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Product Development & Simulation Engineer eM GPPC

Country:
Spain
Work Location:
Zumaia
Advertising End Date:
26 Apr 2019
Job Type:
Regular
About The Opportunity

Support all Traction Motor aspects within the eDrive Product Plan aligned with business strategy:

  • Provide feasibility studies about new eMotors & inverters concepts and its integration

  • Provide eMotors & inverters technical documentation to be discussed in the product plan meeting.

  • Deliver technical information concerning eMotors & inverters partners including their product strategy.

Support  to design new eMotors according to the product plan:

  • Simulate all electromagnetics, electromechanics and electronics aspects with  the TMGPPC SW

  •  

Support eDrive application activities on system level:

  • eMotors & inverters Sizing for new customer programmes opportunities

  • To be one of the prime technical interface between GKN and respective partners on projects with e-machine and power-electronics content

  • Support to develop the technical specifications including validation plan for eMotors and inverters.

  • Support the full integration of the inverter, motor

Develop a close Cooperation with other GPPCs and supporting functions:

  • Support GKN Advanced Engineering

  • Support to Lohmar eDrives team

  • Support to Manufacturing Engineering

  • Support SW GPPC in terms of:

  • Support GKN Sintermetals in terms of eMotors development when required.

SW standardization for eMotors numerical calculations & simulations

Provide technical assessments on potential partners in the field (e-machines, inverters) when requested.

Follow GKN Programme management, STDs and procedures.

Use all the GKN IT tools like:  Windchill,  iShare, etc.
Key Responsibilities

Deliver specific technical information about eMotors to be fed by Inverters for the eDrive Product Plan and/or Advanced Engineering & eDrives Engineering senior directors:

  • Any kind of emotors

  • Consumption simulations considering the complete electric power train.

  • Battery sizing

  • Gearboxes ratios optimization

  • Emotors  industrial partner’s assessment.

  • Etc.

Depth knowledge of electrical engineering and electric machines

Depth knowledge about validation tests for electric machines

Understand the Heat transmission and fluid dynamics to be applied in electric machines

Understand the functionality, key modules and algorithms for any kind of inverter to feed a emotor.

Detail knowledge about stator technologies and solutions:

    • Stator laminations:

      • Grade of quality (permeability, losses, thickness, insulation in surface,  compression rate for stator package, etc)

    • Stator Winding:

      • Distributed winding (1 layer, 2 layers)

      • Concentric winding

      • Concentrated winding

      • Insulation in slots

    • Impregnations technologies and influence in the machine performance

Detail knowledge about rotor technologies and solutions:

    • PMSM

      • Magnet grades (Br vs Hc, Temperature influence, etc)

      • Rotor laminations

    • IM

      • Squirrel cage geometries, slots number and materials

      • Rotor laminations

Depth knowledge about materials and processes for the emotor key metallic components as:

    • Steel shafts and process

    • Bearings and sealings

    • Aluminum shields material and process

    • Aluminum  housing material and process

    • Aluminum connections box

Knowledge about mechanical components process, subassemblies and assembly

Analytical calculations & Simulations  of emotors according to the product plan:

  • It should be in any kind of emotor as:

    • PMSM Radial Flux

    • PMSM Axial Flux

    • Induction Motors

    • Transversal Flux Motor (TFM)

    • Synchronous reluctance motors

    • Switch Reluctance motors

       

      Of course clear understanding of the inner rotor and out rotor lay-out and functionality

       

  • Knowledge about analytical, numerical and simulation tools for:

    • Analytical Electromagnetic calculations (such as Speed SW)

    • FEA Electromagnetic calculations (such as Flux 2D&3D)

    • eMotor Thermal analytical calculations (such as MotorCAD)

    • NVH

    • Computational Fluids Dynamic CFD (such as AcuSolve)

    • MatLab/Simulink

       

  • Detailed simulation by FEA and analytical tools of the electromagnetic field of the emotors:

    • Magnetic Field distribution

    • No load, full load and peak load simulations( voltages, currents, power factors, torques, temperatures, etc)

    • Radial forces in the airgap for bearings calculations.

    • Cogging pulsation torque simulation

    • Ripple pulsation torque simulation

    • Efficiency map matrix output

    • eMotor reactances to provide to the inverter supplier

    • Head windings forces generated

    • Heat generation in the stator active parts (laminations and winding)

    • Heat generation in the rotor active parts (magnets or squirrel cage in case of IM, etc)

    • Fourier Transformer understanding and harmonics calculation of emotor Electric and Mechanical signals as: voltages, currents, torques, etc

  • Numerical calculations and simulation by FEA for:

    • Housing

    • Shields

    • Shafts. (strength, fatigue and natural frequencies)

    • Bearing selection and sizing

    • eMotor natural frequencies

    • Ripple torque influence

    • Cooging torque influence

    • NVH performance

       

  • Numerical calculations about the noise frequencies generated by the machine.

