Automotive Systems Engineer

ASHRAY BHUJANGA SHETTY

**** ********** **, ***. ***, DEARBORN, MI – 48126

Mobile: +1-313-***-**** E-mail: ********@*****.*** https://www.linkedin.com/in/ashray-bhujanga-shetty-11729810b

CAREER OBJECTIVE AND SUMMARY

Automotive Systems Engineering graduate aspiring to have a growth oriented & challenging career in the fields of Hybrid & Battery Electric Vehicles, Powertrain Dynamics and Calibration, Power Electronics, NVH, Vehicle Ergonomics, Vehicle Dynamics, Battery Management Systems and Vehicle Integration where I can contribute my knowledge & skills to the organization and enhance my experience through continuous research, learning & teamwork.

1+ years of experience as a Powertrain Calibration Engineer and Research Engineer-Power Electronics

2+ years of experience in Vehicle Dynamics, Vehicle Testing & Controls, CAD, CAE, and Project Management.

Experienced Team Lead of a BAJA SAE team with a history of working in Vehicle Testing at BAJA SAE INDIA from 2017-2018.

ACADEMIA

Master of Science, Automotive Systems Engineering Apr 2020 Bachelor of Engineering, Mechanical Engineering May 2018 University of Michigan, Dearborn GPA: 3.74 Visvesvaraya Technological University, Karnataka, India GPA: 4

GRADUATE COURSEWORK

Automotive Powertrains I & II

Hybrid Electric vehicles

Systems Engineering

Power Electronics

Vehicle Ergonomics & HMI

Electric Machines & Drives

Energy Storage Systems

NVH

Automotive Manufacturing Processes

PROFESSIONAL EXPERIENCE

Research Engineer-Automotive Power Electronics, University of Michigan-Dearborn SEP 2019 -Present

Worked on a project called "Predictive control of an electric powertrain based on a flexible voltage control of a non-isolated DC-DC converter." under Dr. Taehyung Kim, where I developed and investigated an electric powertrain and control system in Simulink using Simscape driveline and power system.

An interleaved structure was brainstormed to accommodate both energy sources i.e. supercapacitor and battery with a control logic that operates these energy sources according to the specific drive cycle and preset conditions. The average total power loss is 0.6% of the average power transmitted by the electrical system. The load on the battery is reduced due to the presence of an additional energy source during high torque requirement periods, thus increasing battery life.

Developed a bi-directional DC-DC Buck-Boost converter model and implemented new deigns, researched new electrical circuits to optimize and efficiently control the converter using voltage and control-based PI control strategy.

Devised the selective Buck-Boost control strategy to control the converter output voltage using Simulink for constant operation of the vehicle.

Performed model in loop (MIL) simulation and model code generation in MATLAB/Simulink to check model performance.

Contributed actively in weekly meetings. Documented test plans, design, analysis and computer modeling prototype test scripts, and results.

Powertrain Calibration Engineer, UMD Racing, Dearborn, MI. (Formula SAE Team) Sep 2018-Jan 2020

Developed an Electro-Pneumatic System to control the Clutch and Sequential Shifter and calculated the forces and torques required for actuation of both, the clutch and the shifter.

The Electro-pneumatic system helped us in reducing the effort seen by the driver while shifting and substantially improved the lap-times thereby increasing performance during the dynamic events.

Part of the DYNO testing team where I was involved in post test data acquisition and processing.

Aided in the Design and optimization of Powertrain System, light weighted the assembly and reduced installation and service time. Assisted Suspension and Steering Team in troubleshooting the alignments.

Vehicle Dynamics Engineer/Technical Head, Redline Racing, Bangalore, India. (SAE BAJA Team) Aug 2015-Mar 2018

Played a key role and developed experience in the design and fabrication of a cost-effective ALL TERRAIN VEHICLE for SAE BAJA 2017 and BAJA 2018 where I understood the criticality of Suspension and Steering Kinematics, Vehicle Dynamics, Systems Integration and Vehicle Testing.

Spearheaded the Suspension sub team and part of the frame team, where I aided to assess, redesign, analyze and manufacture the ATV frame and suspension system with a focus on increasing durability and reliability from previous renditions.

Succeeded in making the 2018 buggy more durable and dependable. In addition to that the buggy was able to reach a top speed of 65 kmph with a reduced weight of 170 Kgs which was 12.8 % less when compared to 195 kgs of 2017 model.

Acquired auto body and precision machining experience while manufacturing frame, suspension and other vehicle components.

