Controls Engineer

Role Summary

The Software & Controls Engineer is responsible for the specification, development, verification, validation, and support of embedded software and control systems used in thermal management products for commercial vehicles, off-highway equipment, and zero-emission vehicle applications.

The role includes the development of control strategies for HVAC, Battery Thermal Management Systems (BTMS), cooling systems, heat pumps, and auxiliary vehicle systems, ensuring compliance with customer, regulatory, and internal requirements.

The engineer will work closely with systems engineering, electrical engineering, product engineering, test & validation teams, and customers throughout the product lifecycle.

Areas of Responsibility

Requirements & System Definition

• Capture and analyse customer and system requirements.
• Develop software requirements specifications.
• Support system architecture development.
• Generate requirements traceability matrices.
• Support FMEA and functional safety activities where applicable.
• Define control strategies and operating modes .

Software Development

• Design and develop embedded control software.
• Develop Stateflow/Simulink models and auto-coded solutions where appropriate.
• Configure and develop software for electronic control units (ECUs).
• Develop diagnostics and fault management strategies.
• Implement CAN communications and vehicle interfaces.
• Apply coding standards and software quality processes.

Verification & Validation

• Develop software verification plans.
• Produce Software Design Verification Plans (DVPs).
• Support Hardware-in-the-Loop (HIL) and Software-in-the-Loop (SIL) testing.
• Support climatic chamber testing and vehicle validation activities.
• Investigate software-related failures and field issues.
• Analyse test results and produce validation reports.

Product Support

• Support production launch activities.
• Troubleshoot vehicle and customer issues.
• Support root cause investigations.
• Implement corrective and preventive actions.
• Support aftermarket and service engineering where software updates are required.

Continuous Improvement

• Support software development process improvement.
• Contribute to engineering standards and best practices.
• Support cybersecurity and software quality initiatives.
• Mentor junior engineers where required.

Qualifications & Experience

• Degree in Control Engineering, Electrical Engineering, Electronics Engineering, Software Engineering or related discipline or similar.
• Experience developing embedded software for automotive or commercial vehicle applications.
• Experience with CAN-based vehicle systems.

Desirable

• Master's degree in a relevant engineering discipline.
• Knowledge of thermal management systems.
• Experience with electric vehicle applications.
• ASPICE or Functional Safety training.

Essential Technical Skills

The role is expected to have experience in:

Controls Engineering

• Control algorithms development (PID, Hysteresis, MPC).
• Thermal system control strategies.
• HVAC control systems (desirable).
• Heat pump control systems (desirable).
• Refrigeration systems (desirable).
• Battery thermal management systems (desirable).

Software Tools

• MATLAB / Simulink.
• Stateflow.
• Embedded C++.
• Model-Based Design.
• CANalyser
• Version control systems (Git, SVN or equivalent).

Vehicle Communication Networks

• CAN.
• J1939.
• UDS Diagnostics.
• LIN (desirable).
• Ethernet (desirable).

Functional Safety & Quality

• ASPICE awareness.
• ISO 26262 awareness.
• DFMEA.
• DVP&R.
• Change management.
• Requirements traceability.

Competencies

Health & Safety:

• Work in a manner conducive to safety, minimising risk to yourself and others
• Report any health and safety matters to your line manager, department representative, or H&S Manager

Attributes:

• Communications – clear verbal, written and graphical presentation
• Driven – driven to succeed and meet critical project dates
• Team working - able to work across a multi-functional team
• Planning – methodical at project and time management
• Motivation – committed to continuous improvement