Lead Engineer Control System

Anil Koduri **** W Hickory Grove Rd, Dunlap, IL-**525

****.*********@*****.*** 309-***-****

PROFESSIONAL SUMMARY

Experienced Control System Lead Engineer with 11+ years of expertise in requirements gathering/analyzing, designing, developing, and validating control systems from concept to production for commercial and automotive applications

Expertise in MATLAB/Simulink, State flow, and Embedded C/C++/Python for embedded system modeling, I/O processing, and control algorithm development.

Executed structured test plans across MIL, SIL, and HIL platforms including dSPACE and Control Desk to validate open/closed-loop systems against requirements by developing plant models

Collaborated with system and functional teams to gather and analyze system requirements, translating them into implementable requirements also documenting technical decisions

Expertise in system Integration testing, verification, and Validation of safety critical software systems using Black Box/White box Testing, Writing Test Cases and Traceability Metrics

Experience in ISO26262 functional safety implementation

Supported post-deployment validation, calibration updates, and field issues debugging by working with field engineers and customer/clients support teams

6 years of experience at Caterpillar in the Core Implements department, specializing in feature development, integration, and testing across a range of heavy machinery

Hands-on experience with Diagnostic Testing and Troubleshooting using CAN J1939 protocol, On-Board Diagnostics which involves DTC, DIDs/PIDs using CAN parse, CANalyzer, CANape, CANoe, Cadet, CAT ET, dSPACE, Trace32, and Control Desk performed Root Cause Analysis

Achieved enhanced operator comfort and efficiency through modular Simulink architectures to promote reuse across multiple machine platforms, ensuring consistent control logic and reducing development effort

Experienced in reporting the bugs after collecting logs and video files if required and Verification of bug fixes using Defect Tracking tools Azure, Issue list and Rally

Developed I/O processing models for various sensors (pressure, position, flow, speed, tank level, seed sensors) and implemented parallel lift, Kickouts, Snubbing, Fault handling, NVM control, pump flow control, master spray on/off, virtual section handling, and solenoid control modes.

Knowledge in power system design, generator control, and motor control strategies, including DC-DC, AC-DC, and DC-AC converters

Performed design safety analysis FMEA (Failure mode and Effective analysis) at software level.

Utilized simulation tools such as Simulink Test and Google Test to automate test cases, improving test coverage and efficiency for unit/Integration/System testing.

Strong knowledge of communication protocols (CAN, J1939, I2C, Transport Protocol) and AUTOSAR standards for functional safety compliance

Experience working VPUs and Cameras using MQTT for Automotive systems

Developed GUI tools using MATLAB App Designer, GUIDE, and Python to facilitate model testing and visualization

Mentored junior engineers and collaborated with cross-functional teams to enhance software development processes and system efficiency.

Strong experience in various software development life cycles (SDLC) such as traditional Waterfall, and V&V-Model standards in software development process and documentation.

Ability to work in Team as well as independently and able to learn new technologies and tools quickly.

Quick learning and adapting new and changing technologies PROFESSIONAL EXPERIENCE:

Control System Lead Engineer in Automotive Robotics Inc : August 2016 to till date.

Embedded Engineer in Try logic Soft Solutions AP Pvt. Ltd, December 2013 to July 2016. EDUCATION

Bachelors in Electrical and Electronics Engineering (EEE) from JNTU University, Kakinada, India – 2013 TECHNICAL SKILLS

Work Experience:

Automotive Robotics Inc, Peoria, IL - Client John Deere August 2022 – Present Project 1 : “See & Spray Implementation”

Description: Requirements gather/analyze, develop and validate an advanced See & Spray control system using VPUs and Cameras to optimize spraying efficiency and precision Environment: Matlab,Simulink,State-flow,Embedded-C,Auto code generation,CPS,Phoenix,JDGUI,CAN, MQTT, validation using Model in Loop, Hardware in Loop, Cansniff, NI TestStand, Software in Loop, Google Test, Vector Tools, Harness creation, I/O mapping, Oscilloscope, Pico scope, Multi Meter

Integrated Simulink models with custom Embedded C code, ensuring seamless functionality

Enhanced CAN/J1939 communication by updating and maintaining CAN spreadsheets, ensuring accurate protocol adherence and data handling

Gathered the requirements and analyze for diagnostic logic for VPUs and cameras, including real- time LED status monitoring and spray control based on tip support, license interlocks, fault handling.

