K P A CHAITANYA 5-205/1, Chintal, HYDERABAD
+919700781667 • [email protected]
Summary
Detail Oriented, highly motivated engineer with years of experience in major projects and developing innovative processes.
Proven ability to excel in cross- functionality product design in collaboration with multi-disciplinary domains. Committed
to highest standards of quality control with focus on innovative modelling and consistent experimental analysis. Instrumental
in improving efficiency and minimize the costs, works independently with minimal guidance and enjoys contributing as part
of a team
Core Skills
◊ 3D-CAD Modelling (Catia, Creo, SolidWorks, Auto CAD) ◊ GD &T ◊ Reverse Engineering ◊ Star CCM+, Ansys
Professional Experience – (6 years, 5 months )
I. Asst. Manager (Application) at Exide Leclanche Energy Pvt Ltd (From 08/2019 to Present)
Work Responsibilities: -
1. Design calculations for charge discharge rates, cooling rates iterations, Choosing of Cells as per the applications.
2. Design from concept level as per the specs required with all required certifications for High voltage applications
like Cars and Buses using Pouch cells.
3. Testing and validation procedures for the battery pack as per required certifications.
4. Customer interactions for proposals, and tech-commercial offering.
II. Senior Engineer at Exicom Power Solutions Ltd (From 07/2018 to 07/2019)
Projects Involved: -
1. 3.75 kW.hr/6kWhr Battery pack design [Client – Kinetic]
a. Using prismatic LFP cells, Design from concept level to product level design considering the
manufacturing easiness.
b. Thermal calculations, thermal cell behavior study to understand the cell expansion consideration for the
pack level design.
c. OEM cell supplier discussion to understand the scope and make a feasible design of the cell holders,
Selection of appropriate Thermal foam, compression pads.
d. Design of Aluminum extrusion/ enclosures for the battery pack. Vendor interaction, understanding the
DFM feasibility, and cost reduction schemes.
e. Vehicle side integration study and design of the pack.
f. Overseas experience with Chinese Cell manufacturer for design of the battery pack.
g. Testing of the battery pack, thermal foam testing, assembly line check, vibration and IP testing as per the
AIS and ISO standards for the pack and release for production.
h. Wiring Harness testing check for BMS board and all the power cables.
III. R & D Team Member at Sun Mobility Pvt Ltd (From 12/2017 to
06/2018)
Projects Involved:-
1. Design of 1.5kW.hr Pack
a. Cell holder design for prismatic cells, cell bending tools for staking the cells while assembly.
b. Design of Aluminum extrusions considering the number of fins required to increase the heat transfer
through natural convection.
c. Thermal study of the Battery pack to understand the amount of heat generated during charging and
discharging. Thermal calculations for selection of thermal foams/ pads.
d. Structural analysis monitoring of the battery pack to check end plates deformations.
e. Re-Designing the End plates after the analysis results, to withstand 3000 N force due to cell expansion.
f. Design of Battery pack assembly prototype tools.
2. Vehicle Integrations
a. Design of the wheeler dock to place the battery pack in the vehicle.
b. Wear test study of the dock and the Battery pack for 10000 cycles of insertion.
c. Selection of the material for the wheeler dock, thermal calculations and testing of the dock to give a good
thermal insulation to protect the Battery pack from rise in temperature.
d. Vehicle side integration of the dock for easy swapping of the Battery pack.
e. Structural simulation of the Battery pack to determine the deformation at 3G loads conditions and
Sudden and gradual loads.
f. Plastic part design ( Dock) considering the DFM Check feasible for injection molding.
3. Thermal Study of the Wheeler Station
a. Thermal heat transfer Load calculations of the wheeler station, Design of the Station, structures for
cooling the Battery packs.
