Senior Test Engineer - HIL
ON.energy
Salary undisclosed
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Description
ON.energy is setting the standard for large load interconnection. ON’s patented AI UPS™ is a medium-voltage UPS that serves as a firewall, protecting the data center from the grid, and the grid from the data center. With multiple gigawatts currently under construction, we are enabling grid-safe data centers.
Role Summary
The HIL Test Engineer develops and operates hardware-in-the-loop and real-time simulation capability for ON.energy storage and power conversion products. The role covers real-time model development, integration of controllers and firmware with the simulation environment, execution of structured test campaigns, and the reporting that supports design reviews and product release. This is a hands-on laboratory and integration role, working closely with the controls, firmware, modeling, and product engineering teams.
Key Responsibilities
- Develop and maintain real-time models of plant, grid, and equipment behavior for use in controller testing.
- Configure and operate the HIL environment, including real-time simulator, I/O interfaces, signal conditioning, and data acquisition.
- Integrate product controllers, control software, and firmware builds with the simulation environment, and maintain those configurations under version control.
- Integrate supplier-provided equipment models and develop equivalent models where required.
- Plan and execute functional, performance, fault, boundary-condition, and regression test campaigns against defined acceptance criteria.
- Verify control performance across normal operation, disturbances, abnormal conditions, and recovery.
- Compare test results against offline simulation studies and laboratory measurements, and resolve discrepancies.
- Develop scripts and tooling to automate test execution, data processing, and reporting.
- Investigate failures with controls and firmware engineers, support root-cause analysis, and re-test to closure.
- Prepare test reports documenting method, configuration, results, limitations, and recommendations.
- Maintain laboratory safety, equipment, configuration records, and documentation.
Key Requirements
- 5+ years of experience in HIL testing, real-time simulation, controls validation, or laboratory testing of grid-connected power electronics.
- Bachelor's degree or higher in electrical engineering, power systems, controls engineering, or a related discipline.
- Direct experience on at least one real-time simulation platform, such as RTDS/RSCAD, Typhoon HIL, or OPAL-RT.
- Working capability with offline simulation tools such as MATLAB/Simulink and PSCAD, and an understanding of what has to change when a model is made to run in real time.
- Grounding in inverter controls, energy storage systems, and power system dynamics.
- Python, or a comparable language, used in earnest for test automation and data analysis.
- Test plans, procedures, and acceptance criteria you have authored yourself, and the analytical rigor to stand behind the results.
- Familiarity with SCADA systems and industrial communication protocols such as Modbus, DNP3, CAN, and IEC 61850.
- Comfort on the bench with power supplies, oscilloscopes, transducers, and data acquisition hardware.
- The ability to present technical findings credibly to engineering audiences and clearly to field and commissioning personnel.
Preferred Experience
- Experience with grid-forming and grid-following inverter control.
- Experience with uninterruptible power supply systems, microgrids, or facilities serving critical load.
- Familiarity with ISO or utility interconnection requirements, model quality testing, or third-party product certification.
- Continuous-integration pipelines driving automated test suites, with version control applied to models as rigorously as to code.
- Prior collaboration with national laboratories or university test centers.
For US-based roles - What you’ll get:
- Competitive salary + annual performance-based bonus eligibility
- Medical, dental, and vision insurance
- 401(k) with company match
- Paid time off and company holidays
For Mexico-based roles - What you’ll get:
- Competitive salary + annual performance bonus eligibility
- Christmas Bonus (Aguinaldo): 30 days
- Major medical expenses and life insurance
- Paid time off and holidays (per local policy)
For all roles:
- Professional development and growth opportunities
- Opportunity to grow with a mission-driven team shaping the future of clean energy
- Equal Opportunity: ON.energy is committed to equal employment opportunity and to maintaining a work environment free of harassment, discrimination, or retaliation.
- Benefits vary by role and location and are subject to change.
Agency Notice: ON.energy does not accept unsolicited resumes from staffing agencies, search firms, or third-party recruiters. Resumes submitted without a fully executed Master Services Agreement (MSA) and a written request from an authorized member of our Talent Acquisition team will be considered the property of ON.energy. No placement fees or compensation will be paid for unsolicited candidate submissions.
Benefits
- health insurance
- vision insurance
- 401(k)
- paid time off
- life insurance
- professional development
- bonus
About this role
ON.energy is building grid-safe data centers with AI-powered UPS technology, and this role sits at the center of proving that technology works. As a Senior Test Engineer, you'll develop and operate the hardware-in-the-loop simulation environment that validates the company's storage and power conversion products before they go into the field. This is hands-on laboratory work: you'll build real-time models, integrate controllers and firmware into the simulation, run structured test campaigns across normal and fault conditions, and own the technical reporting that supports design reviews and product releases.
The role demands someone with at least four years of direct HIL or controls validation experience and deep familiarity with real-time simulation platforms like RTDS, Typhoon HIL, or OPAL-RT. You'll need solid grounding in inverter controls, energy storage, and power system dynamics, plus the ability to move fluidly between offline tools like MATLAB and Simulink and the real-time environment. Python or equivalent scripting skills are essential for automating tests and analyzing data. Beyond the technical toolkit, you should be comfortable authoring your own test plans and acceptance criteria, troubleshooting on the bench with standard lab equipment, and presenting findings credibly to both engineering teams and field personnel.
This is a full-time, in-office position in Houston. The company offers competitive salary with performance bonuses, standard benefits including medical, dental, vision, and 401(k) matching, plus paid time off. If you have prior experience with grid-forming inverters, UPS systems, or work with national labs or certification bodies, that background would strengthen your candidacy.
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