Jun 2019 – Aug 2019 · 2 mos

Jan 2019 – May 2019 · 4 mos

• Investigated CAN Compatibility of Maretron Compass SC2000 by studying and implementing NMEA 2000 & 0183 CAN protocols and commanding to the device using CANKing
• Developed Wiring diagram for the Kart, Sized Fuse, Resistors, Capacitors, Contatcors, Switches as per the circuit
• Developed motor Command Subroutines for RoboteQ Motor Controller to command the Brushed DC Motor and accepting input from ECU over CAN to run the Motor
• Communicated to the motor Controller through RS232, 485 and CAN to check for the best way to transfer more data at the same time
• Evaluated CAN Compatibility of Race Grade Inertial Measurement Unit (IMU) by sending and receiving messages through CANKing and Calibrating the Values on Moto tune
• Built Simulink model using Motohawk Blocks to generate logic and communicate through the ECU
• Tested position obtained by integrating the accelerometer and gyroscopic data obtained from IMU by Setting a Zero reference on the ground and checked if the IMU detects the Zero Position

Sep 2018 – Nov 2018 · 2 mos · Pontiac, Michigan

• “Fundamentals of Automotive Functional Safety Control Systems using ISO 26262” SAE Certificate of Mastery Course.
• Implemented MATLAB, Simulink, MotoHawk (Similar to dSPACE), MotoTune, CANKing (similar to CANalyzer / CANoe) to implement PI Control Loop to achieve Duty Cycle from Acceleration Pedal Position (APP) and Throttle Position Sensor (TPS) through 48 and 128 pinned ECUs
• Trained in CAN Communications (J1939 Protocol), code generation, and troubleshooting of the system
• Studied Flexray, LIN, TTP automotive network communication protocols which are commonly used to govern on-board automotive computing
• Developed state machine for stall/crank/run/overload states and calibrated engine for different states
• Utilized & implemented different techniques to improve PID Controller model (Gain Scheduling, Saturation, Anti-windup) & designed PID controller, plant model and engine position tracking (EPT) system for a GM Ecotec 4 stroke 2.4 Liters gasoline engine
• Calibrated and tuned the engine using MotoTune to avoid any instabilities while entering the minimum and maximum governor when the engine RPM increases
• Manipulated P and I gain on a min/max governor to eliminate transient state error using model in loop (MIL) Simulation
• Hardware in loop (HIL) testing to validate engine modes and speed governing models for gasoline engine
• Involved with corporate Functional Safety team to define goals, developed DIA to define deliverables
• Developed HARA, ASIL, FMEDA, FTA, SPF analysis and test methods for multiple failure mode using ISO 26262 standards
• Performed case study of automotive functional safety (ISO 26262), safety assessment and validation of the safety lifecycle using the V-Model approach
• Demonstrated traceability from requirements to test results & working alongside with OEM technical team visitors

Jun 2015 – Aug 2015 · 2 mos · Pune Area, India

• I was assigned the task to improve the machining cycle time for Engine Block Machining in Flexible Manufacturing System Cells(FMS) .
• The engine Machining FMS Cell was not efficient enough to reach the daily targets it used to do when it was new.
• Detected Problems in Tool Design, machine faults and Troubleshooting by going back to old G and M codes of the Machine and inspected about the change in tools and alternative tool geometries.
• Coordinated with Tool design Team, Inventory Supervisor, Line Supervisor and Line Workers about the change in data and implementation
• Implemented the alternative tool combination for each FMS machine and noted the change in Cycle time, Followed the improving trend till optimum time was achieved.
• Increased the Number of engine blocks machined per day (3 Shifts) by 108 Units. Target achievement Percentage increased from 58% to 70%.
• Helped maintenance department in daily maintenance tasks.
• Learning Outcomes: Kaizen, MUDA, Data Acquisition, Coordinate Measurement on CMM.

Aug 2014 – Aug 2015 · 1 yr · India

• Designed and built a Go kart for the championship from scratch.
• Considered the Maximum Speed Allowed on wheel and the constraints of the event set by FIA to Design the Powertrain system of the car
• Calculated the max Load to Pull and Payload to design the chassis which could Sustain 5g Front impact, 2.5 g Side and Rear impact.
• Innovated an Automatic Fire extinguisher System which would Turn on the Fire Extinguisher in case of Fire and would Provide enough time for driver to leave the car
• Prepared the Business Plan, DFMEA, Ghantt Chart for the Car
• Software Used
• Chassis design: using Nx Cad 9.0 and Catia V5 R20
• Analysis : using Ansys Workbench

Jul 2014 – May 2015 · 10 mos · India

• Designed and built an All Terrain Vehicle (ATV) for the championship from scratch.
• Considered the constraints set by SAE for the event and tests.
• Tackled problems regarding excessive weight of Suspension Components.
• Used Ansys 14.5 Toplolgy Optimization to reduce mass for the rear Swing arm.
• Designed 1 Stage Reduction Gearbox and an FNR with Selection of a CVT Transmission System for the Specified engine.
• Designed the Roll cage in Unigraphics NX 9.0 and CATIA V5 R20. Performed all Crash Simulations Static and dynamic Analysis on ANSYS Workbench for Front, Side, Rear and Roll Over Impact with 5g, 3.5g, 2.5g and 2.5g G forces respectively. Considered the U.S. Military Handbook for Ergonomics for driver Safety.
• Thermal and Torsional analysis done on the Brake Disc and Rotor.
• Chassis design: using Nx Cad 9.0 and Catia V5 R20
• Analysis : Ansys WB 14.5 and Lotus Simulation.

Jun 2014 – May 2015 · 11 mos · India

• Designed and built a Go kart for the championship from scratch.
• Considered the Maximum Speed Allowed on wheel and the constraints of the event set by FIA to Design the Powertrain system for maximum Fuel Economy of the car
• Calculated the max Load to Pull and Payload to design the chassis which could Sustain 5g Front impact, 2.5 g Side and Rear impact.
• Awarded as "Most Economic Vehicle" in the event, Place Overall 5th among 60 Teams.
• Prepared the Business Plan, DFMEA, Ghantt Chart for the Car
• Software Used
• Chassis design: using Nx Cad and Catia V5
• Analysis : using Ansys WB