MADHU YACHAMANENI

With 13+ years of experience, currently serve as a Lead Engineer (Mechanical) at Eaton India Innovation Center in Pune. Expertise lies in the design and development of electromechanical equipment, including EM Actuators, Drive systems, and servo Gear boxes. Successfully taken projects from initial specifications through to prototype qualification.

Actively seeking a full-time Lead/Manager role within a Technology Solutions Company. Drawn to challenging opportunities that allow to leverage technical and functional skills effectively. Goal is to advance career growth with the support of a forward-thinking organization.

DFSS – GB certified per Eaton internal certification process

• Unigraphics (NX10) – 3D Modeling, Assembly & Drafting.
• ProE – 3D Modeling, Assembly & Drafting
• AutoCAD 10.0 - Concepts, layouts and 2D drawings.
• KISSsoft - Simulation of planetary gearbox (spur) as per DIN, ISO & AGMA.
• Ansys-18.1 (Workbench) –Structural, Modal and random vibration analysis.

1. Leading the Technical Integrated Product Team (IPT): I oversee cross-functional teams, including Mechanical, Electrical, Electronics, CDP&T, and RMS teams.

2. Conducting Technical Discussions with Customers: I engage in technical discussions with customers, addressing their queries and ensuring alignment between the customer and project teams. I maintain consistent communication with both the customer and global teams.

3. Project Scheduling and Alignment: I create and present project schedules and milestones to customers, ensuring alignment with their expectations.

4. Mentoring Engineers: I guide engineers in concept creation, design, and component sizing for the Electromechanical Actuator (EMA).

5. System-Level Architectures and Interfaces: I define system-level architectures, interfaces, boundaries, and functions based on data packs and requirements provided by the customer.

6. Innovative Concept Creation: I develop innovative concepts and propose solutions to address customer challenges.

7. Concept Evaluation and Selection: I analyze different concepts, perform qualitative and quantitative comparisons (using tools like the PUGH matrix and concept tradeoff), and select the most suitable concept for the application.

8. DFSS Artifacts: I create Design for Six Sigma (DFSS) artifacts, including Boundary diagrams, P-diagrams, Design Failure Mode and Effects Analysis (DFMEA), and sensitivity analyses.

9. Scope Definition for Analysis: I collaborate with the CDP&T (Customer Design and Product Team) to define the scope for analysis, track progress, and schedule reviews for analysis results.

10. Product and Technology Roadmaps: I contribute to creating product roadmaps and technology differentiators.

11. Supplier Interaction: I engage with suppliers, addressing technical queries related to procurement and testing.

12. Analytical Calculations and Reports: I perform analytical calculations for components and create stress and sizing reports.

13. Gear Profile Design: I design gear profiles following DIN and AGMA standards.

14. Lead Screw Selection: I choose between ball screws and roller screws based on load, speed, and accuracy requirements.

15. Tolerance Stack-Up Analysis: I perform tolerance stack-up analysis for dimensions and assign tolerances to key dimensions.

16. Environmental Compliance: I ensure product design compliance with MIL-STD-810F and DO-160F environmental standards.

17. Manufacturing and Assembly Knowledge: I possess knowledge of manufacturing and assembly processes for gearboxes and BLDC motors.

18. Supplier Interaction and Deviation Handling: I engage with suppliers to explain requirements and understand any deviations. When deviations occur, I conduct Material Review Board (MRB) assessments to analyze their impact and provide necessary waivers.

19. Technical Reviews and Approvals: I actively participate in technical reviews, including Preliminary Design Review (PDR) and Critical Design Review (CDR), presenting to the chief engineer for approval.

20. Electronics and Electrical Interface Integration: I ensure that mechanical configurations align with the requirements of electronics and electrical interfaces, ultimately achieving the desired final function.

21. Failure Investigation and Root Cause Analysis: When failures occur, I collaborate with multi-functional teams to investigate root causes and develop solutions.

22. Product Lifecycle Management (PLM): Proficient in Enovia, I manage the product lifecycle, create Change Orders (CO) and Change Requests (CR), and release drawings and documents within the Enovia system.

23. Requirements Management: I utilize Jazz DNG for requirements management, ensuring seamless flow-down of requirements across the project.

24. Test Plan Creation: I am capable of creating development test plans, acceptance test plans, and qualification test plans and procedures .

Electro-Mechanical actuator for Air borne Launcher : The Linear Electromechanical Actuator (EMA) finds application in airborne launchers. Its primary purpose is to rapidly actuate the launcher mechanism within an astonishingly short time frame of less than 0.3 seconds, thereby releasing articles from the aircraft. The EMA comprises several essential subsystems:

1. Lead Screw Mechanism: This component plays a critical role in converting rotary motion into linear motion, facilitating precise movement.

2. Transmission Mechanism (Gear Train): Responsible for transmitting power efficiently from the motor to the actuator.

3. Brushless DC Motor: The heart of the EMA, providing the necessary force and speed.

The EMA is meticulously designed to withstand an axial force of 500 kgf and achieve a linear speed of 300 mm/sec. Its critical-to-quality (CTQ) parameters include stroke time, weight, and envelope dimensions.

Electro-Mechanical actuator for Flap System : In aircraft systems, the Linear Electromechanical Actuator plays a crucial role in the Flap system. Its primary function is to deploy and retract the flaps. Flaps serve as a secondary flight control system, contributing to lift during takeoff and creating drag during landing. As an individual contributor, I was involved in conceptualizing the actuator. I presented these concepts to the chief engineer and later to customers, ultimately selecting the final concept for detailed design. This process included finalizing the gear ratio to meet load and speed requirements while ensuring the actuator fit within the customer’s specified envelope. Additionally, I reviewed detailed designs, stress analyses, and sizing reports prepared by colleagues. Furthermore, I assessed the DO-160F requirements relevant to the actuator and developed a sealing plan based on this assessment. The selection of static and dynamic seals was guided by specific operational needs.

Electro-Mechanical actuator for Spoiler System : The spoiler actuation system is designed for mid-size business jets and serves multiple functions on the aircraft. These functions include air braking during cruise, roll adjustment, and speed braking on the ground. As the name suggests, these spoilers disrupt the airflow and create drag when their panels extend. This reduction in speed is crucial during both cruise flight and landing.

In this project, we are replacing the conventional hydraulic actuator with an electromechanical actuation system (EMA). The primary critical-to-quality (CTQ) requirement is ensuring a fail-safe function while meeting the specified failure rate probability set by the customer.

My responsibilities include:

· Leading discussions with the customer regarding innovative concepts.

· Proposing the pros and cons of different concepts and submitting a comprehensive report.

· Facilitating discussions on the Statement of Work (SOW).

· Defining test plans for development phases, demonstration phases, and overall scope of testing.

· Leading the Global Integrated Product Team (IPT) to execute the project plan.

· Integrating cross-functional teams to ensure timely completion of milestones.

· Creating architectural boundaries and defining interfaces for both mechanical and electrical components.

· Engaging with customers to align the system’s functions with their requirements.