HIL Testing Engineer

Title - Testing Engineer

Location - Raleigh, North Carolina (onsite only)

Mandatory Skills:

• Hands-on experience with Hardware-in-the-Loop (HIL) testing and validation of power converters, with OPAL-RT experience preferred.

• Strong experience in MATLAB/Simulink and Stateflow model development.

• Solid understanding of power electronics systems, including:

o Inverters

o UPS systems

o AC-DC and DC-DC converters

o Power conversion control architectures

• Strong knowledge of power converter control algorithms and state machine implementation.

• Experience in controller-to-HIL interfacing, signal mapping, and I/O configuration.

• Ability to debug and troubleshoot hardware-software integration issues in real-time simulation environments.

• Good understanding of control systems, embedded controllers, and validation methodologies.

• Experience with real-time simulation and model-based design.

• Exposure to firmware validation and embedded system testing.

• Strong analytical and problem-solving skills with the ability to work effectively in cross-functional teams.

Domain: Power Electronics, UPS, Inverters, Power Converters, Data center Power supplies

HIL Platform: OPAL-RT (Preferred)

Responsibilities:

• Design and develop breakout/interface boards for integrating power converter controllers with HIL platforms.

• Configure and establish Hardware-in-the-Loop (HIL) test setups using OPAL-RT for power electronic systems such as UPS, DC-DC converters, AC-DC converters, inverters, and related products.

• Develop and maintain real-time HIL models for power circuits and associated interface circuits using MATLAB/Simulink and Stateflow.

• Integrate power converter control hardware with the HIL environment, including:

o Signal conditioning and gain setting

o Pin mapping and wiring validation

o Analog and digital I/O configuration

o Communication interface setup and verification

• Execute validation activities as per Design Verification Test (DVT) plans provided by Control Engineering teams.

• Analyze test results, document observations, and generate validation reports.

• Diagnose and troubleshoot issues identified during HIL testing and collaborate with Control, Firmware, and System Engineering teams to drive resolution.

• Support controller algorithm verification, fault injection testing, and system-level validation activities.