Mechanical Design Project Management

Wenchao Zhang

Phone : 313-***-**** Email ID: ******************@*****.***

SUMMARY

* ***** ** ************ ********** in Product Engineering, Engineering process methods and data management in Automotive industry. Proven expertise in managing cross-functional teams, implementing complex engineering processes, and aligning tools and standards with organizational goals.

3 years of industry experience in EV/Clean tech Industry. Specialize in the Mechanical design, development, and implementation of innovative E-Drive solutions for sustainable transportation and clean energy.

2 years of experience in CAE impact analysis. Performance optimization, and safety compliance.Proficient in 1D, 2D, and 3D FEA simulations for structural, thermal, and dynamic analyses. Skilled in evaluating stress, strain, deformation, and thermal behavior of components, with experience in advanced meshing, nonlinear materials, and real-world loading conditions to optimize design performance.

Proficient in systems engineering, with a deep understanding of the Dassault 3D Experience platform and PLM/CAD systems.

Certified in Hypermesh & Hyperview Introduction and SOLIDWORKS Professional in Mechanical Design. EDUCATION

Master of Mechanical Engineering in University of Detroit Mercy, Detroit, MI 01/2016-08/2017

Bachelor of Engineering in Inner Mongolia university of Science and Technology, China. 09/2010-08/2014 SKILLS

Virtual Design Applications: Solidworks, Unigraphics NX, CATIA V5, GD&T Stack up Analysis, Dassault 3D Experience platform.

CAE Structural Modeling Tools: Linear Analysis (OPTISTRUCT, ANSYS), Non-Linear Analysis (LS-DYNA)

Program Management: Agile/Scrum Methodologies, Project Management Tools (Jira, Trello), Budget Management, Risk Assessment.

Soft Skills: Leadership& Project Management, Team Coordination, Communication, Problem-Solving, Time Management. WORK EXPERIENCE

Electric Motor Product Engineer 10/2021 to present JING-JIN ELECTRIC(JJE) NORTH AMERICA LLC

Advancing Innovation and Integration for Electric Drive Modules in Commercial Vehicles: 03/2022 to present

Led the development and implementation activities, managing cross-functional teams (Mechanical, Design, Electrical, Hardware, and Software Engineers) for multiple advanced commercial E-Drive products delivered to the U.S. market.

Led the engineering team in conducting technical assessments, analyzing challenges in the RFI&RFQ, and providing appropriate engineering Proposals and solutions. Collaborated with the motor, inverter, and gearbox teams to design a highly integrated E-drive unit assembly for vehicle applications.

Worked with major commercial vehicle customers as the primary representative of the Engineering team to gather and communicate technical needs and feedback, acting as the Voice of the Customer (VoC) to ensure alignment with technical specifications and requirements.

Supported Mechanical design optimization to balance performance, manufacturability, cost, and system requirements, delivering technical solutions for diverse customer needs.

Defined key engineering specifications for E-Drive operations, including performance requirements (continuous and transient), ensuring alignment with customer technical specifications.

Led product design reviews to ensure compliance with engineering principles, company standards, and customer expectations.

NVH Analysis 03/2024 to 07/2024

Supported the NVH team in the local mass production planning for the 200KW 3-in-1 EDM system, featuring a hairpin electric motor, integrated gearbox, and high-power controller.

Performed daily maintenance of Dyno NVH judgment for end-of-line testing, following EOL NVH judgment work instructions and methods for assessing noise in electric powertrain systems for electric vehicles (QC/T 1132-2020T & CSAE 176-321).

Completed NVH analysis using Discom color map data to root cause noise issues and collaborated with teams to optimize manufacturing processes, isolate defective components and minimize defect rates. Worked closely with the Quality team to compile test results in the NG Rate Sheet, ensuring that only products meeting quality standards were approved for shipment to customers.

Mechanical Design & Development of Electric Beam Axle for Medium Duty Truck 10/2022 to 04/2023

Conducted competitive benchmarking of the E-Beam axle product for Medium -duty applications. Collaborated with the motor, inverter, and gearbox teams to develop a conceptual prototype design.

Stack up Analysis 11/2021 to 03/2023

Performed stack-up analysis of Motor rotor& stator air-gap tolerance, ensuring precision in alignment and minimizing manufacturing variations for optimal motor performance. CAE Engineer 10/2018 to 10/2021

Daimay North America Automotive, Inc. Redford Charter Twp, MI 48239

CAE model development for arm restraint and head restraint CAE analysis using finite element tools such as Hypermesh, Abaqus and LS- DYNA in Ford Mustang Mach-E project.

Identified OEM requirements and developed CAE model for seat structures (head restraint, arm restraint) in support of vehicle seat structures impact and crash simulations for occupant safety analyses followed by GM Global Seat Modeling Guideline for CAE simulations to meet the requirements of GMW14957 & Federal Motor Vehicle Safety Standard FMVSS 201,202a.

Led advanced simulation techniques for evaluating dynamic and static impact scenarios, using LS-DYNA and Abaqus to simulate occupant injury mechanisms and optimize the design of restraint systems for crashworthiness.

Played a key role in developing and refining simulation processes for seat structures, leading to a reduction in overall simulation time while maintaining high levels of accuracy and reliability.

Collaborated with cross-functional teams, including design, engineering, and safety departments, to incorporate design changes based on simulation results, improving safety and compliance. Product Engineer 10/2017 to 10/2018

Daimay North America Automotive, Inc. Redford Charter Twp, MI 48239

Interfaced with Project Managers, Product development team, Design Engineer and many others to followed up Performed design failure mode effects analysis (DFMEA), Design for Assembly (DFA), design for manufacturing (DFM), BOM (bill of materials) and design verification plan & Reports (DVP&R).

Supported the manufacturing team by reviewing product drawings and creating detailed Geometric Dimensioning & Tolerancing

(GD&T) drawings to facilitate product development.

Oversaw the product lifecycle management (PLM) system for main OEMs, reviewing Engineering Change Notices (CNs) and submitting product math data and drawings in Team center.

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