BMS Validation Engineer

In this position...

The Battery Management Validation Engineer proves that high-voltage battery management hardware, software, and integrated systems do what they are required to do - from automated software regression on simulation and hardware-in-the-loop benches through energized pack and system-level testing.

Assignments may include software-focused validation on simulation and hardware-in-the-loop benches or system-focused validation on energized hardware and installed systems, and may shift across the product architecture over the life of the program.

The ideal candidate is disciplined about traceability and evidence, capable with instrumentation, and able to script and automate. Strength in either bench automation or energized high-voltage testing is required; strength in both is strongly preferred.

At Ford, we are the movers of the world and the makers of the future. We get up every day, roll up our sleeves, and build a better world - together. Our advanced energy team is a dynamic division dedicated to powering the future through advanced electric vehicle (EV) battery systems and related electrified energy solutions. As we scale these advanced electrification initiatives, we are seeking technically strong engineers who can help establish the foundation for our product execution, safety strategy, and vehicle readiness.

What you'll do...

• Translate system requirements and architect-authored design verification methods into design verification plans, executable test cases, and acceptance criteria with full traceability.

• Execute validation campaigns across sample phases and software release cycles; document results, defects, and evidence to audit standard.

• Perform fault insertion and negative testing, including sensor faults, communication loss, isolation degradation, contactor faults, overvoltage, overtemperature, and thermal event response.

• Verify diagnostic and protection behavior, safe state entry, and annunciation to external systems.

• Root-cause failures with hardware, software, and algorithm engineers; verify fixes and manage regression.

• Witness and technically review supplier verification reports for method conformance and sufficiency.

• Contribute evidence to functional safety, cybersecurity, and product safety documentation packages.

• Build and maintain working competence across both validation domains over time to provide cross-coverage.

• Software-Focused Validation

• Build and maintain software-in-the-loop and hardware-in-the-loop benches with simulated cells, sensors, contactors, and loads.

• Develop and maintain automated regression suites integrated into continuous integration; own the pass/fail gate for software releases.

• Verify base software behavior including bootloader, software update and rollback, secure boot and flashing, communication stacks, and diagnostic services.

• Verify control logic and estimation behavior against models and requirements, including timing and communication performance.

• Maintain plant models and test scripts as the design evolves.

• System-Focused Validation

• Plan and execute validation on energized modules, packs, and full systems using cyclers, environmental chambers, and instrumented test setups.

• Verify measurement accuracy and end-to-end sensing chains, balancing effectiveness, thermal behavior, and high-voltage sequencing on real hardware.

• Verify interoperability with surrounding electrical, thermal, and control systems.

• Define end-of-line and production test content, methods, and acceptance limits.

• Support commissioning, field troubleshooting, and returned-unit analysis.

• Technical Skills

• Design verification plan and test case authorship

• Requirements-to-test traceability

• Hardware-in-the-loop and software-in-the-loop bench development

• Test automation and continuous integration gating

• Fault insertion and negative testing

• High-voltage energized test execution

• Measurement accuracy and sensing chain verification

• Environmental, durability, and EMC test support

• Instrumentation and data acquisition

• Python scripting and data analysis

• Failure analysis and regression management

What you'll do...

• Translate system requirements and architect-authored design verification methods into design verification plans, executable test cases, and acceptance criteria with full traceability.

• Execute validation campaigns across sample phases and software release cycles; document results, defects, and evidence to audit standard.

• Perform fault insertion and negative testing, including sensor faults, communication loss, isolation degradation, contactor faults, overvoltage, overtemperature, and thermal event response.

• Verify diagnostic and protection behavior, safe state entry, and annunciation to external systems.

• Root-cause failures with hardware, software, and algorithm engineers; verify fixes and manage regression.

• Witness and technically review supplier verification reports for method conformance and sufficiency.

• Contribute evidence to functional safety, cybersecurity, and product safety documentation packages.

• Build and maintain working competence across both validation domains over time to provide cross-coverage.

• Software-Focused Validation

• Build and maintain software-in-the-loop and hardware-in-the-loop benches with simulated cells, sensors, contactors, and loads.

• Develop and maintain automated regression suites integrated into continuous integration; own the pass/fail gate for software releases.

• Verify base software behavior including bootloader, software update and rollback, secure boot and flashing, communication stacks, and diagnostic services.

• Verify control logic and estimation behavior against models and requirements, including timing and communication performance.

• Maintain plant models and test scripts as the design evolves.

• System-Focused Validation

• Plan and execute validation on energized modules, packs, and full systems using cyclers, environmental chambers, and instrumented test setups.

• Verify measurement accuracy and end-to-end sensing chains, balancing effectiveness, thermal behavior, and high-voltage sequencing on real hardware.

• Verify interoperability with surrounding electrical, thermal, and control systems.

• Define end-of-line and production test content, methods, and acceptance limits.

• Support commissioning, field troubleshooting, and returned-unit analysis.

• Technical Skills

• Design verification plan and test case authorship

• Requirements-to-test traceability

• Hardware-in-the-loop and software-in-the-loop bench development

• Test automation and continuous integration gating

• Fault insertion and negative testing

• High-voltage energized test execution

• Measurement accuracy and sensing chain verification

• Environmental, durability, and EMC test support

• Instrumentation and data acquisition

• Python scripting and data analysis

• Failure analysis and regression management