Position SummaryThe Electromechanical Engineer is a hands-on engineering role focused on advancing high power-density industrial PMAC motor technology from concept through production readiness. This position supports new product development and improvements to existing motor designs through prototyping, testing, mechanical design, and performance validation. The engineer will evaluate emerging motor architectures, including IPM, SynRM, SRM, and BLDC technologies, while improving manufacturability, reliability, thermal performance, and cost effectiveness across current and future product platforms.
Principal Duties and Responsibilities- Evaluate next-generation motor architectures, including IPM, SynRM, SRM, and BLDC layouts.
- Develop new motor designs and improve existing platforms for performance, manufacturability, reliability, thermal management, and cost.
- Prototype and assess advanced materials, including high-grade electrical steels and specialized winding techniques.
- Optimize copper fill factors by balancing stator slot geometry with mechanical and manufacturing constraints.
- Integrate feedback devices, including shaft-mounted resolvers, encoders, and thermal sensors.
- Design and optimize motor housing structures, including Powertec double-finned frames, to improve heat rejection.
- Conduct thermal analysis for fluid and air-cooling jacket paths in high power-density applications.
- Analyze rotor dynamics, including centrifugal stresses, critical speeds, and shaft interference fits.
- Evaluate bearing life and select appropriate bearing designs for radial, axial, and insulation-related requirements.
- Apply geometric dimensioning and tolerancing principles to produce accurate 3D CAD models and production drawings.
- Perform dynamometer testing to evaluate motor efficiency, back-EMF, thermal performance, and operating characteristics.
- Correlate laboratory test data with finite element analysis (FEA) predictions and design assumptions.
- Prepare engineering documentation, including drawings, test plans, technical reports, and Bills of Materials (BOMs).
- Support prototype builds, DFMEA reviews, production scaling, and factory floor troubleshooting as needed.
Required Education and Experience- Bachelor's degree in Mechatronics, Mechanical Engineering, Electrical Engineering, or a related technical field.
- Three to five years of experience in electromechanical design, advanced prototyping, industrial rotating machinery, or a related engineering environment.
- Hands-on laboratory testing experience combined with production-level 3D mechanical CAD capability.
Technical Skills- Proficiency in SOLIDWORKS 3D modeling and technical drafting; experience with structural and thermal FEA preferred.
- Working knowledge of magnetic topologies, winding behavior, thermal constraints, and motor performance considerations.
- Understanding of fits, tolerances, machining limitations, and design for manufacturability principles.
- Ability to operate or support testing using dynamometers, power analyzers, and data acquisition equipment.
Travel Requirements- Occasional domestic travel, typically less than 5%, may be required to support other HBD locations, customers, and/or vendors.
