Electrical Harness Design Engineer

Job Summary:

REVITUP seeks a highly skilled and motivated Electrical Harness Design Engineer to join our growing engineering team. This role focuses on the design, development, and documentation of complex electrical wiring harnesses and related systems specifically for fire trucks, ambulances, and other specialty automotive vehicles. The ideal candidate will possess a strong understanding of vehicle electrical architecture, harness design principles, component selection, manufacturability, and the demanding requirements of emergency service applications. You will play a critical role in ensuring the electrical integrity, reliability, and compliance of our life-saving vehicles.

Key Responsibilities:

1. Harness Design & Development:

• Design, develop, and detail vehicle wiring harnesses from concept through production release using ECAD software (e.g., Zuken E3, AutoCAD Electrical, etc.
• Create accurate 2D harness drawings, including formboard layouts, connection tables, BOMs, and assembly instructions.
• Perform 3D harness routing and packaging within vehicle CAD models (e.g., SolidWorks Routing, ensuring proper clearance, protection, and retention.
• Develop and maintain detailed electrical schematics and system diagrams.

2. Component Selection & Specification:

• Select appropriate electrical components (connectors, terminals, wire, relays, fuses, circuit protection devices, conduit, shielding, etc.) based on electrical load calculations, environmental conditions, cost targets, and industry standards (SAE, NFPA, KKK, etc.).
• Interface with suppliers to evaluate new technologies and ensure component availability and quality.

3. System Integration:

• Collaborate closely with mechanical, systems, and software engineers to integrate electrical harnesses with vehicle structures, powertrain, chassis systems, multiplex systems (e.g., CAN J1939), communication equipment, lighting, sirens, HVAC, and specialized emergency/medical equipment.
• Design power distribution strategies, including fusing, circuit breakers, and power management modules.

4. Standards Compliance & Validation:

• Ensure designs meet all relevant industry standards, regulations, and customer specifications, particularly NFPA 1901/1917 (Fire Apparatus), KKK-A-1822 (Ambulances), FMVSS, and SAE standards.
• Support the development of Design Verification Plans (DVP&R) and participate in design reviews (DFMEA).
• Assist prototype and production teams with harness installation, troubleshooting, and validation activities.

5. Documentation & Manufacturing Support:

• Generate and maintain accurate Bills of Materials (BOMs).
• Manage engineering changes through the ECN/ECO process.
• Provide technical support to manufacturing, procurement, and service departments regarding harness assembly, installation, and field issues.
• Apply Design for Manufacturability (DFM) and Design for Serviceability (DFS) principles.

6. Continuous Improvement:

• Identify opportunities for design optimization, cost reduction, and quality improvement related to electrical harnesses and systems.
• Stay current with emerging technologies, materials, and best practices in automotive and emergency vehicle electrical design.

Required Qualifications:

• B.E in Electrical Engineering, Electrical Engineering Technology, or a closely related technical field.
• Minimum of 3-5 years of direct experience in electrical wiring harness design for automotive, heavy truck, off-highway, or specialty vehicles.
• Proficiency with at least one major ECAD software package for schematic capture and harness design (e.g., Zuken E3 (strongly preferred), AutoCAD Electrical).
• Proficiency with at least one major 3D CAD software package for harness routing (e.g., SolidWorks).
• Solid understanding of vehicle electrical systems, power distribution, circuit protection, and grounding principles.
• Knowledge of wire harness manufacturing processes and best practices.
• Familiarity with relevant automotive/vehicle standards (SAE required).
• Excellent problem-solving and analytical skills.
• Strong communication (written and verbal) and interpersonal skills.
• Ability to work effectively both independently and as part of a cross-functional team.
• Proficient with standard office software (Microsoft Word, Excel, PowerPoint).

Preferred Qualifications:

• Direct design experience with Fire Trucks and/or Ambulances is highly desirable but does not essential.
• In-depth knowledge of NFPA and KKK standards related to vehicle electrical systems.
• Experience with vehicle multiplexing systems (CAN bus, J1939 protocols) and diagnostic tools (e.g., CANalyzer, P-CAN).
• Experience with high-voltage harness design considerations (relevant for EV/hybrid trends).
• Familiarity with harness testing procedures and equipment.
• Experience with PLM/PDM systems for data management.
• Knowledge of electromagnetic compatibility (EMC/EMI) principles and mitigation techniques.

Work Environment:

• Primarily an office-based role using standard office equipment.
• Occasional work may occur in a manufacturing or shop environment, potentially requiring the use of personal protective equipment (PPE) and exposure to moderate noise levels, vehicle components, and shop tools.