Palo Alto, California, United States
As a self-starting engineer, I’m passionate about multidisciplinary engineering applications (AI Compute/Robotics/Aerospace/Automotive/Stationary Storage). I have a love for making impactful products and a strong curiosity to understand how things work. I have gained fundamental skills and valuable experience in mechanical product design, DFM (forming, subtractive & additive manufacturing), designing thermal solutions for power electronics converters and components, integrating HV/LV electronics with mechanical systems, motor mechanical/rotordynamics design (experience with SPM/IPM machine rotor design and manufacturing), thermal-mechanical design of magnetics components and power semiconductor devices for power electronics converters, electrical sliding contact design, and project management. From a personal perspective, I am looking for exciting opportunities to reinforce my passion for designing products that incorporate technological innovations into a simple and elegant solution for users. As I continue to develop as a multi-faceted engineer, I want to play an active role in robotics and compute hardware technology development.
•Robot Hardware Architecture & Actuator team •Working on actuator hardware design, modeling, and integration for humanoid robots •TMR and Inductive Encoder and motor electromagnetic modeling and mechanical integration •Mechanical design and stress modeling of rotor components and planetary geartrain to optimize mass, reduce rotational inertia, and increase volumetric power density •Thermal interface design for motor and power electronics within the actuators (TIM material selection and characterization) •Actuator characterization testing and reliability analysis
•Working on Power Electronics Systems (Residential Power Converters) •Lead Mechanical Engineer for power electronics converter in all Powerwall 3 variants Directly owned the following: • integrated planar magnetics transformer thermal-mechanical design and modeling • discrete magnetics component thermal-mechanical design and modeling • LV power semiconductor device multiphysics modeling and first-principles analyses (parasitics, loss, thermal, stress/strain) • thermal management system and thermal interface modeling/design/validation (thermal interface materials, heatsink, heatspreaders, thermal controller and derating policy) • Residential Power Electronics ME system HW requirements and specifications • Co-owned electrostatic and AC magnetic field quasistatic modeling for planar magnetics and overall PCBA to evaluate E-field distribution/dielectric breakdown, parasitic capacitance, dielectric loss estimation, B-field distribution, and EM losses • Support thermal modeling and electronics packaging design for inverters and stators in humanoid robot linear actuators
•Working on Energy and Vehicle Power Electronics Systems (Residential Power Converters, Optimus Charger, Wireless Charger) •ME Lead for power electronics converter in Powerwall 3 •Own thermal and mechanical design of integrated planar transformers, discrete magnetics components (inductors, transformers, chokes), power semiconductor devices, and electrical sliding contacts/connectors for the power electronics converter in Powerwall 3 •Designed plastic injection molded insulators and winding bobbins, busbar and sliding contact sheet metal stampings, and high pressure die casting heatsinks for high volume power electronics converters •Own thermal management interface design for residential power electronics converters (Thermal Interface Materials, Thermal stackups, Forced Convective Air-Cooled Heatsinks, Heatspreaders/Heat Pipes) •Led thermal improvement initiatives for Powerwall 3 to reduce power electronics system unreliability% by over 50% from previous generation of power electronics •Own component thermal modeling and system-level CFD modeling for residential power electronics converters (AEDT Maxwell & Icepak, Fluent, StarCCM) •Own thermal characterization and validation for residential power electronics converters •Working with EE, FW, Magnetics, EMC, Reliability, and System Architecture teams to define design specs/requirements for the power electronics converter in Powerwall 3 •Support preliminary thermal architecture concepts and design analysis for next generation Optimus charger power electronics converter
•Power Electronics Mechanical Design (Summer-Fall 2023) •Working on Vehicle and Energy Power Electronics Systems (Powerwall 3, Wireless Charger) -Contributed to the next-generation power converter for Powerwall 3 through the following projects: • Owned new molded magnetics electromechanical connection design + DFM • Owned thermal and mechanical design of new distributed air gap inductor design concepts • Lead cross-functional efforts with suppliers for low viscosity potting encapsulant TIM development • Owned SMT current sensor busbar and PCB trace thermal characterization, SMT magnetics reflow adhesive testing, transformer TIM thermal testing and validation, planar magnetics insulator spacer testing, HV/LV MOSFET transient thermal impedance characterization • Owned electrical sliding contact development and thermal characterization • Provided design support and RCA for production ramp of Powerwall 3
