Rajesh Kumar Thirupathi

Develop a chassis systems where a driver would not feel anything while riding over bumps.Support the ideation process while identifying gaps in the current product or manufacturing technology to guide and provide future R&D efforts. Evaluate technologies and product designs with compliance to scientific principles, engineering principles, company standards, customer requirements, and related specifications

• Design and development of P42V SUV vehicles components
• Improved product quality by conducting detailed design reviews and implementing necessary changes
• Streamlined the design process for increased efficiency by utilizing advanced CAD software tools (UG NX)

• Ride and Handling parameters control as per Toyota standard way of objective and subjective criteria, Spring & Damper tuning for ride, roll and pitch behaviors, ride frequency, roll stiffness, roll degree, Analyze spring and damper communization across variants, Road load data accusation from reference vehicle and predict the input load estimation for fatigue life, L screen durability analysis, tramping test analysis, damper low & high speed damping force settings to meet better handling and worked on A3 documentation.
• Plan and lead the chassis parts development create 3D model and 2D drawing of chassis parts and suspension assembly drawing.
• Study vehicle clearance with CATIA assembly models and actual vehicle test results.
• Calculate vehicle height and other simple suspension specifications and verify them by actual vehicle measurement results.
• Verify the cost and mass of chassis parts and propose reasonable value to suppliers and purchasing division.
• Control chassis parts evaluation in suppliers' and TMNA evaluation divisions and analysis of the results
• Check the supplier's mass production process and propose improvements
• Work directly with other design divisions and evaluation engineers and Japanese counterpart divisions to determine root cause and countermeasure.
• Make some documents (PPR, ECI etc.), following TMNA official way
• Periodically regulatory checks and update the documentation for each milestone changes

• Experience designing and developing chassis sub systems for passenger and commercial vehicles with various manufacturers, including Renault, Local Motors, Aston Martin, OLA, DANA, Arcimoto, Aspark (Hyper Car), Royal Enfield, and Aptera.
• Expertise in steering and suspension hard points, rack force and arm load estimations, kinematic analysis of turning circle radius, bound and rebound travels, steering catchup and assist performance estimation, suspension ride frequency and wheel rate optimization, understeer and roll gradient finalization, steering linkage efficiency and Ackerman error optimization, chassis stiffness and aggregate parts stiffness target fixing, steering, suspension & tires, and bushings specification finalization.
• Assessed vehicle dynamic behavior through analytical and virtual analysis and ability to solve problems with a variety of methods and tools, such as 5Y
• Responsible for chassis tuning, calculations, measurements, integration of chassis sub systems, correction and fine-tuning studies based on tire models and calculations.
• Prepared force moment data and testing specifications and interacted with suppliers for vehicle targets.
• Worked on stopping distance estimation, panic braking simulation, foundation brake design and development, brake actuation/control systems, low drag hydraulic brake system, heat dissipation improvement, pad life estimation, brake field failure issues analysis, disc brake vibration study and optimization, brake noise level optimization, brake squeal analysis, brake hose and pipe routing, hose selection, layout optimization, and working on new technologies such as IBC, EPB, and braking in electric vehicles.
• Involved in slalom, figure of 8, single lane, and double lane simulations and optimization through suspension, steering, tires behaviors, DMU management, Clash and Clearance study, Skeleton model preparation and packaging optimization, Ergo study for Passenger, installation & service, vehicle layout preparation, and rake angle and trial design based on benchmark and stability targets.
• Involved in ride and handling evaluation, column design and development, steering effort calculation, part drawing, assembly, installation, torque requirements analysis, and part level DVP preparation.
• Managed project performance, cost, margin, and effort variants, as well as tracking control parameters, and risk analysis and mitigation plans.
• Component Level DOT Compliance tracking for Safety critical components
• Regulatory Comparison study for current version and revised version of standard
• Gap Analysis / CAD Verification with design team to ensure Zero Non-compliance against the regulatory norms
• In depth study on Chassis specific regulations like FMVSS 106, 106, 109, 110, 116, 117, 129, etc.
• Comparison of ECE Regulations and FMVSS regulations to understand the stringency of FMVSS regulations and its positive on road users.
• Preparing Regulatory Roadmap to have visibility of Upcoming regulations which might cause a huge design impact to current sale models or existing models.
• Segregating Regulatory list for Passenger cars based on its applicability – Vehicle level , Component level
• Preparing detailed Homologation plan to successfully complete self-certification
• Preparing test matrix based on worst case criteria and listing down no. of vehicles required to achieve cent percent test completion.
• Test coordination with Technical services companies like UTAC, ATIC HORIBA MIRA etc.
• Maintaining FMVSS Test Matrix for the test reports obtained.
• Comparison of FMVSS Crash specific regulations (eg: FMVSS 208) with upgrading NCAP crash protocols.
• Maintaining a Regulatory database to keep track of old and new regulations.

• Focused on designing frames, covers, and facades for Hydra and Atellica US products.
• Worked on size, cost, and application requirements, finalized regulatory requirements, designed panels and panels, selected locking and storage systems, and analyzed load and vibration levels.
• Implemented cost-effective designs using VAVE approach, prepared drawing and shape data, selected paint and coating, and confirmed sensor and moving parts packaging.

• Involved in the design and development of steering, suspension for Nissan Motors India (JPN/PRC/NA/EUR).
• Designed and conducted reviews with Quality Assurance, Manufacturing, and all other parties involved in the project.
• Designed change release activities, reviewed activities, layout confirmations, NVH, thermal, brake noise level optimization, and squeal analysis.
• Worked on vehicle packaging, tolerance stack up, VAVE and cost reduction activities.
• Suspension ride frequency target setting, roll gradient target setting, Motion ratio, bump steer, suspension travel requirements, damper tuning, spring stiffness, bump stopper stiffness Anti dive, Anti lift, Anti Squad, camber caster, roll center changes confirmation.
• Steering system performance, linkage efficiency, Ackerman percentage, Wheel angles, steering stiffness, Steering Assist and catchup performance, rake stroke, tie rod articulation and strength, ball joint articulation confirmations.
• Prepared concept sheet and technical file (RFQ), Verified part development, quality check procedures, master development schedules based on regulatory requirements identified in CFT discussion, vehicle spec variants master sheet, and was involved with Part & Tool communication activities, Digital Data Storage, BOM, Installed Drawing, service manual, and involved with homologation activities.
• Teardown and Benchmarking Documentation.

• Analyzed client engine lubrication requirements based on duty cycle, prepared pump discharge and flow rate calculations, and provided specifications.
• Worked on oil pump design, CAE evaluation, process chart, and manufacturing stage drawings.
• Proto built and tested until optimization, involved in drawing release and test result approval.

• Worked on integrating a 3-cylinder engine into a bench-marked vehicle. Focused on fuel line, exhaust, electrical harness routing, and engine mounting design.
• Conducted durability studies, joint studies, and optimized the design.
• Implemented dual controls in a nano for driving training applications.
• Designed pedals for optimal operation, fabrication, durability cycle studies, and released them for mass production.
• Integrated a turbo charger, evaluated the engine in engine bed, and designed layouts and packaging in vehicle.
• Converted existing vehicles to high performance, reverse engined a bench marking vehicle, designed a hydro static transmission, listed agricultural applications, and designed attachments for convertible applications.
• Worked on prototyping and evaluating prototypes, and produced mass production with suitable suppliers.