Sr. Thermal Controls Test & Integration Engineer

Job Description

Position: Sr. Thermal Controls Test & Integration Engineer

Location: Irvine, CA

Overview

A leading automotive technology company is seeking a Senior Thermal Controls Test & Integration Engineer to support the development, integration, and validation of advanced thermal management control systems for next-generation vehicle platforms.

This role will focus on thermal controls software development and vehicle feature integration across cabin thermal management, battery thermal systems, HVAC, refrigeration, coolant systems, and actuator controls. The ideal candidate combines strong controls engineering knowledge with hands-on experience in software integration, vehicle testing, calibration, and validation.

Key Responsibilities

• Develop embedded software solutions for automotive electronic control units (ECUs).
• Design and implement control algorithms for thermal management systems including HVAC, refrigeration, coolant, and airflow management.
• Review requirements and develop high-level functional specifications and control strategies.
• Create and execute test plans for unit testing, Software-in-the-Loop (SIL), and Hardware-in-the-Loop (HIL) environments.
• Conduct software integration, calibration, and vehicle-level validation activities.
• Develop diagnostic and troubleshooting tools for embedded control systems.
• Perform root cause analysis across software, electrical, mechanical, and vehicle systems.
• Collaborate with cross-functional engineering teams to resolve technical issues.
• Prioritize and escalate defects based on system impact and program objectives.
• Support product launches and feature validation efforts.

Required Qualifications

• Bachelor's degree in Electrical Engineering, Mechanical Engineering, Controls Engineering, or related technical discipline.
• 3+ years of experience in controls development, software integration, validation, or calibration.
• Strong programming experience in C, C++, Rust, and/or Python.
• Solid understanding of control systems theory and algorithm development.
• Experience with controller tuning, PID controls, and system optimization.
• Knowledge of heat transfer, thermodynamics, and thermal management systems.
• Experience with software debugging and embedded systems integration.
• Strong analytical and troubleshooting skills.

Required Work Experience

• Automotive or aerospace controls engineering experience.
• Software integration and calibration experience.
• Vehicle-level testing and validation.
• Embedded software development.
• Functional testing and root cause analysis.
• Controller development and validation.

Preferred Qualifications

• Experience working with thermal and HVAC systems.
• Familiarity with water pumps, AC compressors, expansion valves, blower fans, and HVAC modules.
• Experience with requirements management tools such as Jama or DOORS.
• Experience using Jira or equivalent issue tracking tools.
• Experience with Vector CANalyzer or similar communication monitoring tools.
• Experience with CANape, ETAS INCA, or equivalent calibration tools.
• Experience building automated test frameworks.
• Experience with SIL and HIL testing environments.

Technical Skills

• Controls Engineering
• Thermal Controls
• Embedded Software Development
• ECU Development
• Control Algorithm Design
• PID Tuning
• Software Integration
• Vehicle Validation
• Calibration Engineering
• Root Cause Analysis
• Functional Testing
• Embedded Diagnostics
• Software Debugging

Programming Skills

• C
• C++
• Rust
• Python
• Embedded Software
• Test Automation
• Pytest
• OpenHTF

Tools & Platforms

• Vector CANalyzer
• Vector CANape
• ETAS INCA
• Jama
• DOORS
• Jira
• SIL (Software-in-the-Loop)
• HIL (Hardware-in-the-Loop)

Domain Experience

• HVAC Systems
• Thermal Management Systems
• Battery Cooling
• Battery Heating
• Cabin Cooling
• Cabin Heating
• Coolant Systems
• Refrigeration Systems
• Vehicle Controls
• Automotive Electronics
• Aerospace Controls

Applied Skills

• Controls Development
• Feature Integration
• Vehicle Testing
• Calibration Engineering
• Requirements Analysis
• Software Validation
• Thermal System Optimization
• Diagnostic Development
• Multidisciplinary Problem Solving
• Functional Safety Awareness
• Cross-Functional Collaboration