Empowered junior engineers by providing technical guidance and mentorship.

Main driver of the team for the 2018 season and the team managed to secure a top 30 spot and reserve driver of the team for the 2017 season where the team stood 34th among 450 teams all over India.

Participating in BAJA gave me a firsthand experience in dealing with the real-world engineering problems.

Intern, HINDUSTAN AERONAUTICS LTD. ARDC, DESIGN COMPLEX, Bangalore, India. JAN 2017

Interned at HAL, where I was introduced to state-of-the-art technologies that are used to design and manufacture Indian defense aircrafts like Jaguar and Hawk.

Familiarized myself with manufacturing procedures, techniques, aircraft parts, materials used while building an aircraft when I visited most of the departments in ARDC complex which aid in the design & development, testing of basic and advanced trainers, combat aircrafts and UAV'S.

TECHNICAL SKILLS AND SOFTWARE COMPETENCY

MATLAB/Simulink

DFMEA

DVP&R

Six Sigma

Catia V5

AutoCAD

ANSYS

LMS Test lab

Solid Edge

NX-UG

Python Basics

Altair Inspire

MS Office

FMVSS

GD&T

KEY PROJECTS AND LEARNING

Simulation and Analysis of 1-2 shift of a 6 speed Front wheel drive Automatic Transmission.

Simulated and Analyzed the fixed gear operations (1st and 2nd gear) and 1-2 gear shift in MATLAB Simulink to optimize the clutch torque profiles i.e. to reduce torque hole and torque overshoot for improved shift quality.

Derived state variable equations for fixed gear operation, upshift, downshift and identified control variables.

Developed dynamic model for a 6-speed front wheel drive Automatic transmission powertrain and performed shift control simulation on MATLAB/Simulink.

Simulation of Series Hybrid Electric Vehicle Energy Consumption using Control Strategy

Simulated a series HEV car for 4 different driving cycles namely city, highway, us06 and wltp using MATLAB. IC engine, traction motor, and the battery were sized based on performance requirement and degree of hybridization.

The control strategy was devised to minimize the fuel consumption and to balance the state of charge after every cycle resulting in optimized MPG and CO2 emission. Familiarized myself with parallel and series architecture, plug-in HEVs and power electronics involved in both Battery and Hybrid EVs.

Product Development & Process Management Cycle of Dodge Grand Caravan 2024 – Hybrid

The project focused on conducting a benchmarking study of competitor vehicles with the reference vehicle selected and developing preliminary specifications for the 2024 MY target vehicle. Developed PUGH diagrams to determine how the target vehicle and benchmarked vehicles compare with the reference vehicle.

Development of functional specifications through the application of QFD to a selected vehicle System- Suspension.

Interface and requirement analysis of selected system and subsystems in the vehicle. Understood coordination in system design tasks between different design and engineering activities and issues associated with trade-offs.

Business Plan Development, Equipment Lifecycle Planning, Root Cause Analysis of problems in older model, Revenue analysis of the target vehicle.

Conceptual Design- Created vehicle plan view drawings including various vehicle exterior and interior packaging dimensions.

Developed the technology plan which shows the major changes proposed for the vehicle design, and technical challenges needed to be overcome throughout development process.

Bachelor’s Project

•Proportional Integral Derivative Controlled on Boilers (Temperature and Flow Control Parameters).

The project aimed at controlling the temperature and flow parameter of a boiler using software PID integrated in PLC and building a 5% prototype. We successfully integrated LabView and SCADA into KepServerEX and obtained 15% better efficiency in the heating capacity as compared to current Industrial Standards.

The Control of Temperature was done using LabView and flow was controlled using SCADA. This was done so that the process could be remotely controlled with minimum human intervention. It also helps in data analytics as well as predicting failure of components during the process. (Sponsored by Karnataka State Council for Science and Technology-KSCST)

Publication Link: https://acadpubl.eu/hub/2018-119-14/articles/3/91.pdf

AWARDS AND ACTIVITIES

•Teaching Assistant for an Undergrad Course - Automotive Engineering.

•My project Proportional-Integral-Derivative Controller on Boilers (Temperature and Flow Control Parameters) was adjudged as Best Project of the Year by Karnataka State Council for Science and Technology.

•President at the UM- Dearborn Cricket Sports Club.

•Automotive Department Representative at the Indian Graduate Student Association- UM Dearborn.

•Team member of the University Cricket team, which is played at the varsity level at UM, Dearborn.

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