Senthil Ram Nagapillai Durairaj

• Strengthened communication skills through regular interactions with others.
• Proven ability to learn quickly and adapt to new situations.
• Leading the engineering with primary focus on Materials, Magnetics, Mechanical & Testing,
• Design of PMSM motor for EVs and engineering release
• Customer handling for RFQ inquiry submission and Techno-feasibility evaluation through CAE for Vehicle aggregate finalization
• Detailed specification for Motor and controller requirements to meet Performance, Cost Optimization & Material Optimization
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• Passionate about learning and committed to continual improvement.
• Proven ability to develop and implement creative solutions to complex problems.
• Proven ability to learn quickly and adapt to new situations.
• Developed strong communication and organizational skills through working on group projects.
• Resolved problems, improved operations, and provided exceptional service.

Design

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• Design and Electromagnetic Analysis – Optimization – Validation – Evaluating the New Concepts through Simulation & Electromagnetic Analysis -Documentation.
• Design knowledge on PMDC Motor, BISG motors, and BLDC Traction Motor for EV & Starter Motor.
• Design& Electromagnetic analysis of innovative electric motors in various applications of Electric & Hybrid Vehicles & Structural, NVH & CFD Simulation Support for EV Powertrain
• Standardization & Complexity reduction

Development, Prototype & Testing

• Development of PMSM, BLDC Motor, DC Motor
• Light Weighting of the starter motor, PMDC, BSG, PMSM, and Suspension motor
• Standardization & Complexity reduction
• Development of magnets for 6Pole Motor /NdFeB Starter Motors

Magnetics

• Development of higher-grade Ferrite magnets for the weight-optimized Starter motor and power to weight ratio as well
• Magnet development for the EV, BSG, Alternator Rotors & Starters Magnets, Magnetic Application, Solenoid Design, Magnet selection, Magnetic Materials, and Sensors.

Material

• Magnets, Magnetic Application, Solenoid Design, Magnet selection, Magnetic Materials, Sensors.
• Material Specialist & Magnetic Analyst
• New & Alternate materials for BSG EV, Starters
• Standardization & Complexity reduction
• Expertise in Material selection for application-specific design including Metals & Metal Alloys, Polymers, Elastomer, Composites, Sealant, Adhesives, Coating, and Plating.
• BSG, EV, Starter & Alternator Material Template & Material Selection for the new starter and alternator application
• Alternate material for improved performance, low cost, and high durability and endurance
• Material Specialist & Magnetic Analyst
• Starter & Alternator Material Template & Material Selection for the new starter and alternator application

CAE

• Simulation using FEA Tools on Structural, Thermal, CFD, Electromagnetic, and Coupled Analysis.
• Detailed Analysis by Theory & FEA for Starters, Solenoid & Alternator

Failure Analysis

• Skillset on Failure Analysis of Material of Metals & Metal Alloys, Polymers, Elastomer, Composites, Sealant, Adhesives, Coating, and Plating, from chemical composition, metallography, microscopy, spectroscopy, SEM, NDT
• Material analysis for the new applications /failed parts

Skills: Mathematics · Communication · Mechanical Testing · Electrical Machines · Adhesive Bonding

