Systems Integration Engineer

• Oct 2022 - Present

Simulation Engineer: Range and Efficiency

• Apr 2021 - Oct 2022

Saved 90% time in EPA range estimation by interfacing and automating Amesim simulation runs using Matlab/ Python. Increased 20% accuracy by building a power loss-based gearbox model to account for spin losses instead of efficiency. Improved 14% range by developing optimized F/R torque split maps, based on efficiency, with AWD dynamic disconnect. Built analytical tool with average vehicle model for range calculation from roadload curves to support coast-down testing. Created one-stop GUI in Python to run Amesim models for range, drive unit comparison, and energy breakdown analysis. Automated tire model coefficients and data format conversion process to switch in .txt/.mat/.csv/.xlsx/.xml formats. Developed automated visualization tools for loss map comparison, rangewalks, roadload blending, and AWD torque split. Show less

Model-Based Design Engineer

• Jun 2020 - Mar 2021

Built an ADAS feature of Adaptive Cruise Control using optimal control method, and integrated it with EV model in UniPhi Developed Li-ion battery model including hysteresis state and SOC estimation using Extended Kalman filter in Simulink Used Jenkins and TortoiseSVN for version control, test management, and continuous integration of Electric Vehicle model Prepared and managed requirements for Electric Vehicle model, and Performed extensive debugging using graphical tools Co-conducted webinar for 50+ participants to demonstrate the generation of error-free EV model from legacy Simulink models Show less

Graduate Research Assistant

• Sep 2018 - May 2020

Implementing Path Planning algorithms for an autonomous vehicle (AV #2) using Clothoids to ensure a smooth transition in path curvature. Also, optimizing the path to the shortest distance involving feasible maneuvers. Developing a Vehicle Dynamics model for transient conditions such as drift parallel parking and high-speed cornering. And, calibrating the Simulink model by determining tire and road load parameters using Machine Learning in MATLAB. Hence, a simulation environment will be developed to optimize the controller for different maneuvers. Generated energy maps to optimize the stopping distance at a Stoplight for the Chevy Volt Gen 2. Processed the OBD data in Matlab under the NextCAR project. Designed and fabricated an enclosure containing sensors and controllers for the AV #2 test vehicle along with mounted Speed sensor and Steering angle measurement sensor. Developed a prototype Autonomous Vehicle, designed use cases, validation strategies, and determined ODD limitations Performed test-runs and analyzed vehicle test data to determine parameters to implement Emergency Braking System Performed a Tire test rig simulation in MSC Adams templates to obtain Pacejka model fitting parameters and Tire stiffness Improved 20% in IMU sensor accuracy deriving custom calibration matrices using recursive filtering and data processing Gained familiarity with diagnostics using OBDWiz in PHEV testing, CAN tools, D-Space HIL testing and NI systems LABView Show less

ATA Design Engineer

• Jun 2019 - Dec 2019

Led team of 3 for the conceptualization of AT intake optimizing durability, cost by applying DFMEA, DVP project management 10% reliability improvement in AT intake baffle by subjective data analysis and Digital Logic method for design selection Reduced 40% catalyst breaking issue by dimensional variation and root cause analysis using Statistical tools- R, Minitab Saved 50% processing time in converting 300+ legacy assembly drawings into new format using statistical categorization Performed iterative CFD on AT intake and created simplified CFD workflow CTR for design engineers to do CFD in FLUENT Supported Komatsu ATA FEA for tolerance analysis to optimize the weld strength in model preparation using SpaceClaim Used PTC Windchill for version control and updating CAD models, engineering drawings, and publishing CTRs Performed Statistical analysis on the After-Treatment Assembly (ATA) to account for dimensional variations caused due to welding deformation. The standard tool was limited to its application on well-distributed data with control limits on either side of the Mean and Median value. However, due to welding, the Mean/Median values were shifted. Therefore, a new method was introduced in R and a technical report was released. Introduced Digital-Logic method into a design selection process to objectively specify relative weight of a parameter Show less

Research Assistant

• Aug 2017 - Jul 2018

Conceptualized an Electro-Magnetic Continuously Variable Transmission (EM-CVT) for 2-wheelers. The design increased the drive efficiency by 20%. Patent pending. Designed a Solar powered Quadricycle with Swappable battery charging technology. Increased the range to 400 km for a 4 seater quadricycle under city driving conditions. Developed and simulated a 3D model of an elevated car parking for energy harvesting using PTC Creo Conducted experiments for the Solar power heaters with Thermal Energy Storage (TES) tanks. Show less

Racing Driver

• Apr 2015 - Jun 2017

Best Racing Driver Award in BAJA SAE 2016 among 140 drivers with 200+ hours off-road driving. 11 Dynamic Awards and 3 National Championships with a total of 38 awards in 3 years. Fastest Lap timings in 4 out of 5 Endurance races. Driven dynamically varied vehicles from with Cutting brakes on open Differential to Spool gearbox with Anti-roll Bar and Anti-Ackermann steering. Represented India at International events at Tennessee Tech University TN, USA, Pittsburg State University KS, USA, and Caterpillar Testing Facility IL, USA. Show less

Chassis Design Head and Vice-Captain

• Apr 2014 - Jun 2017

Designed Tubular Space Frame Chassis for 3 All-Terrain Vehicles, ensuring driver safety and ergonomics, Design for Assembly (DFA) and Design for Manufacturing (DFM). Carried out CAE of the chassis through Static Structural, Shape Optimization and Modal Analysis. Also, formulated mathematical simulation for the real-time load calculations for front impact. Fastest Baja Buggy at BAJA SAE Illinois 2017. 14% increase in packing efficiency. 20% weight reduction and 30% reduction in build time. Implemented multi-material fragmented chassis concept, including sub-systems mounts made with Aluminium and Kevlar composites. Fabricated Kevlar composites in-house for Structural applications and aesthetics, including the mold. 400+ TIG Welding hours. Show less

Engineering Intern

• Dec 2015 - Jan 2016

2-wheeler assembly line optimization using a barcode scanning system. 2-wheeler assembly line optimization using a barcode scanning system.