The Role

Mechanical engineering within the Low Voltage Wire Harness Engineer in our team.

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Responsibilities

•Engineering design responsibility for a wide variety of electrical wire harnesses in Tesla vehicles, both in production and in development.

•Engineering responsibility throughout all stages: concept, requirements definition (iterative), prototype, detailed CATIA (V6) model, 2D drawing synchronized with electrical circuitry provided by the Wire Harness Electrical Engineer, vendor selection (support to Supply Chain), design validation and optimization in Beta and RC phases, volume tooling and processes for Start of Production and production ramp-up. Life-cycle improvements and cost reductions as needed.

•Make design decisions, and provide leadership in resolving electrical/physical integration and optimization issues with other internal Tesla parties on a daily basis, namely for example: Body, Low Voltage Systems, Infotainment, Audio, PCBA Design, Chassis, Interiors, Seats, HVAC, Environmental/Vibe Testing, CATIA Integration, CAE Crash Analysis, Vehicle Durability and Crash Test, Manufacturing Engineering, etc.

•Design to significantly reduce mass and volume/space and to optimize wire bundle routing in the vehicle, minimize NVH (Noise, Vibration, Harshness), prevent possibility of moisture ingress/damage.

•Work with Suppliers for Design-for-Manufacturability to reduce assembly complexity, cost and lead time reduction.

•Design components for ease and efficiency of manufacture, as well as ease and efficiency of installation in vehicles. Work with manufacturing and assembly process engineers for successful implementation.

•Work with SIE (Supplier Industrial Engineer) to setup and review production lines at suppliers, including any associated mechanical components.

•Support RC (Release Candidate – pre-production) with quick-turn parts and make sure installation works properly as design-intended incl. supporting with a subassembly fixture design prior to full vehicle being available.

•Highlight design concerns (such as high insertion force on connectors, grommet installation and sealing issues) or reliability concerns on detailed design features and drive the solution progress to remove these concerns through weekly tests, follow ups, upper management deep-dive reviews and cross functional team reviews.

•Closely work with Reliability team to ensure proper testing on finished designs (vibe, corrosion, torque-to-failure, EMI/shielding, etc.).

Requirements

•Mechanical Engineering: thermal, heat dissipation, vibration, strength, durability, corrosion-prevention, materials, etc.

•CATIA 3D modeling.

•Design-for-Manufacturability, including Automation.

•Mentor Graphics Capital Harness 2D engineering drawing creation.

•ENOVIA part numbering, drawing maintenance, ECR’s, deviations, etc.

•Quick-turn prototyping using a variety of techniques.

•Project task coordination and tracking using JIRA, Confluence, etc.

•Specifying and directing Environmental Lab testing, CAE analysis, etc.

The Role

We are looking for an electrical engineer who understands system level power delivery and grounding (could be from vehicles, servers, or such complex systems), interconnect (electrical properties and reliability of wires, fuses, and connectors), and fundamentals of serial communication protocols (CAN, LIN, Ethernet, Bluetooth, DP, etc.)

Responsibilities

•Electrical engineering design leadership for a variety of electrical components and wire harnesses in Tesla vehicles, both in production and in development.

•Support the engineers developing 2-d harness and wiring documentation to optimize topology/architecture for best cost/performance.

•Engineering responsibility throughout all stages: concept, requirements definition, prototype, architecture development, circuitry design, tooling, design validation and optimization in Beta and RC phases, volume tooling and processes for Start of Production and production ramp-up. Life-cycle improvements and cost reductions as needed.

•Make design decisions and coordinate with other Tesla parties, for example: Body Controls, Systems Integration, PCBA Design, Materials Engineering, Environmental Testing, Mentor Graphics Integration, Guidance of component selection.

•Support of team during Vehicle Durability and Crash Test, Manufacturing Engineering, etc.

•Identify and resolve concerns, such as high voltage drop in circuits, high power dissipation, fault current related to fuse characteristics, fuse coordination, reliability concerns on detailed design features and drive the solution progress to remove these concerns through weekly tests, follow ups, upper management deep-dive reviews and cross functional team reviews.

•Work closely with Reliability team to ensure proper testing on finished designs (vibe, corrosion, material testing, voltage drop, fuse-blow, EMI, etc.)

Requirements

•Develop and maintain tools to manage the wire, connector and parts libraries and crimp validations and Service documentation.

•Optimization, rapid prototyping and full-scale/automated production.

•Experience with rigorous document control practices.

•Excellent team and person-to-person communication skills.

The Role

Tesla’s Low Voltage Distribution team is seeking a Mechanical Design Engineer with 5-10 years of experience designing products for high-volume production. Ideal candidates will have a breadth of experience in interfacing electronics with mechanical assemblies. They should be smart, fast-learning, imaginative and hard-working. Candidates should be strong at analytical design tools, manufacturing and assembly processes, and reliability validation techniques of electro-mechanical assemblies.

This engineer will have design and release responsibility for components of LV harness in Tesla’s world-leading production EV’s. We are also building Next Generation Interconnect technology to completely re-design the low voltage electrical power/signal distribution systems for high-volume automated manufacturing and assembly of our future cars. We are adopting and advancing the latest technologies to replace the conventional wiring harnesses with high end automation.

Responsibilities

•Assessing and documenting engineering requirements for specific subassemblies

•Gathering input from cross-functional team members and synthesizing inputs into a preferred concept

•Developing in CAD: system interfaces, master model and detailed part models, (Catia V5/V6 preferred); designing metal and plastic parts

•Creating 2-D part documentation appropriate for high-volume production methods and inspection methods (including GD&T)

•Working with product lifecycle management software for managing and releasing structured bills-of-materials

•Fabricating proof-of-concept prototypes to validate feasibility of new designs

•Managing vendors for parts fabrication

•Assembling prototype systems and testing to validate design.

Requirements

•Mechanical Engineering degree strongly preferred

•Strong knowledge of materials properties and applications, fabrication methods

•Strong analytical background to ensure a successful design (tolerance stack-ups, solid mechanics, thermal, cost and mass optimization etc.)

•Experience includes multiple projects taking parts from initial concept and design through to production

•Have a passion for electro-mechanical product design, inventing solutions, and finding better and simpler ways to meet product requirements

•Experience in developing designs for easy automation and developing the automation process

•Experience specifying electrical connectors, considering wiring and EM shielding and managing heat within electronic assemblies to make a physical module which can be deployed in real-world customer applications

•Ability to present data/trade-offs to management to facilitate decision making

•Experience as primary technical and design responsibility for all aspects of small mechanical or electro-mechanical assemblies which were successfully produced in high volume

•Experience in safety critical industries (automotive, medical, aerospace) and in cost/weight critical applications is preferred

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