Engineer Mechanical

KAI ZHAO

**** ****** ***. ***. *** Phone: 248-***-****

Tustin, CA 92780 e-mail: *******@*****.***

SR. PRINCIPAL ENGINEER / CHIEF MECHANICAL ENGINEER

Solid and extensive knowledge in mechanical discipline. Strong background in both product development and

engineering analysis. 20 years practice in developing various mechanical products, from concept and numerical

analysis, to CAD design, through rapid prototyping to mass production launch. Proficient in design sophisticated

mechanisms, proven tracking record of developing complex mechanical equipment. Ph.D. degree received from

the University of Stuttgart in Germany, excellent analytical skills in various aspects:

Load / Stress Analysis Using Various Methods Machine Kinematics & Dynamics Analysis

Gear Design & Gear Loading Capability Calculation Material Fatigue Failure Analysis & Testing

Expertise in Tribology, Wearing & Lubrication Analysis Proficient in Geometric Dimension & Tolerance

PROFESSIONAL EXPERIENCE

ROCKWELL COLLINS ElectroMechanical Systems IRVINE, CALIFORNIA, USA 2008 Present

Sr. Principal Engineer

• Sr. Principal Engineer provides engineering analysis to the team. Key mechanism development, key

component design review. Working on the THSA project for Airbus, system tolerance stack up analysis,

mechanism kinematics analysis. Bearing fitting calculation taking thermal effect into account, especially the

effect of different material shrinkages in extremely cold environment.

SMC CORPORATION OF AMERICA DETROIT R&D CENTER MICHIGAN, USA 2002 2008

Chief Mechanical Engineer / Sr. Lead Products Development Engineer

• Chief mechanical engineer in charge of new industrial automation product development. Conceive and

develop concepts from blank paper. Geartrain, linkage and cam mechanism design, develop and optimize

the right mechanism for the perfect performance. Obtain very robust product, high efficiency, compact size

and low cost. One patent was applied in Mar. 2005 in USA, Japan, Germany and France. Another patent

was applied in Dec. 2006 in both countries USA and Japan.

• Provide expert engineering analysis. Load & stress analysis, parts strength verification, mechanism

kinematics and dynamics analysis, system durability and reliability analysis and evaluation.

• Organize and supervise engineering drawing creation. Finalize and release engineering drawings for

prototype making and mass production launch.

• Conduct product test and prototype performance evaluation. Take charge of developing test methods and

test equipment. Review the test results. Provides the right solution for improvement.

FEV ENGINE TECHNOLOGY, INC. AUBURN HILLS, MICHIGAN, USA 2000 2001

Mechanical Design Engineer

• Valvetrain kinematics and dynamics analysis, mechanism design for the multi-cylinder linear engine project.

Cam design. Load and stress analysis, part strength verification. Gear and bearing loading capability

calculation, dynamics balancing of planetary gearing system, high speed valve control mechanism

kinematics and dynamics calculation.

MAGNA INTERNATIONAL INC. TORONTO, ONTARIO, CANADA 1997 2000

Project Engineer, Product Testing & Validation

• Lead design engineer in charge of developing special testing equipment to simulate the true work condition

of gears in the car. Fatigue test machine design and engineering analysis.

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• In charge of product testing and validation. Focused on various fatigue testing but also includes other tests like strength

testing. Development of various test procedures for different components and different failure mode. Fatigue failure

analysis using various statistics and other engineering tools.

• Conduct the engine balance shaft driveline dynamics analysis, driving gear impact loads calculation.

Machine dynamic analysis, balancing of rotating masses and design parts with balance weight.

INSTITUTE FOR MACHINE COMPONENTS STUTTGART, GERMANY 1992 1996

Mechanical Engineer, Research in the Field of Geometric Dimension & Tolerance

• Research project in the field of Geometric Dimension and Tolerance, focused on 3D tolerance stack up

study and its solution. Manufacturing accuracy and deviation study and their effect on the part function

analysis. Machine kinematics analysis.

INSTITUTE FOR MATERIAL-HANDLING TECHNOLOGY STUTTGART, GERMANY 1989 1991

Mechanical Engineer

• Gear fatigue failure research with load collective, which means cyclical loading with variable amplitude.

Loading collective simulation and fatigue mechanism research.

• Test stand design. In charge of the development of a gear test stand, which was specially designed for the

above mentioned research purpose. Design of various Material-Handling systems.

APPLIED WEARING RESEARCH LIMITED KARLSRUHE, GERMANY 1988 1989

Mechanical Engineer, Tribology Specialist

• Motor vehicle engine wear research with special focus on piston ring and cam wear.

MATERIAL PROTECTION RESEARCH COMPANY OF WUHAN WUHAN, CHINA 1985 1988

Mechanical Engineer, Tribology Specialist

• Material wearing and lubrication research. Lead design engineer in charge of the development of a test

machine used in evaluating the load capability of lubricants.

EDUCATION

UNIVERSITY OF STUTTGART STUTTGART, GERMANY

Ph.D. in Mechanical Engineering (Focal Point: Geometric Tolerance Analysis), May 29, 1996

THE CHINESE NATIONAL ACADEMY OF MECHANICAL ENGINEERING WUHAN, CHINA

Master of Science (M. Sc.) in Mechanical Engineering (Focal Point: Tribology), 1985

SHANXI UNIVERSITY OF TECHNOLOGY FOR MECHANICAL ENGINEERING XIAN, CHINA

Bachelor of Science, in Mechanical Engineering, (Focal Point: Design of Print Machine), 1982

LANGUAGE AND COMPUTER ABILITIES

• Language Ability: English, German, Chinese

• CAD Design & FEA Analysis Tools: SolidWorks, Pro/Engineer, UG, AutoCad, CADKEY & ANSYS.

• Proficient in MathCad, Microsoft Word, Excel and other popular application software running in Windows

98, NT and Unix. Programming in C++ and Pascal.

REFERENCES Available upon request

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