
Sr. Controls Test & Integration Engineer
- Irvine, CA
- $135,100-168,900 per year
- Permanent
- Full-time
Role SummaryWe are looking for a dedicated and innovative Senior Controls Test and Integration Engineer to be in our software development team. This key role includes developing, integrating, and rigorously testing control systems for critical vehicle features across high and low voltage batteries and thermal management systems. The ideal candidate will have a strong foundation in electrical, mechanical, or computer science engineering, along with proven experience in software testing and calibration within automotive or aerospace control systems.
ResponsibilitiesLead strategic planning, development, and execution reporting for comprehensive testing of vehicle, HV, and thermal assets related to energy storage & distribution and thermal features. This includes:
- Architecting and developing robust test plans with clearly defined test & validation Key Performance Indicators (KPIs) to ensure seamless end-to-end integration of cross-functional features for energy storage, distribution, and thermal control systems (e.g., HV power moding, range and efficiency, charging, and pack thermal conditioning).
- Strategically allocating tests across various physical assets (e.g., lab cars, HV benches, full vehicles) based on thorough test coverage requirements and cost-effectiveness.
- Executing tests and conducting in-depth, feature-level analysis based on test engineering data, proactively identifying gaps in both implementation and design.
- Leading the execution of vehicle and HV asset regression testing for critical release candidates.
- Conducting thorough deep dives into new and complex failures in collaboration with developers and systems engineers to achieve a comprehensive understanding of the underlying technical aspects and collaboratively establish robust and timely resolution timelines.
- Systematically tracking, prioritizing, and driving the resolution of software quality gaps, providing clear, actionable, and data-driven metrics per OTA release to inform critical decisions.
- Providing key technical input and actively contributing to the critical sign-off process for embedded software quality during vehicle and HV asset testing, ensuring strict adherence to established quality and safety standards.
- Leveraging automation tools to streamline workflows by automating the post-processing of physical asset test results and the efficient generation of comprehensive reports.
- Presenting clear, concise, and data-backed software quality status updates for vehicle and HV asset test and integration, progress on key roadmap items, and potential risks to leadership for every critical software sign-off.
- Playing a key role in defining relevant Key Performance Indicators (KPIs) for insightful fleet data analysis of energy storage & distribution and thermal features, and rigorously qualifying software releases against defined release milestones.
- Bachelor's or Master’s degree in electrical or mechanical engineering.
- Minimum 3 years of proven experience in controls development, integration, or calibration within the automotive or aerospace industries (preferred).
- Strong understanding of fundamental control theory principles and algorithm design methodologies, including compensator design and closed-loop controller tuning.
- Solid and demonstrable knowledge of battery management systems, energy management strategies, charging technologies, and automotive/EV thermal controls at both the comprehensive systems and detailed software integration levels.
- Working familiarity with software development programming languages relevant to embedded systems (e.g., C, C++, Rust, and/or Python).
- Proven track record in software integration, calibration, vehicle-level testing methodologies, and/or effective software debugging at the feature level.
- Experience utilizing requirements management tools (e.g., Jama, Doors) for traceability and verification.
- Experience utilizing issue tracking tools (e.g., Jira) for efficient defect management and resolution.
- Hands-on experience with communication bus monitoring tools (e.g., Vector CANalyzer) for effective system analysis.
- Practical experience with software calibration tools (e.g., Vector CANape, ETAS INCA) for parameter optimization.
- Previous HV Safety training and certification for working with high voltage energy systems is a plus.
- Strong validation-driven mindset with a clear focus on achieving comprehensive test coverage across a diverse range of test assets (automated virtual software-in-the-loop, hardware-in-the-loop, lab car, HV assets, and full vehicle).
- Excellent communication skills, including the ability to clearly and concisely report findings to leadership and collaborate effectively across multiple engineering teams.
- Willingness to travel up to 20% as needed to support testing activities.