Senior Engine Simulation Engineer - Waukesha - Generac Power Systems

Description

We are Generac, a leading energy technology company committed to powering a smarter world.

Over the 60 plus years of Generac's history, we've been dedicated to energy innovation. From creating the home standby generator market category, to our current evolution into an energy technology solutions company, we continue to push new boundaries.

The Senior Engine Analysis/Simulation Engineer provides engineering input that supports the advancement of the design and performance of internal combustion engines (ICE), through simulation, modeling, and data-driven analysis. This position leverages 1-D & 3-D, CFD, FEA, and machine learning tools to optimize system behavior, reduce emissions, and improve product reliability across a range of applications.

Major Responsibilities:

• Lead the development and performance of system-level and component-level simulations using 1-D tools such as GT-SUITE, Matlab/Simulink, Converge, and Ansys Fluent to support engine and generator design and development.
• Conduct CFD and FEA analyses to evaluate thermal, structural, and fluid dynamics performance of mechanical and energy systems.
• Conduct in-cylinder combustion analysis using Converge to aid in optimizing the power cylinder design for combustion efficiency and thermal management.
• Interpret and make recommendations based upon simulation results and collaborate with cross-functional teams through design reviews and technical discussions to guide product development.
• Develop modeling workflows and analysis best practices to improve efficiency and accuracy.
• Document analysis objectives, methods, and results using standardized reporting formats and recommend modifications based upon findings.
• Apply data analysis techniques, including Matlab/Simulink modeling, Python-based scripting and machine learning, to support predictive modeling and performance forecasting.
• Stay informed on relevant technologies, tools, and industry trends to support continuous improvement and recommend changes to best practice based upon findings.

Minimum Job Requirements:

• Bachelor of Science Degree in Mechanical or Electrical Engineering or related discipline
• 5+ years of relevant work experience

Knowledge / Skills / Abilities

• Previous experience in a Simulation Engineer, Analysis Engineer, or a related engineering discipline.
• Proficiency in 1-D simulation with GT-SUITE.
• Proficient at applying MATLAB/Simulink and Python in engineering analysis and simulation.
• Extensive hands-on experience with GT-xCHEM or CHEMKIN as applied to engine aftertreatment system modeling.
• Proficiency in applying 1-D and 3-D CFD tools to internal combustion engine related systems, including thermal management, lubrication system, crankcase ventilation, combustions phasing, camshaft design, turbochargers, exhaust gas recirculation, and exhaust aftertreatment.
• Proficient in simulating in-cylinder combustion using Converge.
• Proficient with co-simulation environments, including Software-in-the-Loop (SiL) and Hardware-in-the-Loop (HiL).
• Experience with machine learning and predictive analytics techniques applied to engine performance and emissions modeling.
• Experience with internal combustion engine exhaust aftertreatment system design and specification.
• Strong analytical and problem-solving skills, with a deep understanding of internal combustion engine design, operation, and testing.
• Strong written and verbal communication skills with the ability to clearly interpret and present complex simulation results to technical and non-technical audiences.

Preferred Job Requirements

Education

• Master's degree in mechanical engineering, Aerospace Engineering, Computer Science, or a related field of study.

Work Experience

• Expertise in engine and engine system simulation with GT-SUITE.
• Expertise applying MATLAB/Simulink and Python in engineering analysis and simulation to internal combustion engine design.
• Fluency in using Converge to conduct in-cylinder combustion modeling in internal combustion engines.
• Expertise in exhaust aftertreatment simulation with GT-Suite/GT-xCHEM or CHEMKIN.

Knowledge/Skills/Abilities

• Advanced proficiency in applying 1-D and 3-D CFD tools to complex propulsion systems, with demonstrated success in optimizing thermal, lubrication, and ventilation performance.
• Deep expertise in internal combustion engine system architecture, operational dynamics, and advanced testing methodologies.
• Extensive experience designing and executing co-simulation workflows, including SiL and HiL integration for real-time system validation.
• Exceptional ability to synthesize and present complex simulation insights to diverse technical and non-technical stakeholders, influencing design decisions.
• Proficient in applying machine learning and advanced predictive analytics to optimize engine performance and emissions, with experience developing custom models.
• Superior analytical acumen and strategic problem-solving capabilities, with a track record of delivering high-impact engineering solutions.
• Excellent written and verbal communication skills with the ability to clearly interpret and present complex simulation results to technical and non-technical audiences.
• Familiarity with gaseous fuel systems for internal combustion engines.

Physical Demands : While performing the duties of this job, the employee is regularly required to talk and hear; and use hands to manipulate objects or controls. The employee is regularly required to stand and walk. On occasion the incumbent may be required to stoop, bend or reach above the shoulders. The employee must occasionally lift up to pounds. Specific conditions of this job are typical of frequent and continuous computer-based work requiring periods of sitting, close vision and ability to adjust focus. Occasional travel.

"We are an equal opportunity employer and all qualified applicants will receive consideration for employment without regard to race, color, religion, sex, sexual orientation, national origin, disability status, protected veteran status, or any other characteristic protected by law."

Over the 60 plus years of Generac's history, we've been dedicated to energy innovation. From creating the home standby generator market category, to our current evolution into an energy technology solutions company, we continue to push new boundaries.

As one of the leaders and largest suppliers of power generation equipment and technology, the work we do touches millions of lives. Employees at Generac are encouraged to be innovative and are valued as an integral part of our global team. Our challenging goals develop knowledgeable employees dedicated to helping continue Generac's success. Generac provides individuals the opportunity to work in a fast-paced agile work environment where their work makes a difference in people's lives and their own.