Test cases developed using Google test to ensure the feature are working as expected also ensure the test coverage in all scenarios including boundary conditions as well as conner cases.

Configured and validated integrated features on the HIL test bench with generated flash files under dynamic conditions also tuning parameters for stability ensuring system performance

Resolved system-level issues in MATLAB/Simulink models and application code, improving efficiency and reliability from requirements gathering/analyzing.

Led machine/vehicle testing, ensuring full validation of system functionality in real-world conditions Project 2 : “E-Meter Implementation with 4 Rows ”

Description: Developed and optimized the control system for an electric meter in a planter machine, enabling precise seed placement using Monosem motors to manage four-row unit controllers Environment: Matlab,Simulink,State-flow,Embedded-C,Auto code generation,CPS,Phoenix,JDGUI,CAN, validation using Model in Loop, Hardware in Loop, Cansniff, Software in Loop, Google Test, Vector Tools.

Enhanced scalability by converting Simulink models from single-row to four-row support using "For Each" blocks, by creating Model/Subsystem reference blocks to improving system efficiency

Optimized communication protocols by updating CAN spreadsheets, ensuring seamless data exchange across controllers.

Improved system performance by configuring queues and data store memory blocks with custom code for efficient data management from requirements gathering/analyzing

Increased precision by implementing motor speed control logic to achieve the exact seed count based on target values, ensured data integrity by updating EEPROM and End-of-Line (EOL) data to meet project specifications.

Prepared harness creation HIL bench, I/O mapping by reading electrical schematics, used Oscilloscope, Frequency generators, Potentiometers, Solenoids & Multimeter to diagnostic and troubleshooting with the simulating signals to observe the system in different conditions.

Strengthened reliability through rigorous unit testing, HIL validation (NI TestStand) with flash files in identifying and resolving issues early if needed tuned/updated the application from the results.

Feature validation on machine/vehicle testing, verifying real-world functionality before deployment. Skills Experience/Expertise

Programming Language Embedded C, MATLAB, Simulink, Stateflow,Labview,CCSA Scripting Languages Python, MATLAB(m-script), CAPL Defect Tracking Tools Issue List, Rally, ADO

Lab tools Oscilloscopes, Pico scope, Multimeter, Frequency generators. Protocols CAN, LIN, J1939, Transport Protocol (MAP), I2C, RS 232 Debugging Tools Trace 32, Putty, Tricore VX, Visual Compiler Version Control GitHub, Git, ClearCase, Tortoise SVN Testing Tool CANalyzer, CANape,CANoe, Google Test, Simulink test, ECU test, Control desk, CAT ET, Cadet, CAT system architect, dSPACE (HIL), NI TestStand, MIL, SIL, Harness creation, I/O mapping, Candb+ Version Management MS Project, MS Office & MS Visio Project 3 : Sprayer PUK for 30 series Individual Nozzle Controller (INC) pro Machine” Description : Developed Spray Rate Control (SRC) and Master Nozzle Control (MNC) functionalities for 30-series chassis control. SRC handled pump and section control, while MNC regulated flow, minimum/maximum duty cycles, and individual nozzle control performed 5 solenoids per INC to enhance spraying precision and efficiency.

Environment: Matlab,Simulink,State-flow,Embedded-C,Auto code generation,CPS,Phoenix,JDGUI,CAN, tresos configuration, test case creation, validation using MIL, HIL, Cansniff, Vector tools, Requirement gathering/analyzing, Harness creation, I/O mapping, Oscilloscope, Pico scope, Multi Meter, Google test

Engineered and integrated 16-bit & 32-bit INC code, implementing boost, hold, and off modes for nozzle control by gathering/analyzing the micro controller schematics to match timing of the signals.

Updated pump speed and pressure control algorithms according to system requirements gathering/analyzing, ensuring accurate performance from requirements analyzing.

Designed virtual section control logic, enhancing section on/off management for precise application.

Developed boom pressure models, ensuring pressure consistency based on target values.

Implemented job summary logic, providing accurate real-time data on flow, area coverage, and operation time

Established and validated CAN 60/61 communication (SRU MNC) and DM7/DM8 messaging

(CCU SRU) for seamless system integration.

