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Controls Engineer

Columbus, Indiana, United States
January 16, 2018

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Vignesh Balachandran (open to relocation) 317-***-****


I have expertise in modeling and manufacturing of Automobiles. I gained hands-on experience on CAN J1939, OBD Testing, Calibration, Verification & Validation, HIL System testing through an SAE credentialed course in Automotive Functional Safety (ISO 26262). My background with engines helps me understand engine behavior. Adding this to my recent experience with Autonomous EV helps me to understand ICE vehicles as well as electric vehicles better


Hardware : Woodward ECUs, Kvaser CAN, Arduino Hardware

Software : MATLAB, Simulink, MotoHawk, MotoTune, HIL Systems, CanKing, NI LabVIEW, MES Examiner

CAD Software : AutoCAD, CREO, ANSYS, SolidWorks, CATIA v5, GD&T, NX CAD

Technical Skills : Six Sigma, OBD Calibration, Agile SCRUM, Problem solving and Analytical skills

Professional Experience:

Relevant Work:

Controls Engineer, Intern, LHP Engineering Solutions

(Oct’17- Present)

Led a team of 10, managed SCRUM meetings and provided weekly updates to the Team Lead

Programmed the Remote Control to manually operate the AEV

Modeled Autonomous EV (steering & Power train) control module using Simulink-MotoHawk (code-gen tool)

Calibrated steering system and drive motor using MotoTune (Calibration tool)

Developed models for GPS and IMU and implemented CAN communication with ECM

Implemented ISO 26262 Functional Safety by performing HARA and DFMEA

Troubleshot errors and Verified the Functional Safety compliance using MES Examiner tool

Controls Engineer Trainee, LHPU, Columbus, Indiana


Development of Speed Governor Control Models

Developed in Simulink minimum and maximum governor models for controlling engine speed

Performed Unit and System level Verification & Validation

Calibrated the PI gains on Model In Loop (MIL) using a plant model

Simulated the control model on Hardware In Loop (HIL) using MotoTune

Calibrated and tuned the engine using MotoTune calibration tool

Tested final control model on Cummins 5.9L ISB diesel engine at different load conditions

Development of Diesel Engine Speed Control System

Developed engine PI controller, plant model, and Engine Position Tracking (EPT) system for a diesel engine using MotoHawk, MotoTune, and Simulink

Performed OBD Calibration of a Diesel engine for different states (Stall, Crank and Run)

Executed gain scheduling and feed forward look up table for lower response time and stabilized engine speed

Electronic Throttle Controller (ETC), ISO 26262 and CAN J1939 Implementation

Developed a feedback PI model for ETC (bench test model) using Simulink and MotoHawk (code-gen)

Calibrated PI gains and stabilized electronic throttle and pedals position using MotoTune

Performed HARA and determined the ASIL, implemented ISO 26262 Functional Safety in the Control system

Developed test cases such as Power Failure test and Struck throttle valve test to detect failure

Controlled remotely the ETC using CAN Communication

Development of a Control System for an Electronic Actuator (Fuel Injector)

Developed a control system and feedback PI for an electronic fuel injector using Simulink and MotoHawk blocks

Calibrated the actuator using MotoTune calibration tool

Simulated the actuator control system for different engine speeds and tested on a fuel injector

Educational Qualification

Masters of Science in Mechanical Engineering

Purdue University, Indianapolis Aug’15- May’17 3.2/4

Bachelors of Engineering in Mechanical Engineering

Anna University, India July’11- May’15 3.3/4


Fundamentals of Automotive Functional Safety Control Systems using ISO 26262, SAE Certificate of Mastery Course, LHPU (Oct’17)

Automotive Functional Safety Training: Intro to LHP-TUV ISO-26262 certification

CAN J1939 Implementation

Electronic Throttle Control & ISO 26262 Implementation

Code Generation & Calibration Training

Diesel Engine and Controls Training (Speed Governing; Controls Modelling; System Diagrams and Wiring)

Agile SCRUM, Leadership, Stress and Conflict Management, IP Training, Teamwork, and Budgeting

Master in Product Design & Analysis, CADD Center (June’15)

AutoCAD, CREO, ANSYS, CATIA v5, SolidWorks & GD& T

Lean and Six Sigma Green Belt, Simplilearn (Sep’17-Present)

Mechanical Experience:

Manufacturing Engineer, Intern, Beacon Industries, Connecticut, United States

(June’17- Aug’17)

Modeled profiles in NX-CAD & generated CNC codes for Aircraft Engine parts

Optimized CNC codes and reduced production lead time by 3 hours

Tested and Validated programs on Facing, Turning & Milling machines

Design Engineer, Intern, Bharat Heavy Electricals Limited, India


Modeled in CREO & ANSYS Mandrel Plug and cooling system used in extrusion process

Selected optimal design using Design Failure Mode & Effect Analysis

Minimized cost by 40% and production lead time by 8 hours using Six Sigma

Design Engineer, National Go-Kart Championship, SAE, India


Led a team of 25, Modeled and simulated brake calipers and the chassis frame

Utilized tools such as CREO, ANSYS, MATLAB and Simulink

Finished 5th in the race nationally

Manufacturing Engineer, Intern, Murugappa Group, India


Programmed and operated ABB 6-axis robots

Created and documented Bill of Materials (BOM) for raw materials and tools required for the unit

Suggested replacing Line followers with 6-axis robots which resulted in reduced time, cost and labor

Manufacturing Engineer, Intern, Larsen and Toubro, India


Designed in CREO conveyors, welds for boilers and tested the weld defects

Created BOM and managed inventory for raw materials

Operated grinding, cutting, milling & drilling machines

Mechanical Projects:

Design of Automatic Center Stand


Modeled and simulated in CREO and ANSYS the Center Stand mount

Integrated components such as servo motor, Rack and Pinion assembly

Balanced the Stand statically and dynamically to lift 350 lbs.

Engine Assembly and Mechanism Simulation


Modeled in CREO Engine parts such as piston, sleeve, cylinder, crankshaft and connecting rod

Assembled and simulated Engine parts used in an Air-Circulator

3D Printing Technology


Modeled in RepetierTM different test parts

Programmed in MATLAB Arduino hardware and integrated it with Prusa-I2 kit

Calibrated and improved the printer accuracy by 60%

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