XINGMIN (SIMON) CAI

ad2kmj@r.postjobfree.com (preferred contact) Mobile Phone: 860-***-****

SUMMARY

Subject Matter Expert in Mechanism synthesis, Kinematics, Actuator and Actuation.

An expert in application of PLM/CAD/CAE techniques for design and engineering solutions, in development of engineering process, and data exchange protocol with using CATIA V5/ENOVIA, SolidWorks, CREO 4, UNIGRAPHICS/Teamcenter.

Valuable experience in structure analysis, fatigue analysis, damage tolerance analysis, repair substantiation.

Proficient in Product ideation, Product specifications, Design, FEA, kinematics and mechanism synthesis, tolerance; Design for six sigma and Lean manufacturing; APQP, FMEA, Statistical Process Controls; GD&T; Gage R&R etc.

Collaborated with many product integration teams in development of commercial aircraft engine system, aerial delivery system, aircraft landing gear system, automotive seating, automotive convertible roofs, automotive interiors, and electronic control unit.

Designed products in mass production such as in automotive industry and electronics manufacturing as well small volume production such as aerospace components. Designed components manufactured by machining, injection molding, stamping, forging, casting, bonding and welding processes.

PROFESSIONAL EXPERIENCE

L3Harris Technologies Inc., Wilmington, MA 5/23/2022-Present

Senior Specialist Mechanical Engineer

.Opto-Mechanics, Mechanisms, GD&T Checker, Qualification Test Plan for Spacecrafts.

Eaton Corporation, Grand Rapids, Michigan, 3/18/2019-5/18/2022

Project Lead, Actuation system.

Actuator and Actuation system designs and solutions for Flight controls and Thrust Reverser Controls.

Mechanical system analysis, which is driven by actuators, for inputs of actuator requirements and performance.

Develop general concepts of architecture, CTQs for electrical actuation systems

Derive requirements for actuator from loads, strokes and the times for completion of the strokes; size actuator and specify electrical motor requirements.

Add details to architecture diagrams for controls, communications, sensors and feedbacks etc.

Derive specific requirements for devices such as no-backs which prevent back-driving from aiding loads; for load limiters to protect structures once there are jams or other impacts; for locks to secure positions.

Derive system requirements for actuation system and actuators.

Do actuation system reliability studies to learn if redundant arrangements are necessary.

Generate input data for simulation with AMESim.

Costs, weights, trade studies, and down selection for design option.

Design electrically-controlled lock with CREO 4 for modeling or selection of bearings, shafts, seals, spring, fasteners, motor, housing, ball screw etc. Verifying by manual mechanics analysis.

Hydraulic Control Valves, Compliance to requirements, Documentation for certification.

United Technology Corporation, East Hartford, Connecticut, 12/01/2010-03/15/2019

Lead Engineer for Design Integration 12/2010-09/2014

Create design interface requirements between mechanical modules of commercial aircraft engine system, define specifications and interface control drawings, Analyze tolerance stack-up and quality for propulsion system and actuation systems.

Thrust Reverser Actuation System, TRAS loads, safety, reliability, and design integration.

Write process documents of product data management, releases in Teamcenter PLM system, data conversions between different CAD systems such as UG/NX, CATIA V5, Solidworks, and product data exchanges with customer and supplier.

Plan budgets and costs control, and lead a contract service firm for product data management, design releases, production releases, and data conversion with conformity to the process procedures.

UG NX and Teamcenter Engineering are used for design integration and Product Data Management.

Lead Engineer for Structure Analysis, 10/2014-03/15/2019

Structure analysis on engine cases / kinematics structures in engine compressor system. Assembly Finite Element Analysis, linear and no-linear, rigid body and flexible body, normal constraints and kinematics constraints, ANSYS, ABAQUS.

Motion accuracy analysis of compressor variable vanes which are controlled by synchronization ring and actuator with consideration of elastic deformation.

Low cycle and high cycle fatigue life, serviceable limits and repair limits for engine overhaul.

Lead and coordinate with Partners for structural analysis of variable stator vane actuation system, Bleed valve actuation system,

Analyze actuator loads for maneuvering operations. Specify actuator capability, slew rate and other requirements.

Belcan Technical Services Inc. Novi, Michigan, 07/2009-11/2010

Contract Lead Design Engineer

Design an electrically controlled mechanical lock system for aerial delivery system with kinematics analysis to ensure that the system is actuated properly in 4 modes of delivery.

