Maharashtra, India
Onsite
Our work is guided by our purpose: creating an energy-resilient world for a better future. This purpose embodies the legacy we bring, with more than 100 years as the global leader in energy resilience, delivering solutions critical to sustain and improve life.
Our teams have the opportunity to provide a critical resource – energy – that ensures safety, security, and independence for people around the world. Our team members are focused on pushing boundaries, continuing to innovate in an ever-changing landscape, and keeping up with the pace required to create solutions for today’s world demands.
Our product range includes engines, generators, power conversion, UPS systems, EV components and electrification solutions, microgrid controls and management, and clean energy solutions that serve a broad spectrum of OEM, residential, industrial, and commercial customers. At Rehlko, you have the freedom to identify, create, and deliver solutions – large and small – that help people and communities thrive in the moments that matter.
At Rehlko, our team members are the essential energy that powers our organization’s success. We are committed to fostering a safe and sustainable work environment where safety is everyone’s responsibility. We empower every team member to actively participate in our Zero Is Possible safety culture by encouraging open communication, proactively reporting hazards, following protocols, and suggesting improvements. Join us in creating an energy resilient world for a better future!
What We Offer
At Rehlko, our Total Rewards programs are designed to accelerate growth, energize performance, and support a culture of inclusion at every stage of life and work. We offer total rewards that are easily understood, recognize results, enable career mobility, and reflect our commitment to valuing diverse needs in a fast-moving world. We provide:
Competitive compensation and benefits
Work-life flexibility
Recognition and rewards
Development and career opportunities
A safe and inclusive workplace
Why You Will Love this Job
Below details are as per resume.
PROFESSIONAL SUMMARY
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Electrical Systems Simulation, Modeling, Optimization, and Controls Engineer: 9+ years of experience in system-level modeling, simulation, control, and optimization of electrical, mechanical, and thermal systems across automotive, aerospace, and power generation domains, including electrified powertrains, batteries, gensets, engines, and cooling systems.
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Model-Based Design & Multi-Domain Optimization: Strong background in model-based control design, calibration, and multi-start optimization using MATLAB and Simulink, supporting repeatable tuning, architecture trade studies, and performance evaluation of complex physics-based systems.
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System Diagnostics & Health Monitoring: Broad experience developing signal-processing and feature-based diagnostic methods for dynamic systems, including combustion health monitoring, rotating machinery analysis, and fault detection using time-domain and frequency-domain metrics validated against real test data.
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Thermal & Energy Management Systems: Extensive experience in thermal system modeling and optimization, including heat exchangers, cooling architectures, and energy flow management, integrating thermal physics, fluid dynamics, and control interactions.
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System Validation & Cross-Functional Engineering: Proven ability to translate real hardware and test data into validated, deployment-ready simulation and analysis tools through close collaboration with electrical, mechanical, controls, and test teams.
WORK EXPERIENCE
Staff Electrical Engineer (Simulation) – Advanced Development
Rehlko Power Systems, Mosel, WI | May 2025 – present
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Developed MATLAB and Simulink based workflows for genset sizing and performance analysis under steady-state and transient operating conditions.
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Built and validated genset performance models capturing engine–alternator dynamics, load acceptance and rejection, and frequency response across customer load profiles.
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Designed multi-start calibration and optimization pipelines using Simulink Design Optimization (SDO) and real test data to achieve stable, repeatable results.
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Developed combustion health monitoring and misfire diagnostics for multi-cylinder engines (V8 and V16) using crank-angle based signal processing and cylinder-level metrics.
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Created a unified cooling radiator sizing and optimization framework supporting single-core, front-back, and side-by-side heat exchanger configurations (including MATLAB GUI integration).
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Collaborated with test, reliability, and simulation teams to capture engine and system data and validate models for deployment-ready engineering use.
EV Systems Controls & Optimization Research Engineer
Ford Motor Company, Dearborn, MI | Apr 2023 – Apr 2025
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Developed and validated system-level simulations for power generation, battery storage, and energy management using MATLAB, Simulink, and Simscape.
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Designed and implemented feedback and predictive control algorithms for powertrain, battery, and thermal systems, with embedded implementation in C and C++.
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Built automated model-based calibration and optimization workflows (MBCO) to tune system attributes such as fuel economy, efficiency, and actuator parameters including pumps and valves.
