Senior Motor Technology Development Engineer

Job description

Job responsibilities

• Lead the development and industrialization of stator winding and other novel motor assembly processes for new motor technologies, from early prototypes through production readiness.
• Develop practical manufacturing methods for processes such as wire forming, winding, insertion, termination, impregnation, adhesive application, and related motor assembly operations.
• Design, prototype, debug, and validate tooling, fixtures, gauges, and semi-automated or automated production equipment.
• Translate motor design intent and performance requirements into manufacturable process specifications, equipment requirements, and acceptance criteria.
• Plan and execute hands-on experiments, design-of-experiments studies, and process trials to evaluate new materials, tooling concepts, equipment architectures, and winding methods.
• Build and test prototype motors and stators; investigate defects and performance variation using structured root-cause methods.
• Establish process windows, key process parameters, inspection methods, and test requirements that support repeatable manufacturing.
• Partner with electrical, electromagnetic, thermal, controls, test, quality, and operations engineers to resolve design-for-manufacturing and process integration issues.

Job requirements

• Experience designing or commissioning winding, coil-forming, wire-handling, insertion, stripping, crimping, welding, impregnation, or stator assembly equipment.
• Experience with magnet wire, enamel insulation systems, slot liners, wedges, varnish or resin systems, lacing materials, and related motor manufacturing materials.
• Experience developing automated or semi-automated equipment from a blank-sheet concept, including vendor selection and factory acceptance testing.
• Familiarity with PLC-controlled machinery, industrial motion control, machine vision, force or torque monitoring, and production data collection.
• Experience with motor electrical and mechanical validation, including winding resistance, hipot or insulation testing, surge testing, dimensional inspection, balancing, and functional testing.
• Experience with design for manufacturing and assembly, PFMEA, process validation, capability studies, and production ramp-up.
• Experience working with contract manufacturers, equipment integrators, or overseas suppliers.
• Proficiency with CAD and drawing-release systems; experience with machining, sheet metal, additive manufacturing, or other rapid-prototyping methods.