Senior Test Engineer - HIL

Role Summary

The HIL Test Engineer develops and operates hardware-in-the-loop and real-time simulation capability for ON.energy storage and power conversion products. The role covers real-time model development, integration of controllers and firmware with the simulation environment, execution of structured test campaigns, and the reporting that supports design reviews and product release. This is a hands-on laboratory and integration role, working closely with the controls, firmware, modeling, and product engineering teams.

Key Responsibilities

• Develop and maintain real-time models of plant, grid, and equipment behavior for use in controller testing.
• Configure and operate the HIL environment, including real-time simulator, I/O interfaces, signal conditioning, and data acquisition.
• Integrate product controllers, control software, and firmware builds with the simulation environment, and maintain those configurations under version control.
• Integrate supplier-provided equipment models and develop equivalent models where required.
• Plan and execute functional, performance, fault, boundary-condition, and regression test campaigns against defined acceptance criteria.
• Verify control performance across normal operation, disturbances, abnormal conditions, and recovery.
• Compare test results against offline simulation studies and laboratory measurements, and resolve discrepancies.
• Develop scripts and tooling to automate test execution, data processing, and reporting.
• Investigate failures with controls and firmware engineers, support root-cause analysis, and re-test to closure.
• Prepare test reports documenting method, configuration, results, limitations, and recommendations.
• Maintain laboratory safety, equipment, configuration records, and documentation.

Key Requirements

• 5+ years of experience in HIL testing, real-time simulation, controls validation, or laboratory testing of grid-connected power electronics.
• Bachelor's degree or higher in electrical engineering, power systems, controls engineering, or a related discipline.
• Direct experience on at least one real-time simulation platform, such as RTDS/RSCAD, Typhoon HIL, or OPAL-RT.
• Working capability with offline simulation tools such as MATLAB/Simulink and PSCAD, and an understanding of what has to change when a model is made to run in real time.
• Grounding in inverter controls, energy storage systems, and power system dynamics.
• Python, or a comparable language, used in earnest for test automation and data analysis.
• Test plans, procedures, and acceptance criteria you have authored yourself, and the analytical rigor to stand behind the results.
• Familiarity with SCADA systems and industrial communication protocols such as Modbus, DNP3, CAN, and IEC 61850.
• Comfort on the bench with power supplies, oscilloscopes, transducers, and data acquisition hardware.
• The ability to present technical findings credibly to engineering audiences and clearly to field and commissioning personnel.

Preferred Experience

• Experience with grid-forming and grid-following inverter control.
• Experience with uninterruptible power supply systems, microgrids, or facilities serving critical load.
• Familiarity with ISO or utility interconnection requirements, model quality testing, or third-party product certification.
• Continuous-integration pipelines driving automated test suites, with version control applied to models as rigorously as to code.
• Prior collaboration with national laboratories or university test centers.