Design Engineer, Energy Storage Systems

Location: Woking, GB

Purpose of the Role:

 

Responsible for packaging, detailed design & release of ESS components (Battery housing, cell, module, internal HV (hazardous-voltage) cables, bus-bars and connectors, E/E (electrical/electronic) components, LV (low-voltage) components, battery management system, and associated cooling systems on all vehicle projects, from concept to production ensuring the design supports system technical specifications.

Key Responsibilities:

  • Programme specific ESS conceptual and detail design, including 3D package and design studies, supporting design releases and 2D drafting.
  • Supporting vehicle integration design reviews and ESS design reviews.

Principal Accountabilities:

  • Work under the guidance of ESS project engineers, alongside Hybrid Electrical Systems (HES) and Hybrid Control Systems (HCS) project engineers and designers, to package ESS components in new powertrain architecture and installations, progressing concepts through to executing detailed designs for prototype and production release and manufacture.
  • Create CAD models and assemblies utilising best practice surfacing, solid modelling and harness routing techniques
  • Understand and support the package constraints for the ESS.  Work with ESS suppliers, McLaren Concept team & Digital Mock-Up team (DMU), Dimensional Management team (DM) and other Engineering teams to ensure programme specific technical and package targets are met and to deliver detailed designs on time to predetermined quality, cost and weight targets, within Design for Manufacture (DFM) and Design for Assembly (DFA) requirements.
  • Work with the other designers and the HES supplier to achieve efficient, innovative and lightweight designs.
  • Work with Computer Aided Engineering (CAE) teams within McLaren, and at suppliers, to provide 3D models to support their analysis activities.
  • Work with ESS project engineers to ensure design solutions that meet attribute targets such as NVH, thermal, durability & performance (power, energy, response).
  • Ensure the ESS components interface seamlessly to the wider car including structural interfaces, electrical distribution system, cooling components & body panels.
  • Support links with external organisations such as universities, research organisations, etc. on collaborative research projects that will help McLaren deliver innovation in HES technologies where appropriate. This would include research projects collaborating with the Engineering Manager/Principal Engineer of HES and Head of Hybrid to exploit such opportunities.
  • Preparation and presentation of material to support external and internal project status reviews.
  • Provide support on ESS technical risk management to ensure project delivery, optimised vehicle performance and delivery of hybrid system attributes.
  • Guarantee ESS delivery to the specific vehicle programme requirements including:
    • Support Energy Storage System FMEA and component design Validation Plans (DVPs).
    • Support ESS planning, timing & delivery including design, release, Engineering Records (ERs) in line with Engineering Timing Release Strategy (ETRS) requirements, development and validation plans.
    • Support robust resolution of design-related concerns.            
    • Support design-issues for vehicle build & development.
    • Support delivery of ESS for all projects in line with MDP (McLaren Development Process) and that Project Management KPIs are on track.

 

Knowledge, skills and experience

  • Good CATIA V5 2D/3D skills with GD&T application experience.
  • Experience of design and release of moulded plastic, and machined / fabricated metal, parts
  • Experience of design of cooling systems (hoses, pipes, pumps, header tanks, heat exchangers)
  • Technical knowledge of common component manufacturing & tooling methods.
  • Experience of ESS mechanical engineering, design, packaging & release.
  • Understanding of electric-drive systems including batteries, eMotors, Motor Control Units, Chargers, DCDC converters, Functional Safety and High Voltage harnessing.
  • Design of high or low voltage electrical distribution systems
  • Understanding of DVP, FMEA and DFM plans.
  • PC literate and at ease with MS Office products.                                                                                                                                                          
  • Experienced in OEM or tier one component delivery.

     

    Qualifications and Training

  • Mechanical, Electrical/Electronic or Automotive Engineering Degree 2:1 or above.

 

Personal Attributes:

  • Good team skills, willingness to work cross-functionally with excellent communication skills.
  • 1-2 years automotive design and development experience.
  • Logical and methodical approach to problem solving.
  • An ability to deliver under pressure with an appetite for measured success.
  • A passion for high performance ESS engineering.
  • Collaborative working with people with a diverse range of backgrounds.
  • A positive, proactive attitude with a high level of self-motivation to deliver excellence.
  • Ambitious and self-reliant, intrinsically self-motivated.
  • Well organised and delivery focused – with demonstrable track record of on-time delivery.
  • Capable of representing a world class automotive brand.                                                                                                                                          

 

Notes

 

All employees must ensure compliance with the Company Health and Safety Policy, and all relevant other statutory Health and Safety legislation.

 

This job description may not detail some less major duties allocated to the post holder, nor cover duties of a similar nature commensurate with the role, which may from time to time be reasonably required by the relevant manager.

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