Tesla: 5 Internships + Full Time from 2017-2021
2021 Model S & X Rear Suspension
I was the lead engineer for the rear suspension for Model S and X Plaid. During that time, I determined kinematic and compliance targets, architecture, and designed components such as links, knuckles, ball joints, bushing, stabilizer bars and fasteners. I performed structural analysis and focused on using common parts and reducing factory complexity while supporting the high performance and mass demands. This multi-link design is able to semi-independently control all 6 degrees of freedom of wheel while saving money for the company.
Model S Rear Knuckle, Die Cast Aluminum with integrated bushings and sensor mounting
Lower Fore link, common forging and machining with lower aft. Reducing tooling cost.
Toe Link, forged with integrated turnbuckle for toe adjustment.
Upper Aft Link, Forged complex profile to clear body and damper clearances.
GA4 Knuckle Sub Assembly Line
Designed the build pallet and interlock system for the GA4 knuckle assembly sub-line. Per Elon’s Twitter, we assembled the line in less then 2 weeks allowing for another 1000+ cars per week of production. This line was assembled in a very scrappy manor, taking advantage of rapid manufacturing processes. In order to insure the fasteners were correctly torqued, I designed an interlock system that used body controllers and door actuators to hold the part until torque is achieved. This saved time since had controllers and actuators in house and money since we were able to leverage the scale of automotive parts.
US20190300048 - STEERING SYSTEM FOR A VEHICLE
Received Patent for a steering system. Conventional steering systems are generally hydraulically operated to augment the steering effort exerted by a driver. Such hydraulically operated steering systems are typically bulky and space consuming as they include a number of components, for example, cylinders, pumps, hoses, control valves, etc. Additionally, hydraulically operated steering systems are complex in design, expensive and add to an overall cost of vehicle. Hydraulically operated steering systems are also less efficient and typically require a large amount of power for operation. Thus, there is a need for a new steering system having a simpler and compact structure with high operating efficiency to solve the aforementioned problems.
Model 3/Y GB (China) Charge Port
While still on Chassis Team, we heard the High Voltage Distribution team needed some assistance and I volunteered to help. During the 3 month stent, I learned about high voltage creepage and clearance requirements and plastic injection molding design.
I designed the locking mechanism that prevents the handle from being prematurely removed as well as the main structural bracket that holds the two charging pucks on the GB charge port. The locking mechanism is optimized to use as little torque as possible to extend two locking pins using a single motor by the use of a cam system.
Tesla Semi Tires, Front Suspension, and Subframe
Lead architecture selection for the tires, front suspension, and front subframe. Performed cost of ownership simulations accounting for tire rolling resistance, wear rates, and tire mass.
Determined kinematics and compliances for independent front suspension and coordinated testing to confirm model correlation.
Performed material selection and design of front subframe to handle abuse loads from a Class 8 semi truck.
Internships
Chassis-Dynamics
Summer 2015 and Summer/Fall 2016
Designed wheels and interfaced with Class A surfacing and other teams
Developed packaging and design specifications for active rear toe system
Designed and tested prototype components to allow for an accelerated build schedule
Conducted testing for the design specification of snow chains
Designed rear knuckle for mass production using topology optimization
Performed Simulink simulations of steering system to improve the dynamics and feel
Instrumented cars and tested for various driving and autopilot scenarios
Contained and implemented countermeasures for MFG concerns during initial production
Quality Control and Metrology - Stamping
Summer and Fall 2014
Designed CMM check fixtures for body in white components
Contained production quality issues and implemented solutions to prevent recurrence
Closures Engineering
Summer 2013
Designed initial concepts for Model X Falcon Door upper section
Developed sealing concepts for closures systems