Tested in black/white box testing using model in loop or feature testing with the predefined inputs and observing outputs in different conditions and compare the results with expected results

Resolved critical issues with master spray on/off functionality and flow control, achieving optimal spray performance with unit/integration testing using MIL, SIL, and HIL testing (NI TestStand) with Oscilloscope, Pico scope, Multimeter and frequency generators to check the system behavior.

Led machine/vehicle testing, validating sprayer performance in real-world conditions Automotive Robotics Inc, Peoria, IL - Client Caterpillar March 2022 – July 2022 Project 4 : “BTE Machine application development -Transport Protocol” Description : Developed and validated MATLAB/Simulink-based models for various machine attachments, ensuring seamless data transmission using CAN Transport Protocol Environment: Matlab, Simulink, State-flow, Embedded-C, Auto code generation, CAN, J1939, Transport protocol, CAT ET, Cadet, CANape, dSPACE, Canalyzer, Trace 32, validation using Model in Loop, Hardware in Loop, Field Testing, Harness creation, I/O mapping.

Designed and implemented BTE machine models, optimizing attachment functionality using MATLAB, Simulink, and State flow by analyzing transport protocol.

Integrated CAN Transport Protocol for multi-packet data exchange, enhancing communication reliability between controllers

Create libraries to reuse the models across different applications and maintain revision history in the models to understand what changes made.

Utilized CATUTILS libraries and integrated them in the application and discussed with that team members to understand/update the models as per the need.

Diagnosed and resolved CAN communication issues using CANalyzer, CANoe,CANape and Trace32, improving data integrity.

Validated models through MIL and HIL testing with generated hex files, and also performed machine/vehicle testing to ensuring robust performance in real-world machine operations. Automotive Robotics India Pvt Ltd - Client Caterpillar Onsite, Chennai August 2016 - Feb 2022 Project 5 : Electro Hydraulic Machine Implements - Compact Wheel Loader (CWL)” Description : Designed and implemented control logic for Lift and Tilt cylinders in CWL machines, enabling smooth raise/lower, tilt rack/dump operations, and quick coupler functionality. Enhanced operator comfort through advanced hydraulic control features.

Environment: Matlab, Simulink, State-flow, Auto code generation, CAN, J1939, Caterpillar System Architect tool, Validation using MIL, SIL, and HIL using dSPACE, CAT ET tool, Cadet, CANpe, Canalyzer, Control desk, Simulink test, Unit/Integration testing, plant model, I/O mapping

Developed I/O processing models for lift/tilt levers, pitch, and quick couplers, optimizing control responsiveness.

Implemented fault-handling logic for shutdown control and sensor fault conditions, enhancing system reliability from requirement analyzing

Created libraries for parallel lift, kick-outs, dump stop snubbing, and snubbing features, and integrated them in the application to improving operator efficiency and comfort.

Developed and calibrated control algorithms for lift and tilt levers ensuring precise actuation.

Designed NVM control logic (single, two, and three-point controls) to store start and end currents, optimizing machine performance.

Variant management properly handled using Cat System architect tool to control the parameters data across different applications

Performed open loop testing using model in loop or feature testing with the predefined inputs and observing outputs without system dynamics affecting future inputs and validated the behavior with closed loop system with the real inputs/outputs by developing plant model.

Validated models using MIL/SIL methods and performed HIL testing on dSPACE benches, ensuring seamless real-world performance by developing the plat models.

Used to follow checklist for every activity by documenting the details about the activity

ISO standards, Misra C, CAT guidelines, MC-DC coverages followed to improve the model behavior Project 6 : Wheel Tractor Scraper (WTS) Implements Features development” Description : Developed and optimized control system models for key WTS machine components (apron, bail, bowl, ejector, and cushion hitch) to enhance ground leveling and surface finishing operations. Environment: Matlab, Simulink, State-flow, Auto code generation, CAN,J1939,Cadet,Canalyzer, Validation using MIL, and SIL simulator, Unit testing, Integration testing, Open/Closed loop testing.

