Job Details

Job DescriptionJob DescriptionJob Summary:

The Mechanical-Thermal Engineer will be a key member of the development team for multilevel converter technologies for applications in renewable energy, grid infrastructure such as Static Synchronous Compensators (STATCOMs), specializing in the mechanical design and thermal management of high-power systems. This role focuses on creating robust enclosures, efficient cooling solutions, and seamless mechanical integration to ensure optimal performance, reliability, and durability under diverse environmental conditions. The ideal candidate will apply expertise in thermal analysis and mechanical engineering to support the integration of power electronics components, collaborating with electrical, control, and test engineers to deliver innovative power electronic systems that enhance grid stability and efficiency in renewable energy and transmission applications.

Essential Functions:

• Design and develop enclosures for multilevel converter systems, ensuring structural integrity, protection from environmental factors, and compliance with safety standards such as IP ratings and IEC guidelines.
• Engineer cooling systems, including liquid cooling (e.g., water-glycol loops) or air-cooling solutions (e.g., forced convection with heat sinks or fans), tailored for high-power modules to manage thermal loads and prevent overheating.
• Lead mechanical integration efforts, coordinating the assembly of components like converters, capacitors, and switches into cohesive systems, while optimizing for space, weight, and manufacturability.
• Ensure system reliability under environmental stresses, such as temperature extremes, humidity, vibration, and shock, through stress analysis, material selection, and accelerated life testing.
• Perform thermal simulations and modeling using tools like ANSYS, COMSOL, or SolidWorks Flow Simulation to predict heat dissipation, airflow patterns, and temperature distributions in system prototypes.
• Collaborate with power electronics and control systems teams to align mechanical designs with electrical requirements, addressing issues like thermal expansion, electromagnetic shielding, and modular scalability.
• Conduct failure mode and effects analysis (FMEA) for mechanical and thermal aspects, implementing design improvements to enhance longevity and fault tolerance in field deployments.
• Develop and maintain technical documentation, including CAD drawings, thermal reports, and assembly instructions, for internal teams and regulatory approvals.
• Support internal audits and enforce adherence to documented policies and procedures to uphold quality of designs.
• Support prototyping, testing, and validation phases by overseeing mechanical assembly, thermal cycling tests, and environmental chamber evaluations to verify design performance.

Minimum Qualifications:

• Bachelor's degree in mechanical engineering, Thermal Engineering, or a related field.
• At least 5 years of professional experience in mechanical design and thermal management, preferably in power electronics, high-voltage systems, or industrial equipment.
• Proven expertise in designing enclosures, cooling systems (liquid or air-based), and mechanical integration for high-power applications.
• Strong proficiency in CAD software (e.g., SolidWorks, AutoCAD) and thermal simulation tools (e.g., ANSYS, Fluent).
• Solid understanding of environmental stress factors and reliability engineering principles, including vibration analysis and material science for harsh conditions.
• Experience with prototyping, testing, and integration of mechanical systems in multidisciplinary projects.
• Excellent problem-solving skills, attention to detail, and the ability to collaborate effectively in a team environment.
• Strong communication skills for documenting designs and presenting technical findings.

Qualifications:

• Master's or Ph.D. in Mechanical Engineering with a focus on Thermal Sciences or Mechatronics.
• 7+ years of experience, including work on HVDC, FACTS devices, or similar high-power converter systems in grid or renewable energy sectors.
• Familiarity with advanced cooling technologies, such as phase-change materials or hybrid cooling systems, and standards like IEEE or IEC for thermal management.
• Experience with finite element analysis (FEA) for structural and thermal simulations, and knowledge of computational fluid dynamics (CFD).
• Proficiency in additional tools like MATLAB for thermal modeling or LabVIEW for test automation.
• Knowledge of sustainable design practices, including lightweight materials and energy-efficient cooling for eco-friendly applications.

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