Hardware-in-the-Loop (HIL) Test & Validation Engineer
LOCATION:
Remote
SCHEDULE:
Standard Business Hours
DURATION:
12-Month Contract
PAY RANGE:$64-69/hr
Job Overview
The HIL Test & Validation Engineer will own and operate the Hardware-in-the-Loop (HIL) platform used to validate control software for utility-scale Battery Energy Storage Systems (BESS). This role involves developing real-time plant models in Simulink, executing them on Speedgoat hardware at millisecond time steps, integrating with power plant controller PLCs, and building automated requirement-based test suites. The engineer will ensure fast, deterministic, end-to-end validation of controller behavior, enabling safe and reliable grid-scale energy storage operations.
Key Responsibilities
HIL Platform Development & Operation
- Build, configure, and manage Speedgoat real-time systems running Simulink Real-Time.
- Optimize solver settings to maintain deterministic ~1 ms execution rates.
- Map hardware I/O, manage harnesses, and maintain HIL system performance.
Plant Modeling & System Simulation
- Develop and refine Simulink/Simscape Electrical models for PCS/inverters, transformers, filters, battery systems, and BMS interactions.
- Validate model accuracy using lab data and field measurements.
- Support simulation fidelity improvements and model debugging.
PLC Integration & Controls Validation
- Interface Schneider M580 PLCs with Speedgoat over Modbus/TCP and DNP3.
- Validate command sequencing, telemetry, time synchronization, fail-safe behavior, and alarm/event handling.
- Ensure full controller ↔ PLC ↔ plant model communication integrity.
Test Development & Automation
- Derive requirement-based MiL/SiL/HIL test cases for power/VAR control, frequency/voltage response, state-of-charge management, thermal derates, startup/shutdown logic, and fault scenarios.
- Automate regression testing, waveform capture, and reporting.
- Integrate automated test workflows with Git-based CI pipelines.
Defect Analysis & Documentation
- Analyze logs and test outputs to identify root causes across software, PLC logic, and plant modeling.
- Track issues through complete defect lifecycle, verify resolutions, and maintain requirement-to-test traceability.
- Deliver thorough documentation and technical communication for internal teams.
Lab Reliability & Safety
- Maintain HIL rig configurations, calibrations, and system health checks.
- Support safe lab operation and uphold engineering best practices.
Qualifications
- B.S. or M.S. in Electrical, Controls, Power, Mechatronics, or related engineering field.
- Professional Engineering (PE) license preferred.
- 3–7+ years of experience in embedded controls testing, validation, or HIL systems.
- Strong proficiency with MATLAB/Simulink, Simulink Real-Time, Simulink Test, and Simscape Electrical.
- Hands-on Speedgoat experience operating at ~1 ms step sizes.
- Programming/scripting in Python, VBA, or similar.
- Experience integrating PLCs; Schneider M580 familiarity preferred.
- Knowledge of protocols such as Modbus/TCP and DNP3.
- Proficiency with Git version control and modern branching workflows.
- Excellent analytical, communication, and documentation skills.
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