Validation Engineer Software Developer

Manoj Dilip Dalvi - page *

Manoj Dilip Dalvi

******@***.*** 906-***-****

linkedin.com/in/manoj-dalvi-299804150

Summary

I have always been fascinated by new advanced technologies, especially in the thermal and automobile sectors. Wants to contribute to new product development in a reputed institute. I am currently working for GM for the last 3 years as a validation engineer. I have a total of 5 years of automotive industrial experience and 1.5 years of experience working on lab projects that were funded by different organizations.

During 5 years in the automotive industry, I worked on different validation aspects such as EV and conventional IC engine powertrain validation, and ADAS validation. I developed an in-depth understanding of the validation process by analyzing system requirements, designing test plans, set-up test environments, conducting testing to gather data, and analyzing data with different tools to create validation reports. In my current role, I am working on system safety validation for upcoming all GM EV projects globally. Some key highlights of my career are 1. Developed safety-critical test cases based on ISO 26262 standard for battery controller(ECU) and conducted all test cases for each new software release which includes EPA certification, production vehicles or OTA sw updates for current customers. We use HIL benches for most of the testing but for some integration testing, we test it in vehicles. For this testing, we are using different tools like Intrepid Vehicle Spy, Vector Canoe for serial communication, ETAS INCA for XCP calibration and data logging, and Lauterbach Trace 32 (JTAG debugger) for debugging. 2. Worked on many critical launches such as Hummer EV, Cadillac Lyriq (which include USA, Mexico, China and Europe version), Silverado EV, Chevy Blazer, etc. 3. Worked on automation test script creation in python for basic software functionality check. 4. Collaborated with cross function teams like control designer, software developer, calibrators, application and simulation teams to set-up test environment and troubleshoot different issues. Experience

Validation engineer

Proterra

Feb 2025 – March 2025

Working on customer engineering projects like Volvo, international to debug BMS issues.

Implement J1939 standards and CAN 2.0 for serial communication for different battery architectures.

Develop DVP&R for different test requirements.

Work with suppliers and external testing facilities for battery software and hardware testing. System Test engineer

General Motors

Nov 2021 – Aug 2024 (34 months)

Working on electric powertrain controller software functional safety testing for upcoming GM EV products like Hummer EV, Cadillac EV, Silverado etc.

Support global programs software validation which includes China GM, Mexico GM, GM Euro upcoming EV programs.

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Validating various battery functionality like thermal propagation, contactors controller, AC and DC fast charging.

Working on battery heat control logic validation by performing extreme condition test cases.

Analyze safety critical requirement based on ISO 26262 standard and create or modified test cases for new or updated requirements.

Conduct diagnostic testing for MIL, fault levels, remedial actions.

Writing test cases for open issue which is raised in ALM system i.e., Problem Resolution and Tracking System (PRTS)

Conduct vehicle and HIL bench testing as per requirement. Collect data by using different tools like ETAS INCA, Vehicle Spy or through dSpace ControlDesk.

Analyze data in ETAS MDA and Vehicle Spy.

Calibrate controller by using INCA experiment and CDM.

SIL testing for HV battery software based on software unit testing requirement.

Write and modified automation scripts for testing and data analysis.

Working on setting up and troubleshooting new CATL LFP dSpace Scalexio battery HIL configuration in development phase. Debug different issues related to software and hardware integration.

Control system integration – Worked on root cause and feedback closure steps for issue tickets created in problem resolution tracking system (PRTS). ADAS test engineer

ZF Group

May 2021 - Nov 2021 (7 months)

Worked on GM camera module testing as per customer requirements.

Used IBM DOORs software for requirement analysis for different features like AEB, AHBC, Lane detection. Used PTC Integrity for application lifecycle management for various sw releases.

Test analysis using CANanalyzer and Mobileye EyeQ client.

CAPL scripting for test automation.