IV. Project Engineer at NFTDC, A govt R & D center (Under Aegis of Ministry of Mines) (From 06/2014 to 11/2017)
Project involved:-
1. Mechanical Design of Electric motor (BLDC motor and Induction Motor). [Client – Tata Motors]
a. Generating Preliminary concept designs, material selection and design of Motor Casing, Rotor shaft, End
bell caps and Motor adaptor plate.
b. Bearing selection for the motor depending of the RPM and life.
c. Generating Bill of Materials, drafting using ASME 14.5M and ISO, using GD & T, and mechanical
fabrications and assembly of the motor,
d. Design and fabrication of dies (punch and blanking) for lamination cutting of stator and rotor.
e. Client interaction, dealing with vendors for quotes and fabrications.
f. Responsible for complete fabrication, assembly and delivery.
2. Design of Electronic Control unit for Electric traction motor. [Client – Tata Motors]
a. Design of jigs and fixtures for brazing of bus bars with semi-conductor devices.
b. Design of Heat sink, coordinating with the electrical team for the required inputs.
c. Material selection and design of Heat sink by performing thermal calculations supported by thermal
analysis to maintain them at the optimum temperature.
d. Generating Bill of Materials, manufacturing drawing, drafting using GD & T (ASME 14.5M and ISO
standards), and fabrication and the final assembly of all the components.
3. Retrofitting and mechanical integration of a 4 –wheeler into an Electric vehicle (Design of Li-Ion Battery Pack)
a. Reverse engineering of the Car body for calculation of the space available and CAD modelling.
b. Design of casings for battery pack cover using Sheet metal, design of fluid lines for the cells.
c. Li-Ion Battery packaging design iterations for reducing the weight of the battery pack compartments
along with BMS and cooling arrangement design.
d. Thermal Analysis of the Battery pack for checking the fluid flow rates required for cooling.
e. Design of Gear Box by making modification and conversion from 4 speed to 2 speed hear box, by
calculating the forces and torque required for the vehicle.
4. Design of Solar Parabolic trough collector’s structure of 2 meter aperture and 7.2 meter length producing
14.5 kW.
a. Design, stress and thermal analysis of structures for 7.2 meter long parabolic trough and receiver tubes
and mountings.
b. Casting of GRP petals for making the collector petals, by understanding the shrink rate and making a
feasible design.
c. Structural analysis of the frame and Heat transfer fluid and flow rate calculations, by using the
calorimeter design and measurement of flux at the receiver point.
d. Trough fabrication and assembly by implementing DFMA concepts for time reduction while assembly of
frame and structures.
Reverse Engineering Works:-
1. Complete Body reverse of Car body for finding the available space in the car for battery pack placement.
2. JoTruck transmission line
a. Gear box disassembly and generating drawings of the driving gear and driven gear, gear box casing,
driving shaft and couplings.
3. Cold Rolling mill( to increase the width of the roller)
a. Study of the rolling mills side pillars, material handling space and power drive.
b. Calculations required for design of new rollers with increased length and power calculations.
c. Reverse engineering of the whole rolling mill, shaft and generating manufacturing drawings by
applying GD & T and material selection for the rollers
V. Research Intern at NFTDC (From 2013 to 2014)
VI. Teaching Assistant at CMR College of Engineering and Technology (From 08/2011 to 09/2012)
Work Highlights:-
a. Teaching the subject of engineering drawing/Machine drawing for the Students of B.Tech 1st Year and 3rd Year.
Education Details
M.Tech Solar Thermal Energy - SRM University (Gold Medalist) – 9.26 GPA (2012 to 2014)
B.Tech Mechanical Engineering - DVR College of Engg and Tech (JNTUH) – 69.79% (2007-2011)
Key Skills & Competencies
Self-learning and initiation of tasks allotted
Experience of interpreting specifications and preparing project Reports.
Ability to multi-task in a demanding engineering environment.
A strong track record in delivering projects on time and within budget.
Awards & Recognitions
Best paper award at a National Conference conducted by MNRE
Other Personal Details
1. Full Name : Kotha Pramod Ankala Chaitanya
2. Date of Birth : 29th June 1990
I hereby declare that the above furnished details are true to the best of my knowledge.
K P A CHAITANYA
