with very large and complex model setup, analysis, post processing and automation (Java and Python). 3. Performing vehicle cabin interior thermal systems and human comfort modeling. 1 year of experience with the following skill is required: 1. Performing analysis and relate human Equivalent Homogeneous Temperature to sensation Fiala model and comfort Berkeley model. We are offering a salary of $125,362.00 - $164,192.88/yr. As an established global company, we offer the benefit of choice. You can choose what your Ford future will look like: will your story span the globe, or keep you close to home? Will your career be a deep dive into what you love, or a series of new teams and new skills? Will you be a leader, a changemaker, a technical expert, a culture builder or all the above? No matter what you choose, we offer a work life that works for you, including: Immediate medical, dental, and prescription drug coverage Flexible family care, parental leave, new parent ramp-up programs, subsidized back-up child care and more Vehicle discount program for employees and family members, and management leases Tuition assistance Established and active employee resource groups Paid time off for individual and team community service A generous schedule of paid holidays, including the week between Christmas and New Year's Day Paid time off and the option to purchase additional vacation time. https://fordcareers.co/GSR-HTHD Verification of employment eligibility will be required at the time of hire.

Responsibilities

The engineer will lead and guide a CAE team to ensure optimal thermal environments for various vehicle components. They will perform full vehicle transient thermal CAE modeling and continuously innovate CAE processes for improved accuracy and efficiency.