• Introduced new methods, practices, and systems to reduce turnaround time.
• Evaluated suppliers to maintain cost controls and improve operations.
• Conducted 70 audits annually to keep store presentable and functional.
• Partnered with upper management in executing functional strategies and reporting capabilities.
• Implemented process improvement to shape organizational culture, optimize procedures for higher efficiency and help company evolve and grow.
• Supported general manager in loss prevention efforts.
• Liaised with team members, stakeholders and vendors to coordinate activities, provisioning, environment setup, risk mitigation and follow-up.
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NdFeB Magnets & NdFeB Magnets Quality
NdFeB Magnet Test Equipment
Evaluation of Supplier Quality
NdFeB Magnet Testing Methods
NdFeB Magnet quality inspection at incoming & inprocess
Development and Testing methods on NdFeB magnet
1.Finite Element Analysis for Airgap Flux Density on Wind Mill Generator
2.Measurement of Airgap Flux Density using Hall Sensor
3.Finite Element Analysis for Heat flow in the WEC to Study the Temperature effect on NdFeB Magnets during WEC working
4. Bonding strength between glue and NdFeB magnet by shear and pull
5. Establish Durability of NdFeB magnet by salt spary test method
6. Study on the coating thickness of PU on the surface of NdFeB magnet poles on the rotor
Cross Functional Team to develop alternative sources for magnetsMagnets & Magnets Quality
Magnet Test Equipment
Evaluation of Supplier Quality
Magnet Testing Methods
Magnet quality inspection at incoming & inprocess
Development and Testing methods on Magnet
Finite Element Analysis for Airgap Flux Density on Wind Mill Generator
Measurement of Airgap Flux Density using Hall Sensor
Finite Element Analysis for Heat flow in the WEC to Study the Temperature effect on Magnets during WEC working
Bonding strength between glue and Magnet by shear and pull
Establish Durability of Magnet by salt spary test method
Study on the coating thickness of PU on the surface of Magnet poles on the rotor
Cross Functional Team to develop alternative sources for MagnetsNdFeB Magnets & NdFeB Magnets Quality NdFeB Magnet Test Equipment Evaluation of Supplier Quality NdFeB Magnet Testing Methods NdFeB Magnet quality inspection at incoming & inprocess Development and Testing methods on NdFeB magnet 1.Finite Element Analysis for Airgap Flux Density on Wind Mill Generator 2.Measurement of Airgap Flux Density using Hall Sensor 3.Finite Element Analysis for Heat flow in the WEC to Study the Temperature effect on NdFeB Magnets during WEC working 4. Bonding strength between glue and NdFeB magnet by shear and pull 5. Establish Durability of NdFeB magnet by salt spary test method 6. Study on the coating thickness of PU on the surface of NdFeB magnet poles on the rotor Cross Functional Team to develop alternative sources for magnetsMagnets & Magnets Quality Magnet Test Equipment Evaluation of Supplier Quality Magnet Testing Methods Magnet quality inspection at incoming & inprocess Development and Testing methods on Magnet Finite Element Analysis for Airgap Flux Density on Wind Mill Generator Measurement of Airgap Flux Density using Hall Sensor Finite Element Analysis for Heat flow in the WEC to Study the Temperature effect on Magnets during WEC working Bonding strength between glue and Magnet by shear and pull Establish Durability of Magnet by salt spary test method Study on the coating thickness of PU on the surface of Magnet poles on the rotor Cross Functional Team to develop alternative sources for Magnets

Skills: Communication · Adhesive Bonding

• Roles & Responsibility # Magnets, Magnetic Application, Solenoid Design, Magnet selection, Magnetic Materials, Sensors
• Design knowledge on PMDC Motor, BISG, BLDC Traction Motor for EV & Starter Motor
• Magnet development for the EV, BSG, Alternator Rotors & Starters # Expertise in Material selection for application specific design including Metals & Metal Alloys, Polymers, Elastomer, Composites, Sealant, Adhesives, Coating, Plating
• Skillset on Failure Analysis of Material of Metals & Metal Alloys, Polymers, Elastomer, Composites, Sealant, Adhesives, Coating, Plating, from chemical composition, metallography, microscopy, spectroscopy, SEM, NDT # Light Weighting, New & Alternate materials for BSG EV, Starters #, # BSG, EV, Starter & Alternator Material Template & Material Selection for the new starter and alternator application # Material analysis for the new applications /failed parts
• Key Contribution:
• Development of magnets for EV Motors, BSG, Starter Motors
• Failure Analysis of Material
• Material selection for application specific design

• Design of sensors based on technical input,
• Design, analysis and calibration of Sensor
• Mathematic Modelling
• Business development and strategic planning,
• New project design,
• implementation and execution,
• New technology initiatives,

• Developed strong communication and organizational skills through working on group projects.
• Worked effectively in fast-paced environments.
• Managed time efficiently in order to complete all tasks within deadlines.
• Delivered services to customer locations within specific timeframes.
• Challenged to handle the design, analysis and calibration of Hall Effect Throttle Position Sensor (HE-TPS).
  Actively involved in the Design and FE Analysis Solenoid Air By-pass valve for two wheeler
  Handled the Magnet development, magnetization and measurement of HE-TPS Magnet and the Mathematical modeling of Design, Analysis and Development of Solenoid for Fuel Pump Application, Throttle Valve Actuation
  A key person for the Mathematical modeling of Design, Analysis and Development of Solenoid type Exhaust Gas Recirculation valve for four wheeler
  Instrumental in Magnetic Sensor Development for Electronic Governor Control
  Responsible for the Magneto-Rheological Fluid preparation and characterization for Active suspension cum vibration damping system.
  Design and development magnetic perpetual motion device/ alternative energy system

• Worked flexible hours across night, weekend and holiday shifts.
• Used critical thinking to break down problems, evaluate solutions and make decisions.
• Excellent communication skills, both verbal and written.
• Worked well in a team setting, providing support and guidance.
• Actively involved in the Design and Analysis of multipole Magnetizing Fixtures for Multi-Magnetic Profiles, Magnetic measurements and Calibration.
  Assigned responsibility of Magnet and respective Magnetizing Fixture Development & Design Calculation
  Ensuring implementation of ISO 14001-1996 (Environmental Management System) & OHSAS 18001-1999 (Occupational Health Safety Assessment Series)