Do functional performance analysis of 4 modes along motion paths with combining tolerance and kinematics to ensure that tolerance is properly allocated.

PCE Industry Inc., Los Angeles, California, 11/2007-12/2008

Senior Deputy Manager for sales and Operations on mass production of iPhone and laptop computer

Provided planning, direction, and decision for the operation of a manufacturing business unit of the company. Gave directional instruction in cost analysis, pricing, quotations and negotiation.

Led manufacturing operations, capacity planning, supplier, inventory management and lean Manufacturing.

Reviewed product data with Solidworks system to ensure that product specification are met.

The manufacturing operations include injection molding, sheetmetal stamping, machining processes, pressure casting in Desktop/Laptop PC enclosure parts and assembly

The Boeing Company, Everett, Washington State, 09/2005-10/2007

System Engineer for 787 Landing Gear

Work with suppliers on designing electrical actuators in B787 Braking system.

Do system testing on software, electrical and mechanical systems to verify if system performance requirements are obtained.

Attend technical meetings with suppliers, review technical reports of design, analysis and testing on stress, fatigue life, kinematics, thermal distribution, and tolerance.

Review design models, drawings through CATIA V5/Enovia LCA.

Johnson Controls, Plymouth, Michigan, 01/2004-08/2005

Staff Engineer

•Design an electrical actuator of gear box and motor for seat automation of the third-row stowflat in Ford Expedition and Navigator Vehicles.

•Do modeling, mechanism synthesis, cable design for motion control in mechanisms with CATIA V5.

•Perform DFA, GD&T, PDFSS (Product Design For Six Sigma) with assumption of variation and tolerance.

IDEM Tech, Inc., Contract to TGNA, Sterling Heights, Michigan, 02/2003-12/2003

Project Engineer

•Coordinate testing and FEA, do Gage R&R testing for correlation analysis to pursue supplier FEA certification from General Motors

•Design automotive seals of injection molding parts, modeling and drafting with UNIGRAPHICS NX2/Teamcenter.

Dura Convertible Systems, Inc., Adrian, Michigan, 01/2000-01/2003

Design Engineer

•Create BOMs, product structures and part lists; design parts for component commonality to save tooling cost.

•Explore concept design options of mechanisms on automotive convertible roof systems

•Design of hydraulic driving systems which are combine hydraulic pump and hydraulic actuators.

•Do much hands-on work on part modeling, surface modeling, drafting and GD&T markups with CATIA system.

Easi Engineering Inc., Contract to General Motors, Warren, Michigan, 04/1998-12/1999

Project Engineer

•Perform stress, strain and thermal analysis on automotive engine components with calculation and FEA.

•Apply FEA based techniques to simulate sheetmetal assembly.

•Predict distortion and variation of elastic deformation in datum locating, assembly clamping, welding with FEA techniques.

•NASTRAN, ABAQUS, HYPERMESH, UNIGRAPHICS and Teamcenter are used.

The University of Michigan, Ann Arbor, Michigan, 02/1994-12/1996

Research Investigator

Assigned to work in General Motors and Chrysler Assembly Plants.

•Process measurement data statistically from Coordinate Measurement Machine, analyzing deviation, six sigma variation, and process capability, finding statistical patterns and plot statistical charts.

•Troubleshoot problems of fixture locating, and other failures.

•Troubleshoot problems on assembling sheetmetals of automotive body-in-white, and fitting the panels of hood, fender and decklid.

•Propose actions to problems, and report evaluations of the actions to plant engineers.

•Computational geometry, NURB, C/C++ programming

Beijing Institute of Technology, Beijing, China, 04/1988-01/1994

Associate Director

Teaching and research in mechanical design, GD&T and engineering graphics.

•Do researches on splines, spline surfacing, NURB, Class A surfacing.

•Develop algorithms and CAD system software, C/C++ programming.

•Teach engineering graphics, mechanical design and Computer Graphics.

EDUCATION

•Master of Business Administration, Business Administration,

Wayne State University, Detroit, Michigan

•Master of Science, Mechanical Engineering,

Kettering University, Flint, Michigan

•Master of Science, Computer Graphics,

Beijing University of Aeronautics & Astronautics, Beijing, China

•Bachelor of Science, Mechanical Engineering,

Chongqing University, Chongqing, China

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