Embedded Controls Engineer - PCS (Power Conversion System)

About the Team

We are seeking an Embedded Controls Engineer to own and expand the control software for a power conversion system (PCS). This is a hands-on model-based controls and embedded-software role responsible for evolving an existing Simulink implementation into a robust real-time application that supports increasingly complex system behavior and operational requirements.

The ideal candidate has developed and deployed model-based control software for automotive powertrains, motorsport, high-performance propulsion, aerospace, or similarly demanding real-time electromechanical systems. The PCS behaves more like a complex powertrain control system than a conventional industrial controller: multiple operating states, fast-changing conditions, extensive sensing and diagnostics, fault management, degraded modes, and real-time hardware interfaces. This engineer will work across electrical, mechanical, systems, software, and test teams to simulate, validate, deploy, calibrate, and troubleshoot the control system.

Roles and Responsibilities:

• Own the architecture, development, validation, deployment, and long-term health of the PCS control application.
• Develop, modify, and maintain model-based application software using MATLAB, Simulink, and Stateflow.
• Establish and maintain a scalable Simulink architecture with reusable subsystems and libraries, and clearly defined signals, parameters, and interfaces.
• Define execution rates, scheduling, I/O abstraction, and deterministic real-time behavior for the control application.
• Design and tune closed-loop controls for power conversion and related thermal, electrical, or mechanical processes.
• Develop controls including operating modes, sequencing, state machines, interlocks, limits, and transition logic.
• Expand the existing controls implementation to support greater system complexity, additional operating modes, and degraded operation.
• Perform mathematical modeling, simulation, and analysis of stability, dynamic response, operating limits, and transient and steady-state behavior.
• Integrate sensor-plausibility capabilities and develop diagnostics for failed, degrading, or implausible sensors, including thermocouples.
• Define fault responses, degraded operating behavior, and safe-state actions for sensor, actuator, and abnormal system conditions.
• Develop and execute Model-in-the-Loop, Software-in-the-Loop, and Hardware-in-the-Loop testing, and support bench and system validation.
• Instrument models and analyze simulation, bench, system-test, and logged operational data to diagnose and improve control behavior.
• Support model-based code generation, build, deployment, and integration of Simulink models on real-time PCS hardware.
• Troubleshoot control behavior during simulation, commissioning, test, and system operation.
• Document control architecture, algorithms, interfaces, assumptions, calibration logic, and validation results.
• Support software used for both test activities and Mark-1 operation.

Basic Qualifications:

• Bachelor's degree in Electrical Engineering, Mechanical Engineering, Controls Engineering, Computer Engineering, or a related technical field.
• 3+ years of experience developing and deploying model-based embedded controls for automotive powertrain, motorsport, propulsion, aerospace, or similarly demanding real-time systems.
• Strong MATLAB and Simulink experience, including architecture and maintenance of production-scale models and model-based code-generation workflows.
• Experience taking controls from simulation through Model-in-the-Loop / Software-in-the-Loop, Hardware-in-the-Loop or bench testing, and deployment onto real-time embedded hardware.

Preferred Skills & Experience:

• Direct experience with McLaren Applied / Motion Applied control systems and tooling, including TAG ECUs, vTAG, ATLAS, or related Simulink-based application-development workflows, is strongly preferred.
• Strong understanding of control theory, dynamic systems, feedback-control design, diagnostics, and state-based supervisory logic.
• Ability to take ownership of an existing controls implementation and work effectively across controls, electrical, mechanical, software, systems, and test disciplines.
• Experience developing powertrain, hybrid, energy-management, or other embedded controls in professional motorsport, high-performance automotive, or aerospace programs.
• Experience with Simulink Coder, Embedded Coder, Stateflow, or comparable production model-based code-generation toolchains.
• Experience with multi-rate models, deterministic execution, task scheduling, model references and libraries, and parameter or calibration management.
• Experience with calibration, instrumentation, telemetry, data logging, and test workflows common to automotive, motorsport, or aerospace controls development.
• Experience with embedded communications and vehicle networks such as CAN, and with integrating sensors, actuators, and real-time I/O.
• Experience developing sensor plausibility checks, diagnostics, fault detection, safe-state behavior, and degraded operating modes.
• Experience analyzing noisy, drifting, failed, or otherwise unreliable signals involving temperature, voltage, current, pressure, flow, speed, or torque measurements.
• Familiarity with version control, model configuration management, requirements traceability, automated testing, and disciplined embedded-software development practices.

ITAR Requirements

To conform to U.S. Government export regulations, applicant must be a (i) U.S. citizen or national, (ii) U.S. lawful, permanent resident (aka green card holder), (iii) Refugee under 8 U.S.C. § 1157, or (iv) Asylee under 8 U.S.C. § 1158, or be eligible to obtain the required authorizations from the U.S. Department of State.