Product Development Engineer eMotors GPPC
GKN Automotive
Zumaia, Spain
hace 1 día

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 tobe fed by Inverters for the eDrive Product Plan and / or Advanced Engineering &eDrives Engineering senior directors :

  • Any kind of emotors
  • Consumption simulations consideringthe complete electric
  • power train.

  • Battery sizing
  • Gearboxes ratios optimization
  • Emotors industrial partner’sassessment.
  • Etc.
  • Depth knowledge of electrical engineering and electricmachines

    Depth knowledge about validation tests for electricmachines

    Understand the Heat transmission and fluid dynamics tobe applied in electric machines

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

    Detail knowledge about stator technologies and solutions :

    Stator laminations :

    Grade ofquality (permeability, losses, thickness, insulation

    in surface, compression rate for stator package, etc)

    Stator Winding :

    Distributedwinding (1 layer, 2 layers)

    Insulationin slots

    Impregnations technologies andinfluence in the machine performance

    Detail knowledge about rotor technologies andsolutions :

    PMSM

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

    Rotor laminations

    Squirrel cage geometries, slots number and materials

    Rotor laminations

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

    Steel shafts and process

    Bearings and sealings

    Aluminum shields material andprocess

    Aluminum housing material and process

    Aluminum connections box

    Knowledge about mechanical components process,subassemblies and assembly

    Analytical calculations & Simulations of emotorsaccording to the product plan :

  • It should be in any kind of emotoras :
  • Induction Motors

    Transversal Flux Motor (TFM)

    Synchronous reluctance motors

    Switch Reluctance motors

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

  • Knowledge about analytical, numerical andsimulation tools for :
  • Analytical Electromagnetic calculations (suchas Speed SW)

    FEA Electromagnetic calculations (such as Flux2D&3D)

    eMotor Thermal analytical calculations (suchas MotorCAD)

    Computational Fluids Dynamic CFD (such asAcuSolve)

    MatLab / Simulink

  • Detailed simulation by FEA and analyticaltools 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 bearingscalculations.

    Cogging pulsation torque simulation

    Ripple pulsation torque simulation

    Efficiency map matrix output

    eMotor reactances to provide to the invertersupplier

    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 andharmonics calculation of emotor Electric and Mechanical signals as : voltages, currents,torques, etc

  • Numerical calculations and simulation by FEAfor :
  • Shields

    Shafts. (strength, fatigue andnatural frequencies)

    Bearing selection and sizing

    eMotor natural frequencies

    Ripple torque influence

    Cooging torque influence

    NVH performance

  • Numerical calculations about thenoise 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 battery

    Obtain the current harmonics andthe influence in the motor losses

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

    Replicate driving cycles andobtain 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 orcustomer specifications

  • GB+emotor in offset design
  • GB+emotor in coaxial desing
  • Both even integrating the inverter
  • Both considering HV & LVconnectors, bus bars, devices for grounding the shaft, resolvers, differentcooling systems, etc
  • Definition of the validation plan for the eMotors andinverters according to the customer or GKN specifications :

    Functional tests (to characterizethe motors)

    Heat generation

    Environmental conditions

    others

    Product & process standardization includingChange Management

    Release product validation Final Reports :

  • Product description
  • Drawings, BOM and Models
  • Test results
  • Conclusions
  • Upload in WT.
  • Ensure design and process Deviation Control

    Drivestandardized calculation and simulation Tools

    EnsureBenchmarking of state of the art competitor products

  • Materials and process analysis
  • Geometry analysis
  • Simulations to replicate
  • Test definitions including thecharacterization tests
  • Final report
  • IntellectualProtection (IP). Propose patents and content review of

    competitorspatents

    Supportto Application / Account Teams

  • Training & Know-How-Transfer
  • eMotor, inverter and batterysizing for the requested application
  • andspecifications

  • Packaging analysis of the completesystem.
  • Release product & testspecifications for the potential industrial
  • partners(emotor active parts supplier)

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

  • Support in quality issues with thetechnical knowledge.
  • Root cause analysis. Implement andassess potential problem
  • solution.

    Supportto Lohmar eDrives GPPC :

  • Integrations architectures tooptimize the performance and
  • packaging.

  • Prototypes manufacturing support
  • Testing follow up in a systemlevel including test rig definition
  • Simulations for complete systems(GB + emotor + inverter)
  • Acceleration time

    Ratio optimization for consumption& acceleration.

  • eMotors and inverters sizings
  • Support to eDrives Manufacturing GPPC :

  • eMotor detail design and invertersgeneral design for
  • manufacturing

  • Drawings & BOM
  • 2D&3D models
  • EOL testing definition
  • Ideas for cost reduction in asystem level.
  • Ideas for optimized manufacturingintegration
  • gearbox+motor+inverter)

    Support to SW GPPC to :

  • Actuator Motor characterizationsimulations
  • Inverter + eMotor simulations
  • Communications from resolver andinverter.
  • ISO 26262 functional safetyanalysis
  • Support to GKN Sintermetals eMotors activities asrequested :

  • Ideas to apply SMC material on newmotors development.
  • Testing support
  • Support to GKN Advanced Engineering :

  • Electromagnetic Simulations
  • Emotor Prototypes design andmanufacturing support
  • Testing specifications definitionand support
  • Management of his / her working area :

  • Programme planning andachievements
  • Risk analysis during thedevelopment
  • Identify critical aspects andescalate them
  • Participate in the daily&weekly meetings with theTraction Motors

    GPPC.

    Review validation test results before report release.

  • Functional testing(characterization).
  • Endurance analysis
  • Environmental conditions
  • Others
  • Control of the applicable KPIs, taking care of :

  • Collecting the appropriateinformation
  • Calculation and interpretation ofthe KPIs
  • Control of GKN procedures and standards, taking careof :

  • Revision, realization and controlof applicable procedures
  • Update and control of GKN STDs
  • Management and control engineering support requestsfrom the Traction Motors GPPC :

  • Requester
  • Type of eMachine
  • Site
  • Management of external associated costs, taking careof :

  • Realization of purchase requests
  • Control and storage of thedocumentation
  • Follow the GKN management tools as WT, iShare, WHC,etc.

    Qualifications / Experience / Skills :

    Electronic / Electrical Engineer

    High Level of English ( writing and talking)

    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.

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