Gelam Saidinesh

R&D Engineer

Medha Servo Drives Private Limited

Hyderabad

09.2020 - Current

Axial flux motor
Thermal design and CFD of cooling system for Axial flux motors (30 kw) which is capable of dissipating heat flux
More than 50 W/cm2 by using ANSYS (and mathematical modeling of entire thermal system using octave and
C programming)
Complete Mechanical design of axial flux motor with includes both rotor and a stator (15 KW)
Project 2: oil cooled radial flux motor
Converted an existing water cooled ( water jacketing) radial flux motor of power rating 260 KW to an oil cooled (direct injection) and doubled it current rating and total power using ANSYS fluent (CFD)
Model preparation in Spaceclaim, Meshing and analysis in ANSYS Fluent with different topologies, interpreting results for further design changes
Project 3: Cold plates for IGBT cooling
Thermal and mechanical design of different cold plates which are used as heat sinks for IGBTs mounted in
The motor control units using ANSYS
Model preparation in Spaceclaim, meshing and analysis in fluent-steady state thermal
Coupled system
Project 4: Integration of Electric Vehicle ( gross weight of 65 ton dump truck)
Examined the functions of each EV subsystem and gained an understanding of the topology of an EV
Developed the layout for the vehicle level integration with the entire propulsion system while cooperating with the cross-functional teams and taking into account different factors like weight distribution, ideal wiring length, serviceability, etc
The mounting brackets for each integrated Subsystem were designed by performing structural analysis,
And optimized in ANSYS
Topology optimization was used for all the structures using compliance, weight, and stress as constraints
DFMEA like Shock, Modal analysis is performed for all the mounting brackets for all the traction and
Power subsystems to avoid failures and unwanted noise
Determined the primary vibration sources for the motor-gearbox assembly
To avoid having external vibrations excite the system modes, the appropriate vibration mounts
Were chosen using modal and harmonic analysis
Completed detail design and drawings
Lead the team for the complete integration and testing of the vehicle Multi-objective optimization is used to optimize the motor rotor profile
Determined the rotor design's current flaws and areas for improvement
Created manufacturing and geometric constraints in MATLAB and coupled ANSYS Mechanical with it for iterative runs in batch mode
A multi-objective optimization problem with electric efficiency and performance characteristics as objectives, stress as a constraint, together with manufacturing and geometric limitations, was designed
The optimization problem is solved using genetic algorithms
Rigid body dynamics
Performed rigid body dynamics for various transmission mechanisms like gear trains, propeller shaft to find the allowable miss alignments and complex angles by keeping reaction forces and input-output accelerations as constraints
Battery thermal management system
Performed thermal calculations to choose the BTMS's compressors, condensers, heat ex-changers, and other components
To simulate the system's performance, all components and system interaction are mathematically modeled in Octave
Simulated driving cycle circumstances are used to gauge real-world performance and establish the temperatures at which BTMS switches on and off
Successfully tested the unit in the electric vehicle after doing testing and validation on it on a test bed.

Summary

Overview

Work History

R&D Engineer

Education

Mechanical - Engineering

Intermediate MPC - undefined

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embed systems python Programming

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Skills

Certification

Timeline

R&D Engineer

th - undefined

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Mechanical - Engineering

Intermediate MPC - undefined

undefined

embed systems python Programming

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