Developed I/O processing models for critical machine components (Apron, Bowl, Cushion Hitch), improving machine control precision

Designed a Caterpillar-specific cushion hitch valve model, eliminating dependency on third-party components and ensuring performance by refining transfer functions, lookup tables, and system parameters from requirement analyzing

Optimized model performance by converting floating-point algorithms to fixed-point representation, ensuring efficient resource utilization while maintaining data precision

Developed a Sequence Assist model to automate repetitive loading and dumping operations, enhancing operator efficiency through push-button controls.

Implemented an engine over speed protection system that automatically engages gears in the absence of operator input, improving machine safety and reliability

Tested in open/closed loop testing using model in loop or feature testing using Simulink data inspector to inspect the signals to compared the results with expected results

Led model validation and reviews, collaborating with cross-functional teams to ensure alignment with functional requirements and performance expectations. Project 7 : Large Wheel Loader (LWL) Implements Features development and testing” Description : Developed and tested control system models for Large Wheel Loader (LWL) Implements, optimizing lift and tilt cylinder operations to enhance operator comfort, safety, and machine efficiency while minimizing downtime

Environment: Matlab, Simulink, State-flow, Auto code generation,CAN,J1939,Cadet,Canalyzer, Validation using MIL, and SIL, Unit testing, Integration testing, Open/Closed loop testing, dSPACE, Control desk

Developed pump control models for lift and tilt operations using flow-based control methods, improving hydraulic efficiency using variant subsystems by requirement analyzing

Designed cycle time calculation models for standard and high lift, optimizing performance for rack back, raise, dump, and float-down operations

Implemented advanced automatic bucket control features like kick-outs, Auto-Dig, and Return-to- Dig, significantly improving operator comfort and precision

Developed Engine Idle Shutdown and Lift Stall Prevention logic to enhance fuel efficiency and prevent hydraulic stall during heavy load operations.

CAT System architect tool used to create the flash memory variable or Direct to flash memory variable for different variants based on different applications

Tested in black/white/integration testing model in loop or feature testing using Simulink design verifier to inspect the signals to compared the results with expected results

Collaborated with cross-functional teams to review, refine, and validate models, ensuring alignment with system requirements through MIL and SIL validation. Project 8 : Model based development from reverse engineering” Description : Developed Simulink and state flow models based on understanding the custom code applications and validated the models to satisfy the requirement. Environment: MATLAB/Simulink, State flow, Custom code understanding, S-Functions, MIL and SIL

Requirement understanding for dump stop snubbing from legacy code, and VSD diagrams understating for finite state machines and quick coupler fault handling logics.

Design the feature implementations and conduct the demo with the customers, if any improvements need will update the designs based on optimization/reviews

Create s-function to the plant, Mex build for the given controller and plant code verify the V-V analysis of model using MIL and SIL testing

Report generation in the form of plots and HTML and documenting the process involved. Project 9 : Model development and Verification & Validation using MIL/SIL/Integration Testing” Description : MATLAB Simulink and state flow models development from requirement gathering/analyzing and performing Verification and Validation using MIL/SIL and integration testing using generated code. Environment: MATLAB/Simulink, State flow, MIL, SIL, dSPACE, HIL, Integration and Machine testing, MC-DC code coverage, Simulink design Verifier, Google test, Simulink test,GUIDE,App designer

Functional Requirement analysis and Developing Simulink/State flow Model for requirements.

Test case preparation and harness model creation for Model-in-Loop Testing to ensure Coverage analysis and report generation, documenting the difference between requirement and MBSD logic

Conversion script developed using Google test to convert physical (model) value to hex value to feed in code will ensure the SIL validation for C code and MIL validation for model both working with same functionality. GUIDE and app designer tool used to create the GUIs in model testing

Models are developed by features in components, these components are combined made developed integrated models, these models validated using system/integration testing in model also tested auto code using dSPACE HIL bench to the behavior across the multiple controllers

Performed machine testing to check behavior in real time conditions for post-deployment validation, calibration updates, and field issues debugging by working with field engineers and customer/clients support teams

Project 10 : Auto Code generation using Embedded Coder/Real Time Workshop (RTW)” Description : This project is concerned to develop fixed point/floating point code of various modules based on specification document as per MISRA C or CAT coding rules, prepare data description file (XML) for every module, Unit testing using Simulink design verifier to verify the code coverage, boundary and MCDC conditions.

