THAYALAN SHANMUGAM

-Company Overview: Consultant from TATA Technologies.

• Currently leading the Electric Power (EV) train Inverter, DCDC, ACDC, BMS verification and validation team for Polestar 3 and Volvo XC90 AWD vehicles.
• Preparing system verification plans and test cases to test it in High voltage test rig, and vehicle testing scenarios.
• Setting up the HV benches and vehicle with the required external sensors to verify electrical and thermal parameters
• Performing essential tests to validate Supplier Software delivery for each release.
• Analyzing the test log from different test environment using Matlab M-Script and Python scripts.
• Updating the Matlab Simscape Plant model based on test feedback from Vehicle and High voltage Dyno rig testing
• Defining software acceptance criteria, ensuring seamless integration of supplier deliveries, and alignment with project requirements.
• Conducted Functional Safety concept (FSC) testing based on TSC at the vehicle level, contributing to the overall safety and performance assessment of the Electric powertrain.
• Expertly prepared PRST (Product Requirement Specification Test) and SWRT (Software Requirement Test) documents for the test systems, ensuring comprehensive and efficient testing processes.
• Participating in HARA to provide feedback based on test experience/
• Performing detailed validation of E2E and SecOC testing on CANFD communication.
• Powertrain ECUs Software Download and Diagnostic testing using UDS protocol (ISO 14229).
• Implementing continuous integration (CI) strategies to facilitate seamless testing and integration processes.
• Employing a problem-solving approach to analyze issues identified during various tests, engaging with suppliers to facilitate timely and effective issue resolution.
• Maintaining test artifacts and verdicts using Systemweaver and Doors to keep track of each release testing.
• Participating in EMC testing to verify that complete electric powertrain meets EMC standards requirements.
• Demonstrating exceptional coordination with suppliers, actively managing system extracts, and clarifying functional requirements (SWRS), fostering effective communication and collaboration
• Managing project delivery processes following Scrum principles, ensuring timely completion and adherence to quality standards.
• Expertise in dSpace HIL system, vTestStudio, CANoE, INCA, CAPL, MATLAB, Python, MDA
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• Led a dedicated team responsible for the Matlab Model-based software development of HV Charger and Battery Management System (BMS) activities based on AUTOSAR platform
• Developed meticulous modeling guidelines and established rules using tools like Model Advisor and MXAM, ensuring a standardized and efficient development approach
• MATLAB based auto code generation and optimizing the design using Fixed point tools
• Leveraged MATLAB TargetLink and SPEEDGOAT for rapid prototyping, accelerating the development cycle while maintaining high-quality results
• Successfully coordinated efforts with diverse battery suppliers to strategize and construct Battery packs tailored for the EPT2020 platform
• Collaborated closely with cell manufacturers to meticulously define and establish comprehensive test cases, facilitating the meticulous selection of optimal cells for Alliance development
• Spearheaded the development of HV battery charger software, encompassing diverse charging standards such as COMBO, CHADeMO, GBT, AC Basic, V2L, V2H, and intelligent charging functionalities
• Engaged actively with system teams to consolidate and streamline functional requirements using DOORS, ensuring a cohesive development process
• Devised and presented comprehensive validation plans to both vehicle and Hardware-in-Loop (HIL) teams, ensuring robust testing and validation of HV Chargers
• Provided crucial support to a series support team, conducting in-depth analysis of field issues and delivering bug-fix software to ensure seamless milestone delivery
• Implemented innovative cost-effective strategies (Electrified AGV) that led to a substantial reduction in manufacturing costs at the RENAULT plant, contributing to enhanced operational efficiency

• Proficiently managed requirements using DOORS, conducting thorough requirement analysis and assessing the impact of design changes on inverter and DCDC, OBC converter ECUs
• Conducted comprehensive Edrive System Simulations (MIL/SIL) using tools such as MATLAB, PSPICE, PLECS, PSIM, and ASCET
• Inverter and DCDC converter control algorithm development using Matlab Simulink, Stateflow
• Closed loop controller gain optimization using Matlab tools Optimization and parallel commuting tools
• These simulations validated system concepts, facilitating effective hardware and software modifications.
• Some of the system concepts developed include IGBT switching suppression, variable switching frequency for power loss reduction, e-machine stator temperature estimation, IGBT protection, and e-machine rotor angle estimation.
• Provided crucial support to the project acquisition team by defining electric power train tolerances and performance benchmarks in alignment with OEM requirements
• Collaborated closely with the safety team to develop and review technical safety concepts, contributing to the overall safety assurance of the systems.
• Played a pivotal role in providing essential calibration parameters to the software integration team, enabling effective testing of Inverter ECUs.
• Sensor tolerance calculation to define the ASIL level for Electric power train as per ISO 26262.
• Supported the localization team in adapting power train components to meet India-specific requirements, showcasing adaptability and an understanding of local needs.
• Actively participated in various task force teams aimed at analyzing the root causes of field-reported complaints, demonstrating problem-solving skills and commitment to quality.
• Gained hands-on experience by working at HV test bench to rigorously test electric power trains, ensuring their performance and functionality meet high standards

• Led the comprehensive design and development of both hardware and software components for AC-DC Lithium ion battery chargers for Electric Vehicle, showcasing proficiency in both domains.
• Methodically validated P-spice simulation results through real-world hardware testing, ensuring alignment between simulated and actual performance.
• Successfully created and developed schematics, as well as carried out PCB development using industry-standard tools such as Cadence and Allegro software.
• Harmonic calculations for multilevel inverters, including H-bridge-based and diode-clamped inverters.
• Solar MPPT algorithm for integrating solar power into charging lithium-ion batteries.
• Demonstrated technical expertise by conducting conductive EMI/EMC (Electromagnetic Interference/Electromagnetic Compatibility) testing at the prestigious 'Society for Applied Microwave Electronics Engineering & Research' (SAMEER) laboratory