ARJUN M

Roles & Responsibilities: Battery Pack Hardware (HV Vehicle)

• Feasibility studies for repositioning and packaging existing Battery Pack to improve performance of vehicle considering mechanical and battery requirements.
• Identifying cells from Lithium-ion supplier and justifying choice to ensure that the targets of performances (energy, power) are met by cells.
• Cell selection based on cost, chemistry & application.
• Based on Battery State of Art, developed efficient cell layout and created multiple mechanical CAD design proposals
• Review of Battery Pack Cell Layouts, Bus Bar design with respect to packaging constraints.
• To lead HW design and release of pack battery (packaging, weight, HW durability).
• Design and development of plastic, sheet metal & die casting parts for BATTERY PACKS
• Working on Thermal Management To design and release the venting/degassing & thermal components (cooling plates, pipes, gap filler, thermal pad).
• To lead and to achieve internal packaging of battery pack (physical architecture) while optimizing layout of all sub-components and respecting all technical rules.
• Direct Coordination with Clients for Deliverables (Milestones, gates reviews) on projects.
• Organize and review DFM, DFA, DFS, & DFMEA for BATTERY PACK components.
• Planning, organizing and overseeing development activities on daily basis to support testing and validation of BATTERY PACKS
• Work closely with suppliers in evaluation of DFM, optimization of designs and fine tuning with respect to tooling feasibility.
• Examine functionality and assembly feasibility of components at proto-release and improve design at different build stages of program
• Work closely with CFTs to support process optimization and VAVE activities.

Roles & Responsibilities: Electro-Mechanical Hardware Design (2,3 & 4-Wheeler Vehicles)

• Feasible Packaging study to design and accommodate sheet metal products in EV Platform.
• Safe, Robust and Durable Sheet Metal structure design for whole new powertrain (integrated transmission & MCU), steering and suspension systems, Axles, Cooling unit, IPDU).
• Rectangular/Circular sheet metal tubes design for Cradle with New/Existing standard materials.
• Complex Brackets design & development as per general sheet metal and stamping processes.
• Design and Development of Casting Enclosures/Covers as per manufacturing feasibility (PDC/GDC).
• Developing Component by understanding functional requirements of Electrical/Wiring Harness/Thermal & other CFT teams.
• Mechanical design Modifications as per PCB and its subcomponents Capacitors, Mosfets, Inductor, Transformers.
• Worked on Parts fixation with different fasteners as per torque and functional requirements.
• Providing Detailed machining areas on Casted component wherever required for assembling various electronic/mechanical subcomponents.
• Solving challenging areas like Heat dissipating fins, Fan and its guard installation and Sealing areas.
• Working on Heat Dissipation ideas based on CFD feedbacks by providing heat sink/Potting materials near Inductor/Transformer areas.
• Developing Parts with given studio surface to maintain Styling requirements.
• Design and Development of Plastic Enclosures as per different casting/molding process.
• Hardware design and sealing considering Ingress protection understanding (IP67/ IP65/ IP40).
• Internal and External DFM, DFS, DFMEA, DFA meetings and reviews with respective CFTs, Suppliers to achieve deadlines.
• Continues discussion & involvement with suppliers on making component feasible for manufacturing.
• Supplier Visits for Raw material check, manufacturing process details & Proto builds.
• Involved in Testing and Validation for all components and assembly of parts for positive takeaways in future.

Commodities: Climate Control (Plastic ducts, AC VENTS, Heating and Cooling lines)

• Designing Experience with good understanding on CLIMATE SYSTEM, HVAC Process, and Refrigeration Cycle.
• Good Understanding on HVAC Components (Compressors, Condensers, Expansion Valves, Evaporators) and its working.
• Designing Experience in HVAC Plastic components (Ducts, Housings) with manufacturing feasibility.
• Designing Experience of Aluminum and metal AC Pipes with manufacturing feasibility knowledge.
• Good Understanding in CFD (Pressure drop, Velocity, Air flow, Uniformity).
• Design Experience on AC Vents, Fresh air inlet components.
• Developing Mountings features with respect to feasibility in different Moldings processes.
• Experience in designing parts with BLOW MOULDING & INJECTION MOULDING feasibility.
• Completing DFMEA, DFA, and CAE analysis for designed components.
• Good knowledge of climate Component selection for passenger and commercial vehicles.
• Involved in Supplier selection for Raw Material and further process of RFI, RFQ.
• Packaging Study for New Vehicle Program, developing Ducts with available space and by maintaining minimum duct cross sections for required air flow.
• Developed Ducts using environment parts as input.
• Developed proposals with given standards and maintaining clearances w.r.t environment parts.
• Design experience in INSTRUMENTAL PANEL, DEMISTER & DEFROSTER DUCTS.
• AIR VENTS MECHANISMS using CATIA kinematics.
• Modifications following CFD analysis reports.

Project commodities: Ford Explorer (Interior Cockpit components)

• Product development feasibility check considering tooling, manufacturability, assembly, Packaging.
• Developing Proposals by considering theme surface (studio surface).
• Checking the manufacturing feasibility of the A-surface with given tooling direction.
• Offsetting surface w.r.t to input surface to create B-surface maintaining uniform wall thickness.
• Clearing patches / tangency errors that are on B-Surface.
• Developed feasible 3D solid model considering Ejection/draft angle from core and cavity.
• Developed engineering features like (Ribs, Snaps, Doghouse, Hinges, mountings, gussets)
• Checking clash and clearance between environmental data.
• Master section w.r.t surrounding parts for easy understanding of assemblies.
• Developed 2D for multiple plastic and sheet metal component with GD&T application.
• Avoiding the part defects by considering design guidelines.
• Ensured proper gap and flush with respect to surrounding parts.
• Modifications in different stages as per the new requirements of the client.