Research Design Engineer II
2 weeks ago
Research Design Engineer II with G & W Electric Company (Bolingbrook, IL)
Conduct research, designs and tests for new product concepts and technologies to transfer innovative technology to the new product development group. Lead research projects from idea to proof-of-concepts while overseeing some projects with a cross-functional team. Determine optimal design concepts and fundamental technology used for new products or to improve existing products. Collaborate with the cross-functional team during the design process. Design accurate layouts, assembly drawings, details and bills of materials. Develop project schedules and manage feasibility projects of minor to major size. Interface with purchasers and vendors in the selection and approval of component parts and assemblies. Prepare budgetary and resource information regarding projects or parts of a project in the areas of assigned responsibility. Lead research and design concepts while evaluating prototypes in accordance with technology roadmaps. Draw upon engineering and technical knowledge through books, white papers, and engineering standards. Utilize established mathematical and scientific techniques to compile and analyze technical data. Perform engineering analysis of the design of new products and their subcomponents. Follow established procedures for the creation and maintenance of computer-aided design (CAD) databases and libraries. Build and test prototypes in the laboratory and facilitate testing in the outside lab. Troubleshoot and conduct root cause analysis of the prototype testing. Write test reports and technical white papers.
Instruct and support engineering teams on the use and selection of high-pressure air and other gas systems. Assist drafters in developing the structural design of mechanical products using drafting tools or computer-assisted drafting equipment or software. Design the mechanical components of switchgear designs according to given parameters, including nuts, bolts, threads, chains, links, and seals. Calculate the compression force for components subjected to press fits such as rubber gaskets, O-rings, and rubber cones. Conduct research that tests or analyzes the feasibility, design, operation, or performance of mechanical equipment, components, or systems. Design, evaluate, and select mechanical springs and dampeners for prototypes of new products. Perform kinematic evaluation of 1D and 2D mechanisms using analytical methods for prototypes of new products. Conduct mechanical stress simulation of sheet metal tanks under pressure with the use of finite element analysis tools. Identify materials according to the mechanical stress, shear stress, mechanical cycles, and corrosion environment for new products and prototypes. Select the best manufacturing processes for structural, electrical, and insulation components according to specifications.
Below is additional information about the products the employee will oversee, develop, and design:
Product: Medium Voltage Switchgear Product without SF6 Gas
Oversee the project including state-of-the-art research, product design, and engineering analysis for mechanical, electrical, and material components. Lead factory acceptance testing to verify IoT switchgear capabilities. Develop prototypes, sensors for performance measurement, and alpha switchgear prototypes with IoT capabilities. Perform design of experiment testing and optimize the design based on the test results.
Product: Compact Rotary Puffer Medium Voltage Switch with Natural Origin Gas
Oversee outside vendors to perform computational fluid dynamics (CFD) simulation. Perform development through testing and analysis of test results, including mechanical and electrical finite element analysis. Design prototypes and perform design optimization based on the analysis.
Product: Point of Wave Switching/Reclosing Products
Oversee the project that includes collaborating with the external supplier to integrate the point-of-wave solution on the existing product and communicating results. Develop testing by writing the test plan, preparing the units for testing, and conducting testing in the external power laboratory. Design new functionality to the existing product and work with the client to install the alpha prototype on its network.
Product: Smart Bushing with Voltage and Current Sensors
Develop prototypes, write test plans, and conduct testing to industry standards, including dielectric, temperature, current, and voltage testing. Design smart bushing for low carbon footprint switchgear with embedded current and voltage sensors. Optimize the design by performing mechanical and electrical finite element analysis.
Requirements: Requires a Master’s degree or foreign equivalent in Mechanical Engineering, Industrial Engineering, or a related field.
Requires 2 years of experience.
Must have some experience in each of the following skills:
High voltage physics and the design of high voltage equipment;
Finite Analysis software, such as CST Studio and COMSOL Multi-physics, for electrical and mechanical simulations;
Prediction and modeling of electrical breakdown in air insulation using COMSOL, CST Studio, or MATLAB based on inception and streamer phenomena;
Implementation of accelerated aging of materials and analysis using Arrhenius material models and glass cells;
Study of the current interruption process in medium-voltage switchgear through measurements of mechanical and fluid dynamic parameters using dynamic pressure sensors and linear or rotary transducers, or simulated values;
Assessment of gas toxicity in accordance with the OSHA Hazard Communication recommended methodology (Acute toxicity equivalent) for gas mixtures;
Calculation of pressure, weight, mol, and other parameters of compressed gas mixtures based on Peng-Robinson Equation of State;
CAD design using PRO-E and Creo;
Estimation of gas permeation through seals to select and calculate rubber seals for gas-tight switchgear following the guidelines outlined in ASTM D1434 or equivalent standards;
Programming and wiring of SEL relay power controls using AcSELerator; and
Planning, execution, and analysis of power tests, employing tools such as high-speed camera recording, oscillograms, and speed measurements.
Wage Range: $100,568.00 to $116,000.00 per year.
Domestic travel required 10% of the time. International travel required 10% of the time.
Qualified applicants send resume to: Anthony Matteucci, Amatteucci@gwelec.com
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