Electrical Systems Design Engineer

3 weeks ago

Cincinnati, Ohio, United States Hyliion Full time

At Hyliion, we are committed to creating innovative solutions for clean, flexible, and affordable electricity production.

The primary focus of our company is to develop distributed power generators that can operate on various fuel sources to future-proof against an ever-changing energy economy.

The Senior Engineer, Electrical Systems will lead the design and development of large-scale generator systems (megawatt scale).

This position works across the entire project lifecycle from design through commissioning, ensuring that both control systems and power systems are optimized for performance, safety, and reliability.

Duties and Responsibilities:

  • Design and development of large-scale generator systems (megawatt scale) focusing on efficiency, reliability, and scalability.
  • Perform load analysis, fault studies, and risk assessments to ensure system performance and safety.
  • Collaborate with project teams to integrate generator systems into industrial or commercial power networks.
  • SCADA and PLC Integration:
    • Design, configure, and implement SCADA systems for real-time monitoring and control of generator systems.
    • Program and configure PLCs (e.g., B&R, Siemens, Allen-Bradley, Schneider Electric) for generator control, with a focus on integrating fuel, air, cooling, and pressure instrumentation.
    • Develop control logic for managing fuel injection systems, air intake systems, cooling systems (water/air-cooled), and pressure monitoring devices to optimize generator operation.
    • Ensure accurate control and synchronization between fuel supply, air flow, cooling rates, and pressure feedback for optimal system performance and efficiency.
    • Troubleshoot and resolve PLC-related issues in real-time control, ensuring communication between all subsystems (fuel, air, cooling, and pressure) is stable and efficient.
  • Manage communication protocols (e.g., Modbus, DNP3, Ethernet/IP, Profibus) for smooth interaction between instrumentation, control systems, and remote monitoring stations.
  • Implement robust network solutions, incorporating redundancy, fault tolerance, and security to ensure system integrity.
  • Oversee system updates and ensure all data communication channels are secure and optimized for efficiency.
  • System Modeling:
    • Model and simulate electrical power systems, control algorithms, and the dynamic behavior of generator systems.
    • Perform simulations to optimize control strategies related to fuel, air, cooling, and pressure subsystems.
    • Leverage software such as Simulink to troubleshoot system issues and validate performance improvements before implementing physical changes.
  • Compliance with UL Standards:
    • Ensure all designs and systems comply with UL standards, as well as NEC and IEEE codes.
    • Prepare detailed technical documentation to support UL certification and other regulatory approvals.
  • Project Management and Leadership:
    • Manage large-scale generator projects from design through to on-site installation, testing, and commissioning.
    • Provide technical leadership to cross-functional teams and serve as a subject matter expert on PLC integration, instrumentation, and SCADA systems.
    • Mentor junior engineers, particularly in areas such as fuel, air, cooling, and pressure instrumentation integration with PLC and SCADA systems.
  • System Testing, Commissioning, and Troubleshooting:
    • Lead on-site system testing, commissioning, and troubleshooting efforts to ensure generator systems meet performance, safety, and reliability standards.

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