Lead Mechanical Engineer

Job Description Summary

The Lead Mechanical Engineer will be a self-driven engineer responsible for leading the Mechanical design activities associated with the develop of next generation products and the execution of projects for Battery Energy Storage Systems. This individual must have the ability to work with a high skilled team to design the new energy storage products portfolio and provide the full products package to the business.

Job Description

The Lead Mechanical Engineer will require a wide base of knowledges across Mechanical, Packaging, Electrical and Thermal cooling systems with sufficient details to set-up and drive the design across these main areas of the Energy Storage products/projects design. The work will be focused on systems related to internal and external design of the enclosures; internal equipment and Battery layout, Cooling circuits, Chillers & HVACs, and Fire suppression systems while adhering and complying to various published technical standards and codes.

In the Lead Mechanical Engineer role, the candidate will:

• Develop mechanical and thermal design of battery system products from conceptual stage to final design, testing, and manufacturing while meeting the requirements for size, environmental conditions, maintainability, reliability, long lifetime, and cost.
• Work with Global Research teams to productize new technologies.
• Work with the rest of the NPI/Product/Project teams to develop procedures, documentation, user manuals and test plans to deploy the new products into the Energy Storage business.
• Prepare Design FMEA, define validation plan and execute validation activities working with global cross functional teams.
• Lead mechanical system design - Concept design, 3D detailing - Sheet metal component/Plastics mold component, GT&D, Global tolerancing, Stack-up analysis, 2D drawing preparation and review, material selection, DFMEA, DFA, DFM etc. while adhering to common international standards, such as ANSI/ISO.
• Perform and review FEM for structural analysis and mechanical calculations for seismic, transportation, handling & lifting requirements, and other environmental load conditions (i.e., wind load, snow load, etc.) for battery enclosure systems.
• Design and implement the fire suppression systems.
• Build and review thermal models (in MS-Excel and/or Matlab) for overall system level calculations to incorporate the heat losses and their management for different cycles of Charging, Discharging and Rest periods.
• Perform and review CFD analyses, fluid flow analysis, and thermal heat transfer analysis for air cooling and/or liquid cooling systems for the batteries.
• Perform HVAC sizing and rating calculations to determine the overall cooling power required for different operating cycles.
• Collaborate with other teams, including Electrical Engineering, Data Science, Project Engineering, and Sales on ensuring successful deployments of the products in large-scale energy storage projects.
• Support the requisition team by providing optimized integrated both Mechanical and Thermal solutions and customization per customer requirements.
• Work with Suppliers along with Sourcing & Quality to ensure components design can be commercialized for production to meet our business objectives.
• Manage internal resources for prototype building and testing to comply with the associated IEC/UL standards.
• Manage external resources such as consultants or test labs in testing various pertinent aspects of the product such as environmental testing, and arc flash testing.
• Effectively communicate results to both internal and external customers by preparing detailed written reports or presentations describing analyses performed, solutions developed, and customer value propositions.

Qualifications/Requirements:

• Master’s degree in Mechanical or Thermal engineering with minimum 12-15 years of experience.
• Minimum 5-8 years of experience with New Product Development
• Execute with limited guidance, the analysis/evaluation of assigned projects that meets business requests.
• Excellent interpersonal communication skills (e.g., ability to effectively communicate with all levels of GE and customer/plant staff).
• Ability to summarize and communicate complex technical information.
• Practical experience with common field mechanical and thermal practices involving in handling, installation, commission, operating and maintenance of complex systems.
• Have strong Mechanical packaging experience in containerized as well as building solutions. 
• Have strong HAVC systems knowledge - interfaces, usage, and design.
• Strong experience with ANSYS simulation tools.
• Understand grid scale energy storage systems and lithium-ion technology.
• Electrical/LV and control systems knowledge 
• Demonstrated process orientation in approach work.
• Experience with developing product from conceptual stage to mass production.
• Strong skillset in mechanical system design – sheet metal component, weldment design, plastic mold component, material selection, DFMEA, DFM & DFA, etc.
• Highly experienced with solid model design software preferably CREO 8.0 or above and manage Bill of Materials and CAD data within PLM Windchill software.
• Experience in delivering manufacturing drawings for components and assemblies utilizing their excellent GD&T skills and tolerance stack-up analysis.
• Experience of managing Bill of Materials and CAD data within PLM/PDM software.
• Knowledge and experience in cooling system component specifications like ducts, fans and HVAC units are added advantage.
• Strong presentation and interpersonal skills.
• Strong mentoring and Coaching skill set.
• Possesses sound business judgement.
• Ability and willingness to travel 20% of the time.

Additional Information