Environment: MATLAB/Simulink, State flow, Embedded Coder, RTW, RTOS, Floating/Fixed Point, AUTOSAR, Google test, SIL simulator, MC-DC code coverage, Simulink design Verifier.html.

Functional Requirement analysis and Developing Simulink/State flow Model for requirements.

Code generation by the internal script in target language compiler (TLC) using MATLAB and RTW Environment

Code walks through done for generated code if any fixed point/floating point architecture violation to avoid integration issues for various solvers

Source Code compiled using the google test and SIL simulator

Davinci tool used to developed MATLAB supported AUTOSAR composition models to improve the functional safety of the models and generated ARIXML files

Simulink models generated code integrated with Embedded C code feature development for application and used to generate flash files to program them in micro controllers. Project 11 : Development process in different stages includes version control and label releasing” Description : implemented the Global Model Based Design Process for the Caterpillar company. Stages describe the complete Process of each activity followed by Different version control, Different stage of development for various applications, issue fixing from rally and issue list Environment: Version control, checklist, Misra C guidelines, MC-DC coverage, Simulink test, AUTOSAR

Developed the models from the requirement understanding in different stages, generate the ARIXMLs by integrating models with AUTOSAR using Davinci compiler for functional safety, issues identifying by debugging, perform version control using git and ClearCase and release the labels.

Used to follow checklist for every activity for better understanding about the activity and which process has been followed to complete the story

Misra c guidelines followed to improve the model behavior and used to perform coverage analysis using MC-DC code coverage.

Generate the final output expected by the Client, conducted demo with customers about the activity and optimize the process/code based on review points Project 12 : MATLAB-scripting to automate the process” Description : Develop automation of existing working process by Auto capture the details from workspace

& folder structure to ease the work progress.

Environment: MATLAB Scripting, Simulink,GUIDE and App designer

Developing the MATLAB scripting based on requirement for Input/Output (I/O) Conditionings, Identify Used Libraries, Extract Variable Information for I/O’s and Export All Details to Excel/CSV.

Generate the final output expected by the client

Setup the Demo with customer for further development

Optimized the process & script update for client provided inputs

Final review and Release.

Try Logic Soft Solutions Ap Pvt Ltd, Hyderabad December 2013 - July 2016 Project 13: “Novel Integration of a PV-Wind Energy System with Enhanced Efficiency” Description : Developed and optimized PV-Wind hybrid energy system models to improve efficiency and performance using advanced control techniques.

Environment: Matlab, Simulink, State-flow, Power systems, control systems, power electronics, PWM techniques, validation using MIL,Battery Management Control(BMS),State of charge(SOC),DC-DC,PI.

Designed and implemented PV-Wind hybrid models, integrating Maximum Power Point Tracking

(MPPT) determines the state of charge (SOC) to maximize energy extraction under dynamic circumstances from the requirement gathering/analyzing.

Developed wind energy models efficiently convert moving air into electrical power.

Battery management control properly handled using enhanced system stability by applying Pulse Width Modulation (PWM) and Proportional-Integral (PI) control for precise switch pulse regulation for boost converter DC-DC converter to maintain optimal battery performance

Validated hybrid system across linear and nonlinear loads, BMS reacts to high load driving, power spikes, regenerating braking power disturbances controlled under various operating conditions

Real time energy controlled properly by debugging and optimized Boost converter functionalities, resolving PI control issues to improve system efficiency Project 14: “Brush-less DC motor with high power factor: Description : Designed and implemented a high-power factor Brushless DC (BLDC) motor control system to enhance efficiency and reduce current harmonics Environment: Matlab, Simulink, State-flow, Power systems, control systems, power electronics, PWM techniques, validation using MIL,Motor Control,Inverter,PI.

Developed and integrated a BLDC motor model, optimizing motor performance and control of torque, speed, and position handles properly to achieve smoother acceleration and responsive drive control.

Designed an active power factor controller to minimize input current harmonics caused by power diodes and inverter switching reducing electromagnetic interference and improved fast charging.

Implemented Pulse Width Modulation (PWM) techniques for precise IGBT switching, ensuring fast response and stable operation from inverter that is converting DC battery voltage into AC

Applied a PI controller to suppress current harmonics, significantly improving power factor and system efficiency by effective speed/torque, and current control.

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