HEMACHANDRARAO AMPOLU

• SOR understanding and finalization for the 14 kWh High Performance bike project, aligning customer requirements with technical deliverables
• Contributed to E/E architecture definition for seamless integration of battery systems
• Designed Battery packaging for 14 kWh including: Extruded Aluminum enclosure,Injection-molded cell holder,Fusible link Busbars, Serpentine liquid cooling system,Structural module mounting, Battery Disconnect Unit (BDU) Integration
• Developed a comprehensive Excel-based design calculator for
electrical, thermal, and mechanical validation—scalable across all
Battery projects in the Organization
• Conducted initial feasibility studies across multiple customer SORs
• Created standardized, scalable battery pack designs through
component Standardization (cells, modules, BDUs) for cost and
design efficiency
• Designed a 35.3 kWh Modular Battery pack for electric buses and
trucks as part of the standardization initiative

• Design of Battery Pack for Small Commercial Vehicles (43.2 kWh), L5N (16.2 kWh), L5M (12.8 kWh) & e-Rick (6.4 kWh).
• Integration of specific voltage, capacity, and performance requirements for each vehicle type.
• Focus on energy efficiency, compact design, and operational safety in varied environmental conditions.
• Battery Pack Design & Cell Packaging Layout: Creating an efficient design for the battery pack and optimizing cell packaging for space and safety.
• Benchmarking: Comparing and evaluating various cells, modules, and packs to ensure the best fit for performance, reliability, and efficiency.
• Design Calculations: Performing detailed calculations for components such as base plates, pressure plates, cooling systems, and thermal pads to ensure optimal performance and heat management.
• Busbar Design: Ensuring that busbars are accurately designed for proper current distribution and electrical safety.
• Wiring Harness Design: Developing the wiring layout to ensure efficient power transmission and signal integrity across the system.
• Battery Disconnect Unit (BDU): Designing a safe and effective disconnect unit that enables proper battery isolation during charging and discharging.

• Responsible for the creation of 3D models and 2D drawings for the Injection Moulded Plastics, Extrusion, Sheet Metal & Die Casting Components for Li-Ion Battery for the Model of DEFY (90 kWh).
• Design and Development of Battery components including Battery housings, Base Plate, Bus bars, Mounting brackets, Cell Holders, Cooling tubes, Extrusion members & Pressure Plates etc.
• Selection of materials through Ashby methodology and manufacturing processes that are cost-effective and meet design requirements.
• Good technical drawing practice to create new drawings with complete part and assembly definition and Create quality, error free drawings and maintain a mutually acceptable of quality rating.
• Addressed design challenges and evaluated alternative design models to meet project requirements.
• Conducted technical evaluations of engineering designs and test results.

• Responsible for the creation of 3D models and 2D drawings for the Injection Molded Plastics, Die-Casting & Sheet Metal Components for 2W.
• Design and development of Battery components such as Front, Back Panels, Cell Stack, Tab Holders, Enclosures, Sealing for meeting the product requirements and physical compatibility with related sub systems, ensuring quality, cost, weight targets and product development milestones.
• Good at related tasks like GD&T, design for manufacturing (DFM) & design for assembly (DFA).
• Developed prototypes using rapid prototyping methods such as 3D printing or CNC machining for efficient validation of form, fit, and function concepts before mass production launch.
• Identified opportunities for cost reduction through material selection and process optimization, increasing profitability without compromising quality.
• Developed comprehensive design documentation, facilitating seamless transition from concept to production phase.
• Communicated with vendors and key suppliers to select project materials and meet customer needs.

• Gear box with gear ratio of 22.40:1 was designed.
• Calculation of gear characteristics for manufacturing of the gears.
• Determine initial sizing for gearboxes based upon torque requirements, customer existing envelope.
• New Concept Development of Casings, Shafts, Gear pairs, bearings etc..
• Preparation of 3D models of the gear box internals, casings & assembly.
• Generation of manufacturing drawings & quality checking for casings, gear pairs & internals along with assembly drawings taking care of fits, tolerances, surface finish, materials, manufacturing process involved & other parameters.
• Carry out mechanical design work including 2D layouts, 3D CAD modelling, stress, and mechanical design calculations, FMEAs, 2D detailing, agreeing the design approach with the project Chief Designer.

• Modification, maintenance of patterns and core boxes to reduce the defects in end castings.
• Knowledge of N.C Milling, lathe, drilling, air grinding machines.
• Knowledge of 5s principles used on floor shop & Core shop problem solving to reduce the defects in cores.