Graduate Research Assistant

Energy-x lab - Michigan Tech

May 2019 - Dec 2020 (18 months)

1.3D printing Heat exchanger project. (Funded by ARPA-E) – Developed a small scale 3D printed model of heat exchanger. Works on simulation as well as experimental aspects.

Next Generation HVAC system funded by Ford Motor company – In this project, we modified the basic Vapor Absorption Refrigeration system by introducing LiCl as a medium.

Thermal storage in HVAC –

Redesign the conventional HVAC system for the Grid Efficient Building project. Implement a thermal energy storage system to increase the overall COP of the refrigeration system. Manoj Dilip Dalvi - page 3

We utilize the micro-level cooling effect by utilizing the heat of vaporization. Service Engineer

Automotive Manufacturers Private Limited

Sep 2016 - Feb 2018 (1 year 6 months)

Work as a Service Executive as a team leader (led team of 5 mechanics) to provide service and maintenance to Government Transportation Vehicles (Heavy Commercial Vehicles).

Works on troubleshooting and diagnostics for any mechanical (Engine, Powertrain, Brake system, Wheel alignment failure) and electrical problems (AMT, ECU, Transmission control module, interior and exterior lights and driver assistance systems problems) in vehicles.

Prepared Product Failure reports (FMEA) which helpful in product future developments to minimize failure.

Education

Michigan Technological University

Master of Science - MS, Mechanical Engineering

2019 - 2021

Embedded System development, Lab Setup and HIL Testing–

Developed a HIL test setup for vehicle components and part of control system validation using a model-based control system approach to test fuel injector and throttle by wire controller using the MATLAB Simulink MotoHawk. Obtained code by using auto code generation from the model developed and flashed it on the MotoTron ECU-ECM-565-128.

Developed Vector CANoe configuration for communication between the two ECU used for throttle- by- wire system and verified real-time CAN message on the Bus using Vector CANoe tool.

Completed stateflow controller design for HEV powertrain distribution strategy and HEV power split control with engine and stepper motor control.

Also developed discrete fuel injection and engine throttle control in live lab. In this, we developed P, Pi and PID controller for each system and found out best suited controller for system in real time.

Mumbai University Mumbai

Bachelor of Engineering

2012 - 2016

Technical Skills

1. Thermal: Design & analysis of various thermal systems like IC. Engines, Refrigeration & air conditioning. Completed Principal of energy conversion, Phase change courses in masters. 2. Control system design: - Design various types of controllers such as PID, MPC, LQR, data- driven control. Also, I worked on embedded control system, continuous and discrete time system control design.

3. Experience in using ISO 14229 (UDS), ISO 11898 (CAN protocol – J1939), ISO 26262

(functional safety) protocols.

Manoj Dilip Dalvi - page 4

4. Successfully completed Advanced Powertrain Instrumentation & Experimentation, Diesel engine control courses. Advanced Heat Transfer, Control system and Intermediate Thermodynamics and GT Power course.

5. Worked on use of AI in heat transfer phenomenon project for Advanced Heat Transfer course. We are trying to implement AI concepts in nucleate boiling phenomenon to improve the overall heat transfer

6. Completed various machine learning and AI courses on online portal like coursera. 7. Software: AutoCAD, CATIA, Inventor, Ansys (Structural, Fluent), Solidwork, MATLAB, Simulink, Python, R-studio, EES.

8. Test tools: Vector CANoe, CANAnalyzer, Simulink, Stateflow, MotoHawk, MotoTune, ETAS INCA, VSpy, MDA, DAQ: NI, Keysight, INCA

9. Hardware Tool- Oscilloscope, Spectrum Analyzer, Function Generator, Logic Analyzer, Digital Multimeters, MotoTron HIL

10. Sensors: Basics of Camera, RADAR, Pedal Position, Thermistor, Electronic Throttle Control, Thermocouple, pressure transducers, humidity sensors. 11. HV certification from GM to handle high voltage instruments.

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