- Motors and Power Systems
- Malmesbury - United Kingdom
The Research Manager role will be responsible for the management of the Power Electronics sub team within the Power & Electronic Systems Research team, which sits within Technical Research; reporting to the Head of Power and Electronic Systems Research.
The team mainly works on home appliances which involves a diverse set of product categories with the ability to get involved in a range of technologies. The team’s work is split into power electronics, embedded electronics & sensors, and software. We work very closely with the New Product Innovation teams (NPI) in floor care, personal care and new categories (non EV) and deliver technologies into new products during the research phase.
Some of the areas we cover include:
- AC-DC and DC-DC conversion (up to 3kW).
- High speed motor drive design.
- Lithium-ion battery management for robot battery packs and stick vacs, along with emerging categories too.
- Heater control.
- Traction drives (for robot).
- Microcontroller selection and software for the above, including control algorithm implementation.
- temperature particulate and gas sensing.
We work very closely with the mechanical, electromagnetic and aero acoustic teams in research, as well as the energy storage teams to help find the best technologies and integration approaches.
The team takes the products to the prototype stage (typically up to 10-20 prototypes) before transferring to the development and manufacturing teams, often after user trials and detailed laboratory testing (general performance, thermal, EMC etc).
The work often involves shorter term projects targeting specific products, alongside longer term research projects to bring emerging technologies into future products. It is typical to be managing several projects running concurrently.
Ensuring team philosophies and working practices are applied to a project is an essential part of the role.
Applicants should be proficient in creating and developing power electronic hardware and simulations, with particular focus on system architecture, implementation and verification.
The role involves:
- Leading and taking technical responsibility for the Power Electronic sub team within the Power and Electronic Systems Research team, covering multiple software/hardware elements of several projects.
- Working with the different sub teams within Technical Research, as well as NPI, other research groups and development teams to gain an in depth product understanding, while using your expert knowledge of the latest technologies to create innovative systems and solutions.
- Ensuring the team develops the concept and demonstrates designs are robust and viable for use in product through detailed laboratory testing, prior to handover to the development teams.
- Ensuring the team generates suitable test specifications to ensure product reliability, safety and robustness. This includes the development of test environments including simulation, emulation and hardware/test equipment interactions.
- Assisting in the personal development of the team and undertaking regular performance conversations with the team.
- Owning the hardware architecture in certain projects, as well as implementation and verification of the hardware.
- Driving the technical direction for new developments and ensuring that our hardware is developed both efficiently and to our quality requirements.
- Hardware design review activities (schematic reviews and pre/post PCB layout reviews).
- Working with the other disciplines to solve complex system level problems and find software/hardware solutions.
- Ensuring all software/hardware requirements and architecture details are fully documented by the team.
- Pulling together review packs which typically include concept specifications, requirements and specification documentation, risk registers, FMEAs and design guides.
- Managing technical risks in a project through FMEAs, reporting, and actively driving down risk with targeted tasks.
Education and experience:
· BEng/MEng degree in Electrical & Engineering, or other relevant discipline, or a demonstrable level of industrial experience in a relevant industry.
· The team is a research team and candidates should be able to demonstrate an ability to innovate and research (e.g. through patent publications, papers, developing new technologies etc).
Minimum technical knowledge:
· Power Electronics:
o Experience in motor inverter design and motor control, particularly brushless DC motors, servo or stepper motors
o Experience of power converter design
o Knowledge of heater control hardware, control schemes and heater protection approaches
o General knowledge of power electronic devices, including silicon based IGBTs and MOSFETs through to emerging wide bandgap technologies
o Understanding of device characteristics and issues with switching behaviour in real circuits, as well as power switch driver design
o Knowledge and experience of using power hybrid modules and power SoC modules (e.g. drivers and power switches in one device)
o Thermal management approaches for surface mount and through hole devices
o Design of power electronics for both low voltage and mains voltage systems
· Control circuit design:
o Excellent understanding of techniques for accurately monitoring small signals in high power, electrically noisy environments.
o Knowledge of analogue to digital converters, op-amps, comparators, voltage references etc
o Knowledge of low power circuits for maximising battery standby life.
· Design Tools:
o Schematic capture using Altium Designer, Mentor Graphics or other main stream tools
o Use of SPICE based simulation tools such as Simetrix and LTspice
o Design calculation tools such as Mathcad, Matlab, Excel.
· Design Techniques:
o Circuit simulation and design tolerance analysis.
o Good quality engineering process understanding and appreciation.
o Robust design including FMEA techniques.
o Familiar with creating requirement documents.
· Lab experience
o Experience of working in a laboratory environment.
- Use of lab equipment to set up experiments and to take precise measurements
- Experience of writing risk assessments for lab based testing.
Essential Management skills:
· A candidate should be able to demonstrate previous people manage experience, including running 1:1 meetings with direct reports and setting objectives.
· Experience of developing individuals in a team through personal development plans and developing training plans for teams.
· Proven ability to build and manage supplier relationships.
· Manage complex NDA relationships (potential part sourcing from multiple suppliers).
· Project management experience – ability to work with teams to generate task lists and timelines to build project plans and manage risk in projects.
· Experience of budget setting.
· Experience of managing laboratory environments and being responsible for safety in labs.
Essential behavioural skills:
· Good analytical ability and attention to detail.
· Ability to communicate appropriate, concise and accurate information in written and verbal format.
· Ability to adapt or generate imaginative and innovative ideas, in line with core Dyson values.
· Ability to multi-task and plan effectively when working with a variety of project teams.
· Excellent team working skills.
Essential practical skills:
· Ability to build, test and modify prototypes accurately, safely and with minimal supervision.
Additional experience that is desirable:
· Schematic capture using Altium Designer, Mentor Graphics or other main stream tools.
· PCB layout – size/cost minimisation while achieving layouts for inherently good EMC compliance and thermal design.
· Design for high volume manufacture.
· Device selection - Interpretation of datasheets and knowledge of design methods to confidently select the lowest cost devices while achieving reliability targets.
· Experience with Flowtherm or similar thermal modelling packages.