High Voltage Test Engineer

• We need a hands-on mechanically oriented Test Engineer who thrives in the lab. This role balances:
• Logistics layer - coordinating with design counterparts collecting samples creating JIRA tickets for technicians and managing test sample logistics.
• Hands-on test engineering - designing building and iterating on test setups.
• Ownership mindset - treating each setup as if it were their own business balancing speed safety and standardization in a fast-paced environment.

• Architect model and assemble frames (e.g. 80/20 steel aluminum composites) to house power systems control electronics and devices under test.
• Design and build custom control boxes (e.g. microcontroller / relay / switching boards) to actuate and monitor test logic (for example cycling chargeport latches).
• Create harnessing from control box to devices (wiring connectors cable management).
• Select and integrate components: power supplies pumps sensors relays data acquisition modules.
• Rapid CAD design (SolidWorks or equivalent) of parts assemblies and fixtures.
• Develop control scripts (Python preferred) for device actuation chamber/chiller coordination power cycling data logging error handling interlock logic.
• Decompose build and inspection tasks into JIRA (or equivalent) tickets assign to technicians and supervise execution and QA.

• Choose pumps heat exchangers motors actuators (servo stepper etc.) appropriate for the thermal flow mechanical load of the DUT.
• Design structural supports fixtures mounting surfaces force-transmitting links and vibration isolation considering stiffness thermal expansion alignment tolerances and safety margins.
• Apply GD&T (Geometric Dimensioning & Tolerancing) to ensure fixture elements match tolerances and reduce mismatch / rework.
• Fabricate custom parts (machining cutting bending welding) or coordinate with external machine shops when needed.
• Understand mechanical stresses thermal expansion material selection (e.g. aluminum vs. steel coefficient of expansion) to preserve alignment under extreme conditions.
• Recommend and integrate mechanical stress/load elements (e.g. clamping thermal cycling effects flexures) for realistic loading of bus bars junction boxes chargeports.

• Interpret datasheets and performance specs of HV components (contactors shunts relays power converters).
• Size wiring harnesses (gauge insulation derating) design noise mitigation (shielding twisted pairs grounding) and design simple circuits (e.g. resistor dummy loads balancing circuits) to support test logic.
• Integrate measurement hardware: NI DAQ systems thermocouples RTDs pressure sensors accelerometers current & voltage sensors.
• Incorporate HV safety features: interlocks watchdogs fault detection safe sequencing insulation monitoring and emergency shutdown paths.
• Ensure signal timing synchronization sample rate and data integrity across instrumentation channels.

• Work with environmental chambers: plan safe ramp-down sequences (e.g. humidity first) account for thermal soak and enclosure constraints.
• Interface with chillers / cooling systems to integrate temperature setpoints into test profiles and manage coolant circulation.
• Use advanced / bi-directional power supplies (grid simulators programmable sources) with SCPI CAN GPIB Ethernet LXI or RS-232 protocols.
• Manage rack systems: power supplies controllers cabling cooling harness routing cable length constraints.
• Configure and validate test stands to maintain safety clearance mechanical access serviceability and reliability over long test durations.

• Understand and design for reliability test methods common in EV and power component space:
• PTCE (Powered Thermal Cycling Endurance)
• HTOE (High Temperature Operating Endurance)
• HTHE (High Temperature Humidity Endurance)
• IP (Ingress Protection / environmental sealing tests)
• Develop or adapt fixtures and setups for these tests (thermal cycling humidity load cycling) and interpret resulting data for degradation / failure modes.
• Use test data and models to accelerate test times (e.g. using real-world load profiles) while maintaining statistical confidence.
• Understand aging fatigue electromigration thermal cycling cracks insulation breakdown corrosion or humidity-related degradation patterns as inputs to design feedback.

• Validate fixtures: check alignment clearance actuation contact integrity wiring and signal continuity.
• Perform fixture checkout and verification prior to production test runs (probe hits wire verification interlock tests).
• Maintain calibration schedules for sensors and instrumentation to ensure accuracy over long-term usage.
• Monitor fixture drift failure modes and redundancy in critical paths (spare sensors fallback mechanisms).
• Design with safety in mind: include grounding kits proper shielding and ensure human safety in presence of HV.

Must-Have:

• Hands-on comfortable designing AND building test setups
• Mechanical electrical fundamentals (framing pumps heat exchangers wiring)
• CAD (SolidWorks preferred)
• Python scripting (or similar)
• HV safety awareness

Preferred:

• Experience with NI DAQs thermocouples accelerometers
• GD&T knowledge/certification
• Familiarity with environmental chambers and liquid cooling
• Knowledge of power supply communication protocols (CAN GPIB SCPI etc.)
• Reliability testing knowledge: IP PTCE HTOE HTHE

Mindset:

• Scrappy ownership-driven hands-on
• Comfortable balancing speed safety and standardization
• Thrives in a fast-paced dynamic lab environment