“iTRAK” Linear Motion Solution, Rockwell Automation, 2014 – Present
At Rockwell Automation, I am working on a revolutionary linear motor solution, which offers much better performance, lower maintenance and high productivity than existing solutions for the packaging and automation industry.
PMSM Motor Controller, Joby Motors, 2012-2014
I developed motor controllers for electric aviation at Joby Motors. The controllers were designed to run at power levels of up to 4kW, and up to 1200 Hz electrical frequency. The controller is capable of position, speed and current control. The most challenging part of this project was to achieve high power density by paralleling MOSFETs and designing a current controller that could function well with it.
Hardware-in-the-loop electric drive, University of Minnesota, 2011-2012
I developed a lab equipment which could be used for teaching electric drives in undergraduate lab, allowing real-time control of motors directly from the control systems designed in Matlab. It is built around the PIC24 micro-controller, which handles ADC and generates drive signals, while the USB signals are handled by a FTDI chip. The Matlab/Simulink control system is implemented using the real time workshop, with the target being the PC itself. The board for this system was designed in Altium Designer, and the micro-controller firmware is written in C. A communication channel was established between the computer and the controller board. Further development would be needed for the final goal to be achieved
Twistin Tower – Toy Product Design, University of Minnesota, Spring 2012
As part of an introductory product design course taught by Prof. Barry Kudrowitz, we, in a team of 5, came up with the idea for a strategic, turn- based, multi-player game for adults and kids ages 6+. The course was a great learning experience, where I learned various prototyping techniques like laser cutting, 3D printing, vacuum forming, use of basic workshop equipments, etc. I also got a chance to learn and apply basic design techniques like idea generation, ethnography, sketching and 3D modelling. The photo above shows the finished prototype. Manhattan Toy have expressed interest in licensing the product, and I hope it will hit the markets soon.
Consortium of Universities for Sustainable Power, University of Minnesota, 2011-2012
CUSP™, Consortium of Universities for Sustainable Power, a brainchild of Prof. Ned Mohan is a consortium of universities which focuses on developing better curriculum for power and energy courses. I designed the consortium website (www.cusp.umn.edu) and devised the course delivery mechanism for students and faculty. Students can avail the course videos free of charge, directly from the website. Additional instructor materials are available for the faculty upon registration (at no cost). Being a teaching assistant for one of the courses, I also helped in refining the course material.
General Purpose Power Electronics Board, University of Minnesota, Spring 2011
I developed a general-purpose power electronics controller board, which makes prototyping of power converter topologies in research labs easier and quicker. It was a 3×3 array of dual IGBT switches along with appropriate drivers and required sensors. The configuration of the array could be varied to make up to 7 types of converters including current/voltage source inverters, multilevel converters and matrix converters. The switches had a rated collector-emitter breakdown voltage of 600V and rated continuous collector current of 600A. The board was designed in OrCAD initially, and later transferred to Altium Designer.
Internship – Rockwell Automation, Summer 2011
I had a great learning experience at Rockwell. I was involved in evaluation of the power module in one of their upcoming electric drive for industrial servo motors. I had to perform several high-voltage tests. Based on the results obtained, I suggested some design changes, which was seriously considered by the senior engineers. I also had a chance to automate one of the tests using LabVIEW. It saved time and let me work or other interesting things. I also got trained in Design for Six Sigma, and performed Gage R&R studies on design of experiments.
PMAC Machine Animation – University of Minnesota Spring 2011
During my appointment as a Teaching Assistant for an introductory course on electric drives taught by Prof. Ned Mohan, I made a Adobe Flash animation of a PMAC machine. The animation helps the students get a feel for the behavior of the machine at different speeds of rotation, thus increasing their level of understanding.
1kW Turbine – Innovative Engineers, University of Minnesota, Spring 2011
I was involved in developing the rotor of a 1kW turbine which is being built by a student organization called Innovative Engineers. The turbine is being built using recycled car speaker magnets. The aim of the project is to help developing countries get access to clean energy. Click here to know more about the project.
Solar Vehicle Project- University of Minnesota, Fall 2010
I was part of the solar vehicle project during 2010 and helped in re-designing the motor. This involved simulating the design in ANSYS Maxwell, finding the perfect lamination material and implementing the design. Click here to know more about the project.
Simple USB powered motor, Fall 2010
I made a simple motor to understand the basic operating principles of an electric machine. The motor is powered by USB. You can check the Youtube video here.
E@H – Energy @ Homes – Senior Project, Anna University, 2010.
E@H was a smart grid front-end, built from recycled computer motherboards. It essentially has two parts. One is a web-based interface, from where the users can control their home appliances. The web site ran on servers built from old motherboards, which were connected to the network on one side(via Ethernet) and the appliances on the other side(via parallel port). The other part is the MATLAB back-end, which is linked to the website. When the user chooses to, the system can control the appliances itself, based on the demand-response data obtained from the utility over the network. A fuzzy-logic based algorithm decides which is the best time for non-critical appliances like washer/dryer to run, when would be the best time to consume the solar energy from the installed PV panels and when to sell it to the utility, when would be the best time to recharge your electrical vehicle, how to operate HVAC systems efficiently, etc. based on real time pricing. The ultimate goal of the algorithm is to minimize the the utility bills of the consumer, and, at the same time reduce peak demands in load, to benefit the utility.
A part of the setup:
The user Interface:
The Matlab back-end: