Controls and Power Systems Engineer

Controls and Power Systems Engineer (Direct Hire)

Dayton, OH 

Job Requisition: 7490 

Description for Controls and Power Systems Engineer:

The Controls and Power Systems Engineer designs and develops high-power converters, inverters, and motor drive systems for EV off-highway vehicles and other heavy-duty equipment. This role involves developing and testing electronic systems, implementing motor control algorithms, and creating embedded firmware for safe and efficient operation. The engineer will work closely with mechanical, thermal, and systems teams to integrate power electronics into complete propulsion systems and support operations, field service, customers, and sales. The position includes hands-on prototyping, testing, troubleshooting, and preparing technical documentation to deliver reliable solutions for demanding industrial environments.

Responsibilities for Controls and Power Systems Engineer: 

• Lead all electronic and electrical aspects of new product development through production support
• Design and optimize high-power traction inverters (500kW+), converters, and auxiliary power supplies for locomotives, haul trucks, and mining equipment
• Specify and integrate high-voltage semiconductor devices (IGBT, SiC, IGCT, GTO) and power modules
• Develop cooling and thermal management solutions for harsh, high-vibration environments
• Implement advanced motor control algorithms for PMSM motors
• Develop embedded firmware on DSP/FPGA/real-time controllers for safe and efficient system operation
• Conduct hardware-in-the-loop (HIL) testing, dynamometer validation, and field trials on locomotives and mining equipment
• Ensure compliance with rail and mining safety standards, EMI/EMC requirements, and rugged packaging practices
• Troubleshoot and resolve field performance issues in demanding environments
• Collaborate with mechanical, thermal, and systems engineers to integrate electronics into complete propulsion systems
• Provide technical support to operations, field service, and customer engineering teams
• Prepare technical documentation, test reports, and compliance certifications
• Analyze customer returns, identify root causes, and develop corrective actions
• Support the Sales Department with quotations, customer service, and design/price requests
• Build, test, and evaluate prototypes, including setup and instrumentation
• Communicate design objectives and project updates directly with customers and sales
• Adhere to client’s release-to-production protocols and quality processes
• Contribute to the design and build of test cells for technology development
• Stay current on the latest advancements in power electronics technologies

Requirements for Controls and Power Systems Engineer: 

• Bachelor’s or Master’s degree in Electrical Engineering, Power Electronics, or a related field
• Permanent Magnet motor knowledge 
• Strong background in high-power electronics design (converters, inverters, motor drives up to 500kW+)
• Hands-on experience with traction drives, propulsion systems, and high-voltage power electronics (up to ~3kV DC/AC)
• Proficiency with high-voltage semiconductor devices (IGBT, SiC, IGCT, GTO) and power modules
• Knowledge of PMSM motor control and ability to implement advanced control algorithms
• Experience developing embedded firmware on DSP/FPGA/real-time controllers
• Ability to design cooling and thermal management solutions for harsh, high-vibration environments
• Experience with HIL testing, dynamometer validation, and field trials for heavy-duty applications
• Understanding of EMI/EMC compliance, safety standards, and rugged packaging for mining/rail environments
• Strong troubleshooting and critical thinking skills to resolve field performance issues
• Ability to collaborate across mechanical, thermal, systems, and customer-facing teams
• Effective technical documentation and communication skills (reports, compliance certifications, customer updates)

Nice to Have: 

• Master’s degree or higher in Electrical Engineering, Power Electronics, or related field
• Familiarity with battery and hybrid energy storage systems (BESS) for heavy-duty applications
• Knowledge of rail and mining safety standards
• Experience with prototype building, test cell design, and technology development support
• Familiarity with international standards for testing and compliance
• Experience with electronic test equipment, lab procedures, and instrumentation setup
• Knowledge of EMI/EMC mitigation techniques beyond compliance (design-for-EMC best practices)
• Strong background in thermal modeling and vibration-resistant packaging design
• Prior experience providing technical support to sales or customer engineering teams
• Proven ability to analyze customer returns for root cause and corrective action
• Continuous learning mindset to stay current with the latest power electronics technologies