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The Sr. Applications Engineer is the primary technical support interface for commercial-vehicle and industrial applications customers. You will translate vehicle or application requirements and guide customers regarding selection, integration and troubleshooting of our products such as electric motors, traction inverters, gearboxes/e-axles, and microgrid power electronics. You will partner with sales, product engineering, quality, and operations to ensure successful launches and sustained performance in the field. The role requires direct customer engagement to drive the adoption of our electrified propulsion portfolio.

Key Responsibilities

1) Enable Customer Programs & Requirements

+ Serve as the technical lead for assigned Commercial Vehicle programs from pre‑RFQ through SOP, owning “requirements capture”, system definition, and application feasibility for motors, inverters, and gearboxes/e‑axles.

+ Decompose vehicle drive‑cycle and duty‑cycle data into propulsion system requirements (power, torque, efficiency, thermal, NVH, durability) and align with product capability/roadmaps.

+ Decipher application documentation (Interface Control Documents, system schematics, pinouts, harnessing, installation guides, and customer design notes).

2) Integration, Calibration & Validation

+ Lead mechanical and electrical integration: Guide the customer regarding our product use in their application regarding mounting, shafts/couplers, ratios, cooling, lubrication, EMI/EMC, and HV/LV wiring; coordinate packaging studies with CAD and vehicle teams.

+ Guide customers through traction inverter & motor control setup (FOC, SVPWM/DPWM, sensor configuration, torque/speed limits), dyno bring‑up, and on‑vehicle commissioning.

+ Define and execute customer‑specific DVP&R; support HIL/vehicle testing, data acquisition, and acceptance criteria; understand implications of ISO 26262 interface and OEM standards when required.

3) Issue Triage, RMA & Post‑Sale Technical Support

+ Act as primary technical contact for post‑sale support, ensuring rapid response to customer inquiries and technical escalations. Remotely assist customers in diagnosing and resolving issues in the field if possible.

+ Provide proactive customer success support: monitor product performance in the field, recommend upgrades or preventive actions, and deliver technical training for service teams.

+ Maintain clear communication on issue status, root cause, and resolution timelines; drive continuous improvement based on field feedback.

+ Manage RMA process: provide failure analysis/field diagnosis to RMA engineer, initiate corrective actions, and communication between customer and internal teams; ensure timely resolution and documentation.

4) Commercial & Cross‑Functional Collaboration

+ Partner with Sales on pre‑sales scoping, application risk/cost tradeoffs, and quote inputs; articulate value and constraints of product configurations versus customizations.

+ Provide Voice‑of‑Customer insights to drive product manual updates and product roadmaps (ratings, interfaces, software/hardware features, diagnostics, serviceability) for Commercial Vehicle duty cycles.

Required Qualifications

+ BS in Electrical, Mechanical, or Mechatronics Engineering (or equivalent experience); 7+ years in Applications, Systems, or Product Engineering in electric powertrain or commercial vehicles.

+ Strong working knowledge of traction inverters (Si/SiC devices, gate‑driver constraints, DC‑link/filtering, thermal), PMSM motors (maps, demag margins, cooling), and single‑/multi‑stage gearboxes (ratios, efficiency, lubrication, thermal).

+ Hands‑on experience commissioning inverter + motor systems: FOC setup, resolver/Hall configuration, PWM schemes (SVPWM/DPWM/six‑step), torque/speed calibration, current/voltage limits, and safety interlocks.

+ Proficiency with CAN/J1939, UDS, and common calibration/measurement tools (e.g., CANalyzer/CANape, INCA, oscilloscopes, HV meters); familiarity with HIL and dyno test workflows. Experience reviewing CAN logs to validate functions and diagnose issues.

+ Familiarity with EMC/EMI practices and HV safety (NFPA‑70E/lockout‑tagout), and with DVP&R, DFMEA/PFMEA, and PPAP/APQP deliverables for OEM programs.

+ Excellent customer‑facing communication, structured problem solving, and ability to lead cross‑functional teams under tight program timelines.

Preferred Qualifications

+ Experience integrating e‑axle systems in medium‑/heavy‑duty platforms (bus, truck, vocational) and translating CV duty cycles to thermal/efficiency tradeoffs.

+ Exposure to SiC traction inverter architectures, gate‑driver design constraints, and power stage limitations.

+ Working knowledge of ISO 26262 safety interfaces and ISO 21434 cybersecurity at system/application boundaries.

+ MATLAB/Simulink familiarity for control parameterization and data reduction; basic scripting for test automation/reporting.

Core Competencies & Behaviors

+ Systems Engineering V‑cycle thinking; strong customer focus; ability to make functional tradeoffs across motor/inverter/gearbox to meet vehicle/application‑level targets; crisp written/visual communication.

Success Metrics (example KPIs)

+ Program execution: On‑time gateways for application deliverables (ICD, DVP&R, commissioning).

+ Quality: Issue containment ≤ 48 hours; median time‑to‑closure for top 5 issues per quarter.

+ Customer value: Ramp‑to‑performance (efficiency/thermal) achieved within agreed cycles; post‑launch CSAT/NPS improvement.

+ Business impact: Attach rate of gearbox + inverter + motor packages; technical contribution to win rate/Cascadia Motion forecasts.

Work Environment & Physical Requirements

+ Office environment and work around high‑voltage EV systems with appropriate PPE; hands‑on tasks at dyno/vehicle sites as needed.

+ Ability to travel to customer facilities, proving grounds, and supplier/manufacturing locations (~10%).

Salary Range:

$90,800 - $113,000

No Unauthorized Referrals from Recruiters & Vendors

Please note that BorgWarner and any of its affiliated companies does not seek or accept unsolicited resumes or offers from third party recruiters or staffing agencies associated with any published or unpublished employment opportunities. Any unsolicited information sent to BorgWarner will be considered as unencumbered and free from any fee or charge whatsoever. Only members of our Human Resources Team have the authority to engage or authorize recruiting services, which must be agreed upon before the unsolicited resume or offer is received.

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