Project Engineer - Transmission & eDrive Validation at FEV North America Inc – Auburn Hills, Michigan

As a Test Engineer for transmission & eDrive validation, you will be responsible for planning, executing, and leading mechanical and efficiency-focused testing of electrified powertrain and driveline systems in a controlled test cell environment. This role includes supporting hands-on testing of motors, gearboxes, e-axles, and related subsystems with a strong emphasis on efficiency, losses, durability, and fluid performance.

Responsibilities:

• Lead mechanical and efficiency testing activities in powertrain and component-level test cells
• Plan and execute efficiency mapping, spin loss, power loss, and parasitic loss testing for motors, gearboxes, e-axles, and integrated drive units
• Develop and execute test procedures for mechanical performance, friction, thermal behavior, and lubrication performance
• Support durability and endurance testing including load cycling, thermal cycling, and accelerated life testing
• Conduct and support fluid evaluations including lubricant screening, viscosity impact studies, temperature sensitivity, and aging effects
• Configure and commission test cell hardware including dynamometers, torque transducers, speed sensors, temperature and pressure instrumentation
• Analyze mechanical test data including torque, speed, efficiency, temperature, vibration, and loss breakdowns
• Work closely with design, controls, and analysis teams to identify root causes and recommend design or calibration improvements
• Provide technical leadership in the test cell, mentoring junior engineers, coordinating with technicians, and enforcing safe/efficient test execution

Required Qualifications:

• 5+ years of experience in mechanical or powertrain testing within automotive or electrified propulsion systems
• Bachelor's degree in mechanical engineering or related discipline
• Strong understanding of rotating machinery, driveline systems, bearings, gears, and lubrication fundamentals
• Hands-on experience operating and troubleshooting dynamometer-based test cells
• Proven experience leading complex test campaigns and providing technical direction in a laboratory environment
• Efficiency, spin loss, and power loss characterization methods
• Durability, endurance, and thermal stress testing methodologies
• Experience with mechanical instrumentation: torque, speed, temperature, pressure, flow, vibration
• Familiarity with DAQ systems and test automation environments (e.g., ADAPT, iTest, Morphee, CANAlyzer, CANoe, ATI-Vision, INCA, Perception, LabVIEW-based systems)
• Strong data analysis skills using Excel, MATLAB, Python, or equivalent tools

Preferred Qualifications:

• Experience testing electrified drive units (EDU, e-axle, integrated motor/gearbox assemblies)
• Background in NVH testing as it relates to mechanical losses and durability
• Understanding of automotive networks (e.g., CAN, LIN, FlexRay, Ethernet)
• Experience supporting correlation between test cell results and vehicle-level efficiency or range performance
• Familiarity with OEM or supplier development processes for BEV or hybrid powertrains