Tesla - Motor Design Team

Released +100 parts and 2D drawings (using CATIA) with full GD&T to ensure form, fit, and function at the component and system level, participating in multiple R&D projects for the motor design team. Among all of them, my two major projects have been:

Carbon fiber sleeve rotor

o  Owned the design of a fatigue tester used for highly accelerated life testing to optimize and validate sleeved rotors on multiple drive unit programs.

o  Saved +$400k directly to the company by working on a fully customized design oriented for this specific application, which prevented the need to purchase several non-optimized machines to obtain the required results.

o  Streamlined the process to test the sleeved rotors, minimizing the use of resources (from 3-4 employees needed for the test to 1) and reduced by ~10x the time to obtain high-quality results, facilitating fast design iterations.

o  Optimized the design and the material selection by creating FEA models in ANSYS allowing for a design that can withstand over 50kN of tension during its lifespan.

Performed tolerance stackup analysis to minimize manufacturing discrepancies and guarantee the reliability of the results.

Resolver sensor

o   Owned the full development (including mechanical, electrical, & software) of a test rig that allows for easy detection and prediction of the effect of non-ideal conditions on the accuracy and precision of the resolver, with a resolution of up to 1µm.

o   Engineered an indispensable tool to test and validate old and new future program sensors (6 different sensors to date).

o   Programed the software to control the different actuators, as well as monitor the acquired high-frequency analog and digital signals, using LabView and multiple DAQs from National Instruments.

o   Programed multiple post-processing Python and MATLAB scripts of +500 lines/script to analyze the collected data and extrapolate the needed information to drive design improvements at the component and system level.   

o   Participated in the development of a position sensor component from concept to high-volume production, providing valuable insights into designing plastic injection molded parts, particularly with Glass-filled nylon.

o   Helped root cause and characterize a critical resolver signal issue, optimizing the resources allocation to solve it before SOP.

o   Designed custom fixtures to adapt the test rig for diverse sensor configurations across all drive unit programs, optimizing testing efficiency and data consistency.