RAM KARTHIK MUTHUPANDIAN

Electric Drive Unit- Staff Systems & FS Engineer, Aramco Research Center (Client)

Responsible for board bring-up of traction inverters ensuring functional safety compliance and tailoring the system to meet the requirements of OEM.
Verification of the functionality of the Hardware components such as power modules, gate drivers, microcontrollers and communication interfaces with extensive testing on the HIL bench. Coordinate with the team to deploy Simulink models in Typhoon HIL bench and commissioning on the test bench.
Troubleshoot issues encountered during bring-up including signal integrity, power sequencing and hardware-software interactions.
Perform Functional safety validation as per ISO26262 standard.
Conduct safety mechanism testing, such as: Overcurrent, Over-voltage and Over-temperature protection. Fault detection and fault tolerance strategies for PMSMs.
Liaise with hardware design teams, semiconductor vendors, and OEM engineers.

• Review and analyze Stakeholder requirements and create specific test cases on PLM Doors
• Identify and decompose the stakeholder requirements to system level, subsystem level requirements
• Review System Architecture from Rhapsody or VISIO to Design and develop System Integration requirements on PLM Doors based on the stakeholder requirements to identify the interface issues of each individual subsystem assembly within the Electric drive unit system (E-Machine, Inverter and Gearbox assembly)
• Develop specific test cases for system integration requirements by choosing the appropriate testing environment like Dynamometer, HIL, HV-HIL and test bench
• Responsible for the calibration of Electric drive unit as well as verification of the Drive system module for each Software release, calibration release and DCRP
• Responsible to drive the product to meet the Stakeholder requirement by providing feedback to the Software (SW) controls team in improving the performance of the product
• Analyze data to troubleshoot issues with Controls/SW and provide timely feedback to the Controls/SW team to consider making improvements to the product on critical failure
• Analyze data to make temporary changes to the function’s block in SW (via C Source code) and to the Control function in Matlab/Simulink for the purpose of resolving issue with DOE methods
• Experience handling database management tools like PLM doors/IBM RTC to create test case, attach test report, raise failure report, failure analysis report and work in collaboration with project manager to follow-up and form a close loop for issue closure.
• Optimized system performance by identifying and resolving complex integration issues.
• Collaborated with cross-functional teams to deliver high-quality integration solutions on time.

• Review customer test specifications and create specific test cases in Polarion based on test case requirement for dynamometer environment
• Develop testing methodologies for verifying and validating electric propulsion performance
• Responsible for procurement of electric propulsion test equipment and perform measurement and validation of High Voltage and High Current systems using Yokogawa Power Analyzer systems, AVL power analyzer systems
• Lead for testing electric propulsion systems testing activities on dynamometer test bench
• Integrate troubleshoot and commission CAN communication using Vector CAN tools on dynamometer while changing to new projects on dynamometer cell
• Plan, Develop and execute electric motor control software validation on dynamometer
• Responsible for conducting all Software release testing on dynamometer, which includes commissioning, programming, EOL, performing test cases, troubleshooting and analyzing data
• Analyze test data to ensure testing gets executed properly, meets acceptance criteria, and learning is communicated to Application team
• Experience working on Electric drive system regulatory testing.

• Responsible for Fuel Economy (FE) Chassis Dynamometer testing from early prototype stages to production release of light duty vehicles
• Performed extensive FE testing on Chassis dynamometer using ETAS INCA
• Plan, Develop and execute DVP&R documentation for the program that includes Fuel economy, Performance, Capability and Drivability activities
• Analyze data collected during Dynamometer Testing, summarize results, and prepare technical reports and presentations
• Performed top gear elasticity testing and WOT (Wide open throttle) performance evaluations and analysis of test data
• Responsible for Capability Validation (i.e
• Gradeability (32%, 15% durability route), SAE J2807, Eisenhower Pass, Davis Dam)
• Responsible for finding technical gaps and opportunities in powertrain calibration and provide accurate and timely analysis and testing results.

• Responsible for FE testing of the 2.2 L Turbo Mahindra mHawk engine on chassis dynamometer
• Instrumentation of vehicles with data acquisition systems including INCA, data loggers, accelerometers, incorporating external instruments like current clamps, Pressure, Temperature sensors, Fuel Flow meters into CAN measurement experiments
• Assessed on-road fuel consumption testing using ETAS INCA and fuel flow meters
• Assessed Chassis dynamometer testing to measure fuel economy, performance and drivetrain losses
• Fuel Economy evaluation during hot-trip evaluation of utility vehicles by collaborating with Engine and transmission calibration teams
• Provide key inputs to calibration teams by analyzing the data generated from the Chassis dynamometer and on road responsible to deliver detailed reports with recommendations to respective Engine and vehicle team for meeting program targets
• Performed evaluation of drivability parameters to assess Tip-In & Tip-Out behavior of vehicles.