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Performed large-scale data analysis and range prediction using hundreds of on-road customer drive cycles on electrified vehicle co-simulation models.
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Verified and validated physics-based vehicle subsystem models including cabin, refrigerant, front-end, and battery systems using GT-Suite.
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Collaborated with electrical, thermal, and software teams to integrate powertrain and energy storage systems and improve robustness of vehicle control strategies.
Postdoctoral Research Fellow
NSF ERC for Power Optimization of Electro-Thermal Systems (POETS), UIUC | May 2021 – Mar 2023
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Developed MATLAB-based optimization models for thermal management system (TMS) design and 3D spatial packaging in BEVs, impacting Ford, Toyota, and Tesla EVs.
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Created multi-sensor placement algorithms for fault diagnosis in power converters and traction inverters.
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Designed automated EV layout tools to optimize battery array, heat pumps, valves, and electric drive configurations.
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Developed efficient system level design optimization methods modeling and diagnostic tools, and algorithms.
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Led 8+ research projects and mentored 15+ students, contributing to 35+ peer-reviewed publications.
Graduate Research Assistant (Masters and PhD Research Scholar)
Engineering Systems Design Lab, University of Illinois at Urbana-Champaign| Jan 2016 – Apr 2021
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Developed foundational system-level modeling, simulation, and optimization methods for complex electro-thermal and electro-mechanical systems, forming the basis for later work in electrified vehicles, power electronics, and power generation systems.
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Built high-fidelity multiphysics models integrating electrical, thermal, and mechanical domains for automotive and aerospace applications, enabling early-stage design exploration and performance trade studies.
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Designed graph-based and topology-aware optimization frameworks for hybrid electric powertrain configurations, cooling system architectures, and spatial packaging of interconnected components.
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Developed diagnostic and sensor placement methods for power electronic systems and thermal networks, focusing on fault observability, robustness, and efficient instrumentation strategies.
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Twice nominated for Best Paper Award (2020, 2021) by ASME IDETC for work on fluid-based TMS optimization.
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Secured >$1M in research funding from NSF, NASA, DARPA, and ARPA-E.
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Recipient of Grainger Engineering Outstanding Teacher Award (2021) (top 1% of graduate students).
EDUCATION
Doctor of Philosophy (Ph.D.) – Systems and Entrepreneurial Engineering
University of Illinois Urbana-Champaign (UIUC) | Jan 2019 – Apr 2021
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Dissertation: Optimal 3D Spatial Packaging of Interconnected Fluid-Thermal Systems
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Featured in ASME Journal of Mechanical Design (Nov 2022)
Master of Science (M.S.) – Systems and Entrepreneurial Engineering
UIUC | Jan 2016 – Dec 2018
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Thesis: Integrated Design Methods for Optimal Sensor Placement and Flow Control in Fluid-Based Thermal Management Systems
Bachelor of Technology (B.Tech) – Control and Instrumentation Engineering
National Institute of Technology, Trichy, India | Jul 2011 – May 2015
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Best Senior Design Project Award
TECHNICAL SKILLS
• Expert: MATLAB/Simulink, Python, GT-Suite, modeFrontier, TeX, C, Git, OS: Windows/Linux
• Proficient: AutoCAD, Vector CAN, Modelica, FEA (ANSYS, Creo), ETAS INCA, Simscape
• Basic: CATIA (SysML), HTML/CSS
• Certifications: Machine Learning (Python, Apache Spark, TensorFlow – Coursera, IBM)
About Us
Rehlko proudly offers a rich history steeped in creativity and commitment to our associates and communities, along with competitive benefits and compensation. Our Purpose—Creating an energy resilient world for a better future—and Values: Curiosity, Trust, Pace, and Excellence, are important cultural components that shape the way we work and relate to one another. Learn more about Rehlko at https://www.rehlko.com/who-we-are. In addition to the investment in your development, Rehlko offers a comprehensive package with competitive salaries and a range of additional benefits.Rehlko is an equal opportunity employer that prohibits discrimination and will make decisions regarding employment opportunities, including, but not limited to, hiring, job assignment, compensation, promotion, benefits, training, discipline, and termination, promote equal opportunities in every aspect of our process.Our Values
Curiosity – Seek, learn, share
Trust – Go farther together
Pace – Focus to go faster
Excellence – Find the win every day
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