Senior HIL Engineer - Powertrain in Warwick

At Tata Technologies we make product development dreams a reality by designing, engineering and validating the products of tomorrow for the world’s leading manufacturers.

Due to our continued growth we are now recruiting for Senior HIL Engineer - Powertrain to be based at our customer's office in Gaydon.

Our Embedded Systems Solutions department (ESS) encompasses all activities outlined under the Automotive SPICE (ASPICE) process framework, including systems engineering, software engineering, coding, and all levels of functional testing.

Beyond core development, ESS also integrates critical supporting processes such as project management, risk assessment, functional safety, and cybersecurity, ensuring compliance with ASPICE standards and delivering reliable, secure, and high-quality embedded systems & solutions.

Role Summary

Responsible for the technical delivery, development and sustainment of Hardware-in-the-Loop (HIL), Processor-in-the-Loop (PIL) and Lab Car test environments for electric and hybrid powertrain control systems, with specialist focus on hybrid vehicle e Power Train, front & rear motors, and Vehicle Supervisory Control (VSC).

The role combines HIL modelling, HIL maintenance, e Powertrain ECU software testing, root cause analysis and resolution of integration issues.

The specialist will provide deep domain expertise across signal-level and power-level validation, lead complex issue debugging, and contribute to robust test methods, rig capability and engineering process development within a multidisciplinary and global V&V team.

Dimension of Function

Technical ownership across e PT/VSC validation environments covering HIL modelling, rig integration and maintenance, ECU software testing, issue reproduction and root cause analysis.

The role supports electric and hybrid powertrain functions including HV energy management, propulsion drives, batteries, fuel cells and EV thermal management, using both signal-level and power-level test environments.

• Area of Responsibility
• Own HIL plant-model development and integration for hybrid e Powertrain, EDUs, FPGAs and Vehicle Supervisory Control functions.
• Develop, configure and maintain real-time HIL, PIL and Lab Car test environments using NI and d SPACE platforms.
• Maintain HIL rigs, including model releases, I/O configuration, communication networks, calibration, fault insertion and bench health checks.
• Plan and execute e Powertrain ECU software testing, including functional, integration, regression, diagnostic and robustness testing.
• Perform issue reproduction, structured root cause analysis and evidence-based fault isolation across ECU software, plant models, automation, networks, I/O and rig hardware.
• Troubleshoot complex integration issues between transmission control, VSC, propulsion, battery, inverter, motor, thermal and vehicle systems.
• Provide domain expertise in electric and hybrid powertrains, hybrid vehicle transmission and supervisory control strategies.
• Work with e Powertrain signal-level and power-level HIL environments, ensuring safe and controlled test execution.
• Develop and maintain automated test sequences using ECU. test and associated scripting or framework interfaces.
• Integrate and use MATLAB/Simulink, d SPACE ASM and real-time models for closed-loop ECU validation.
• Configure and operate Control Desk, Configuration Desk, NI Veri Stand and related platform tools.
• Use Vector CANalyzer and CANoe for communication analysis, rest-bus simulation, diagnostics and issue debugging.
• Configure and analyse CAN, LIN, Flex Ray, Ethernet and RS232 communication interfaces.
• Support FPGA and DSP-based interfaces or simulation components where required by the HIL architecture.
• Design and maintain fault-injection capability for sensors, actuators, communication buses and electrical interfaces.
• Analyse requirements and develop traceable test specifications, test procedures, pass/fail criteria and technical reports.
• Review test results, defects and logs; communicate technical findings and recommended corrective actions to stakeholders.
• Support rig commissioning, software/model release deployment, configuration management and controlled change implementation.
• Guide engineers on modelling, rig operation, debugging methods, transmission/VSC domain behaviour and engineering good practice.
• Continuously improve HIL development, maintenance, testing, RCA and automation processes and team capability.
• Tool Chain
• HIL platforms: NI and d SPACE rigs.
• Test automation: ECU. test; Automation Desk and Python exposure are advantageous.
• Test environments: HIL, PIL and Lab Car.
• Modelling and simulation: MATLAB, Simulink, Stateflow, Simscape and d SPACE ASM.
• d SPACE tools: Control Desk and Configuration Desk.
• Network and diagnostics: Vector CANalyzer and CANoe.
• Interfaces and technologies: CAN, LIN, Flex Ray, Ethernet, RS232, FPGA and DSP
• Knowledge / Experience
• Degree qualified in electrical, electronic, automotive, controls, mechatronics or a related engineering discipline.
• Relevant automotive systems, controls, HIL or ECU validation experience, with technical-specialist level ownership.
• Demonstrable expertise in hybrid vehicle transmission and Vehicle Supervisory Control (VSC) functions.
• Experienced in electric and hybrid powertrains, HV energy management, HV propulsion drives, fuel cells, batteries and EV thermal management.
• Hands-on experience of e Powertrain ECU software testing, defect investigation and root cause analysis.
• Experience with signal-level and power-level e Powertrain HIL environments.
• Strong issue-debugging skills across ECU software, controls, calibration, model, automation, network, I/O and hardware integration layers.
• Expertise in HIL modelling and real-time plant-model integration using MATLAB, Simulink, Stateflow, Simscape, d SPACE ASM or equivalent.
• Practical experience with NI and d SPACE HIL rigs, including NI Veri Stand, Control Desk and Configuration Desk.
• Experience using ECU. test for automated testing; exposure to Automation Desk, Python or similar automation technologies is beneficial.
• Experience with HIL, PIL and Lab Car validation environments.
• Proficiency with Vector tools including CANalyzer and CANoe.
• Experience using CAN, LIN, Flex Ray, Ethernet and RS232; exposure to FPGA and DSP applications.
• Ability to read electrical schematics, interface control documents, network databases and system/software requirements.
• Experience in rig commissioning, HIL maintenance, fault insertion, I/O configuration and bench troubleshooting.
• Knowledge of transmission control, torque coordination, operating modes, energy management, diagnostics and vehicle-state management.
• Experience with requirements, defect and configuration-management tools such as DOORS/Jama, Jira, Git or SVN is desirable.
• Ability to work cross-functionally with controls, software, systems, calibration, hardware and test teams.
• Excellent technical communication, documentation, planning and stakeholder-management skills.
• Highly motivated to develop HIL rigs and continually improve team processes, methods and capabilities.
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