•Power Electronics Mechanical Design (Fall 2022) -Working on Energy Power Electronics Systems (Powerwall 3) -Working on next-generation power converter (chokes mechanical design + DFM, AC/PV connector pins design and testing, transformer core adhesive testing, PCBA reflow carrier fixture design, PCBA pin insertion fixture design, MOSFET Thermal Interface Stack TTI Testing, thermal validation/characterization units)
•R&D Motor Dyno Engineering - Core Technology (Summer-Fall 2021/Spring-Summer 2022) -Designing powertrain and motor dynamometers used for performance characterization, performance validation, and durability/reliability testing of Tesla motors, actuators, and drive units -Performed FEA simulations (thermal, electromagnetic, static/dynamic loads) on components of Optimus absorber motor dynamometer to optimize 1) motor thermal management solution and 2) component stiffness, strength, and fatigue life while shifting vibrational modes with high structural resonance past high-end operating range of 200 Hz (12000 rpm) -Owned mechanical design and integration of LV Motor Dyno for Optimus actuators from concept to manufacturing to validation -Owned mechanical design of SPM Absorber Motor Rotor with extremely low torque ripple including the rotor shaft, rotor laminations, segmented magnet stack, balance end plates, 3-pole resolver rotor, CFRP sleeve, and various mechanical interfaces between these components to aid DfM/DfA + torque transmission/high speed operation -Mechanical design and DFM/DFA/tolerance analysis of SPM absorber motor stator housing including cooling sleeve sealing solution, resolver integration, endbells, and stator mechanical interfaces -Owned mechanical integration of SPM absorber motor stator laminations and winding as well as phase junction/lugs
• Leading an engineering team of 60 students spread across 6 subteams to build an electric, formula-style racecar • Leading the integration of all subassemblies and components onto the vehicle with consideration for weight distribution, and DFM/DFA • Developing an in-depth manufacturing plan for all mechanical components on the vehicle along with implementing proper application of GD&T and tolerance analysis to reduce stack-ups • Marshal the team's technical resources to maximize vehicle performance • Leading research, development, and design of new accumulator battery pack and in-wheel drivetrain • Started Berkeley’s first Formula Student Autonomous Driving R&D team
• Chassis Subteam (Founding Team Member) -Designed and optimized an adjustable, hybrid regenerative/hydraulic braking pedal box to provide driver with mechanical advantage and consistent brake feel -Designed a redundant, hydraulic power transmission circuit to provide biased brake force to the front and rear wheels -Created Matlab script and GUI to 1) calculate the required brake pressures and input forces and 2) model and better understand braking performance for our 2021 car -Led the integration of braking components onto the chassis spaceframe assembly and wheel assembly along with sensor fusion to aid the development of our traction control system and vehicle simulation model -Designed and ran coupled-thermomechanical simulations on floating, steel brake rotors -Created fastener design specification and selection criteria along with comprehensive fasteners standard parts library -Leading the design of a modular dynamometer to test various parameters for braking, dynamics, and powertrain (brake pad temperatures, rotor temperatures, coefficient of friction, braking torque)
-Educated the team on proper practices and standards (adhering to ASME Y14.5-2018) when drafting engineering drawings for components and assemblies -Created standard sheet format and drawing templates for teamwide use -Drafted team's official competition submission for 3-view drawings
• Designed test platforms and thermal solutions for power converters, PCBAs, electromechanical components, and other high density power electronics assemblies used in defense installation • Performed thermal FEA simulations on liquid-cooled inductors (varying potting encapsulant, TIM, & enclosure material) to determine the optimal configuration, reducing steady state temperatures by ~20C • Designed and ran thermal tests on liquid-cooled inductors; these tests allowed us to reduce our component costs and lead times by assessing the steady state thermal performance of inductors manufactured and potted in-house • Designed & prototyped a 1U air-cooled Diode Rectifier & Resistive Load unit used in testing of production LRUs and R&D prototypes by converting grid 3-phase AC input to a fixed DC output • Designed & prototyped a Line Impedance Stabilization Network (LISN) used in testing of production LRUs and R&D prototypes by 1) providing precise impedance to power input for UUT to quantify amount of noise in the system and 2) functioning as a low-pass filter to provide high impedance to undesired high-frequency noise, preventing it from coupling in the system • Created an NCR matrix for root cause analysis of over 1000 non-conforming parts which informed production managers on necessary changes to production processes and COTS component selection