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Product Development Engineer eMotors GPPC

Country:
Spain
Work Location:
Zumaia
25 Nov 2020
Job Type:
Temporary
About The Opportunity

Based in GKN Driveline Zumaia, as part of the eMotor GPPC team (Global Product and Process Centre) and part of the customer programme team.

The role scope will include leading the eMotor design (incl. simulation) and validation related tasks towards the project team and the OEM.

Experience in programme management (ideally in automotive environment) and a strong background in electric machines and power electronics will be highly valued.

Good English skills are a must and German or French are welcome.

See detailed tasks and skills below.

  • Tasks

    • To be one of the primary technical interface between GKN and key suppliers/partners with e-machine and power-electronics content

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

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

    • Support the full integration of the eMotor in the system

    • Follow GKN Programme management, STDs and procedures.

    • ISO 26262 functional safety analysis

    • eMotor Prototypes design and manufacturing support

    • Testing specifications definition and support

    • Risk analysis  during the development

    • Simulate all electromagnetic, mechatronic and electronic aspects

  • Skills

    • Deep knowledge of electrical engineering and electric machines

    • Deep 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 an eMotor.

    • Detail knowledge about stator technologies and solutions

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

    • Knowledge about mechanical components process, subassemblies and assembly

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

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.

 

 

Qualifications / Experience / Skills:

Electronic/Electrical Engineer

High Level of English ( writing and talking)

Leadership skills

Presentation skills

About Us

GKN Automotive is the market leader in conventional, all-wheel and electrified drive systems and solutions.

With a comprehensive global footprint, we design, develop, manufacture and integrate an extensive range of driveline technologies for over 90% of the world’s car manufacturers.

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 Automotive. We need people of different backgrounds, with different skills and perspectives to spark originality, imagination and creativeness in our teams around the world.

GKN Automotive 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, colour, 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.


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.