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John Deere Construction and Forestry Group (Contract through Entegee.inc), Dubuque, IA.

Mechanical engineer​                                                                                                                                    10/2017 - 7/2020

• Led mechanical design & FEA activities for multi-gen of JD off-road construction vehicle platforms for new vehicle proof-of-concept evaluation, cost reduction on production vehicle, DFEMA, supplier product integration.

• Designed sheet metal brackets and injection molded enclosures for off-road trucks to integrate battery pack, proximity sensor. Leveraged DFM/DFA, heat treatment, surface treatment knowledge to ensure product meet functional improvement.

• Conducted DFMEA using FEA stress analysis or hand-calculation on critical vehicle component designs based on various load cases to predict failure modes and ensure the product design robustness while meeting the functional requirements.

• Conducted tolerance analysis with GD&T using loop diagram to evaluate various sub-assemblies, ensured modular design meet the form and functional fit as well as the DFM requirements.

• Achieved $150K cost reduction goal by leveraging the generative design process to ensure the commonalized vehicle component designs for multiple vehicle platforms.

 

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EcoPrt.Inc (Electric Vehicle Development), Raleigh, NC

Mechanical Design Engineer. ​                                                                                                                        8/2016 - 5/2017

 

• Design/Prototyped gen2.5 vehicle chassis (lower body, upper roll cage, subsystem mounts) using Solidworks based on DFM/DFA principals. The goal for 2017 EV team was to build 5 gen2.5 prototype vehicle for road test in NCSU campus.

• Performed FEA for improving the chassis torsional & bending stiffness, stiffness to weight ratio (50% more than gen2 vehicle) using ANSYS, optimized the chassis durability by using higher yield steel/aluminum with various thickness.

• Evaluated gen2.5 chassis manufacturability with steel tube manufacturer based on DFM & DFA principals, defined chassis CNC milling tolerance limit for tube bending, released 2D drawings for chassis production.

• Designed a plastic heat exchanger assembly (evaporator, electrical fan, sheet metal mounting) using Solidworks based on DFM & DFA, GD&T analysis, prototyped/fabricated full assembly by thermoforming, laser cutting, sheet metal stamping.

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ABB Group, Shanghai, China                                                                                                                                                             5/2016- 8/2016

Design Engineer Intern

• Designed sheet metal enclosures, mounting brackets, and injection modeled enclosures or snap-fit to integrate various sub-systems such as wiring, pneumatic tubing, robotics, sensors, linear guide.

• Conducted DFM/DFA analysis for sub-assembly modular designs in robot station to ensure quality, cost, and functionality requirement can be met.

• Leveraged tolerance analysis with GD&T using loop diagram to evaluate various robot station sub-assembly, ensured the form and functional fit as well as meeting the DFM requirements.

• Conducted modal analysis on platform design to ensure the 1st mode natural frequency is 20% higher than the highest working frequency of motors. Examined the mode shape results and optimized the bracket stiffness using additional bends.

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Gates Corporation, Shanghai, China

Product Development Intern                                                                                                                           4/2015 - 7/2015

• Managed 3D CAD model for Honda ABDS/SBDS tensioner pulley assembly using Creo, updated the design changes from senior product engineer in a timely manner.

• Conducted DFMEA, and defined durability tests based on Honda Japan engine team requirements and Gates tensioner/idlers product development standards to validate new engine tensioners/idlers design.

• Directed quality & test engineers for test scheduling, kept track of tests (product durability and wear amount test, heat & cold test, noise test), and made changes to validate product functionality based on designing spec and customer requirements.

• Analyzed test results (wear amount on pulley and damping pad, etc.) based on endurance test data, and company product design specification, proposed coating strategies for increasing wear resistance, and finalized DVP&R for product design release.

 

Arnott.Inc, Merritt Island, FL 

Design Engineer                                                                                                                                             5/2014 - 1/2015

 

• Established 2D drawings and applied correct GD&T (ASMEY14.5) on prototype design from R&D team for manufacturing.

• Designed a flexible fixture used for the production of three different types of air suspension shock. The fixture streamlined production efficiency by 25% compared to previous fixture.

• Performed first article inspection for prototype using Faro Arm, and updated 2D drawings with GD&T for mass production.

• Performed CAE durability analysis using ANSYS on test vehicle suspension with air shock installed, examined air shock component stress level against material yield strength for product structural optimization.

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