    • Influence of number of slots

    • Stator core stiffness

    • Rotor core stiffness

    • Stator and rotor fixations

       

  • eMotor & GB & Inverter & Battery simulations:

    • Model the inverter

    • Model the emotors

    • Model the battery

    • Obtain the current harmonics and the influence in the motor losses

    • eMotor capacitances calculations (stator slots, airgap, etc) and estimate the current though the bearings

    • Replicate driving cycles and obtain motor torques, voltages, currents, etc

    • Obtain consumptions and savings

       

  • Correlation of the analysis & simulation outputs with the physical test results.

    • Electric parameters and signals

    • Mechanical parameters and signals

    • Noise parameter and signals

    • Temperature distributions

       

Depth knowledge about connectors for HV and LV

Knowledge about rotor speed and position sensors, Temperature sensors, vibrations sensors, etc

Complete design of the emotor for the given GKN or customer specifications

  • GB+emotor in offset design

  • GB+emotor in coaxial desing

  • Both even integrating the inverter

  • Both considering HV & LV connectors, bus bars, devices for grounding the shaft, resolvers, different cooling systems, etc      

Definition of the validation plan for the eMotors and inverters according to the customer or GKN specifications:

    • Functional tests (to characterize the motors)

    • Endurance

    • Heat generation

    • NVH

    • Environmental conditions

    • others

Product & process standardization including Change Management

Release product validation Final Reports:

  • Product description

  • Drawings, BOM and Models

  • Test results

  • Conclusions

  • Upload in WT.

Ensure design and process Deviation Control

Drive standardized calculation and simulation Tools

Ensure Benchmarking of state of the art competitor products

  • Materials and process analysis

  • Geometry analysis

  • Simulations to replicate

  • Test definitions including the characterization tests

  • Final report

Intellectual Protection (IP).  Propose patents and content review of competitors patents

Support to Application / Account Teams

  • Training & Know-How-Transfer

  • eMotor, inverter and battery sizing for the requested application and specifications

  • Packaging analysis of the complete system.

  • Release product & test specifications for the potential industrial partners (emotor active parts supplier)

  • Support eDrive application activities on system level (DC/DC converter, inverter, battery charger, emotor, gearbox, ECUs)

  • Support in quality issues with the technical knowledge.

  • Root cause analysis. Implement and assess potential problem solution.

Support to Lohmar eDrives GPPC:

  • Integrations architectures to optimize the performance and packaging.

  • Prototypes manufacturing support

  • Testing follow up in a system level including test rig definition

  • Simulations for complete systems (GB + emotor + inverter)

    • Consumptions

    • Acceleration time

    • Ratio optimization for consumption & acceleration.

  • eMotors and inverters sizings

Support to eDrives Manufacturing GPPC:

  • eMotor detail design and inverters general design for  manufacturing

  • Drawings & BOM

  • 2D&3D models

  • EOL testing definition

  • Ideas for cost reduction in a system level.

  • Ideas for optimized manufacturing integration (gearbox+motor+inverter)

Support to SW GPPC to:

  • Actuator Motor characterization simulations

  • Inverter + eMotor simulations

  • Communications from resolver and inverter.

  • ISO 26262 functional safety analysis

Support to GKN Sintermetals eMotors activities as requested:

  • Ideas to apply SMC material on new motors development.

  • Testing support

Support  to GKN Advanced Engineering:

  • Electromagnetic  Simulations

  • Emotor Prototypes design and manufacturing support

  • Testing specifications definition and support

Management of his/her working area:

  • Programme planning and achievements

  • Risk analysis  during the development

  • Identify critical aspects and escalate them

Participate in the daily&weekly meetings with the Traction Motors GPPC.

Review validation test results before report release.

  • Functional testing (characterization).

  • Endurance analysis

  • Environmental conditions

  • NVH

  • Others

Control of the applicable KPIs, taking care of:

  • Collecting the appropriate information

  • Calculation and interpretation of the KPIs

Control of GKN procedures and standards, taking care of:

  • Revision, realization and control of applicable procedures

  • Update and control of GKN STDs

Management and control engineering support requests from the Traction Motors GPPC:

  • Content

  • Requester

  • Type of eMachine

  • Customer

  • Site

Management of external associated costs, taking care of:

  • Realization of purchase requests

  • Control and storage of the documentation

Follow the GKN management tools as WT, iShare, WHC, etc.

High level of English (writing and talking)

Qualifications / Experience / Skills

Electronic/Electrical Engineer
High Level of English ( writing and talking)
Leadership skills
Presentation skills
About Us
GKN Driveline Zumaia
Diversity and Inclusion

As a global engineering company, innovation is what differentiates us from our competitors and is central to our success.

A balance of cultures, ethnicities and genders help bring new ideas and creativity to GKN. We need people of different backgrounds, with different skills and perspectives to spark originality, imagination and creativeness in our teams around the world.

GKN is an equal opportunity employer.

We treat all our employees and applicants fairly and are committed to ensuring that there is no discrimination or harassment against any employee or qualified applicant on the grounds of age, race, creed, color, national origin, ancestry, marital status, affectional or sexual orientation, gender identity or expression, disability, nationality, sex, or veteran status or any other characteristic protected by law.

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