Raju Rishi

Design Engineer

2022 - Current

Mechanical Engineer

2021 - 2023

 Designed, developed, and built epoxy bushing insulation for 1800A busbars considering standards. Performed static structural analysis to find the deflection created by low compression-set gaskets. Achieved IPX8 rating on the bushing.  Created hipot test procedure for testing and verifying the defective heat shrink tube insulation on bus bars which was helpful to identify the issues and change the supplier.  Designed water ingress protection systems to improve the IP of medium voltage legacy units. Designed tooling and fixtures for welding and brazing. Created 2D drawings, built prototypes, achieved IP55 rating, and verified them though testing.  Performed root cause analysis on failed high-voltage vacuum switches by developing a fish bone diagram. Prepared a field rework instruction manual for the vacuum switch which reduced the troubleshooting time by 40%.  Built prototype for the fiber optic cable transition box and performed FO cable connectivity test and verified the circuit connections. Created a work instruction manual for freezing and thawing tests for the transition box

Mechanical Design Engineer Intern

2021 - 2021

• Designed a special purpose machine to automate the unbolting process, which is required for detaching car body from the skid after body painting operation. (Model 3 and Model Y) • Worked on an innovative method for bolt removal process by utilizing pneumatic impact wrenches and effectively reduced the operation time from 14 seconds to 8 seconds. • Performed hand calculations to find the loads imposed on the system and finalized the springs, linear guide rails and other machine elements based on the calculation. • Designed the 3D CAD models for the frame of the machine and their associated 2D drawings in SolidWorks. • Worked in the prototype test setup build and completed the electrical system connections to integrate the controller (NI DAQ) with the sensors, relays, and solenoids. • Involved in developing the test procedures and performed testing to evaluate durability and service life for the system. • Worked closely with multiple discipline teams such as controls and electronics team and effectively provided input for automation programming by providing the digital I/O and analog I/O values required for each step of machine operation. • Tested the system and provided inputs to improvise the code based on the deviation observed from machine operation. • Completed prototype build and was responsible for ordering the off the shelf parts and manufacturing the in-house parts from vendors. Selected suppliers based on cost and lead time. • Coordinated with in-house manufacturers and welders for fabricating the machine fixtures required for testing.

R&D engineering intern

2020 - 2021

➢Developed a proof of concept for a short leg ankle splint, for bi-malleolar and tri-malleolar ankle fractures. The versions of the designs included the company’s proprietary technology as well as traditional splint concepts. ➢ Conceptualization activities included literature research, anthropometric research of diverse populations, and market research on competitor products on the market. Performed statistical analysis on anthropometric data to develop design controls for the product line. ➢ Developed basic sketches and CAD models to evaluate proof of concept, and analysed and recommended materials which could be used for the development of the product line. The product line thus developed, enhanced the product portfolio of the company.

Junior Design Engineer

2017 - 2019

• Design and development of Bus Body components for Intermediate Commercial Vehicle Buses (ICV) including sheetmetal and plastic components (TRIMS) such as GI exterior panels, ABS inner Dome panels etc in CATIAV5. • Detail designing of bus body components such as the shell structure, plastic and sheetmetal components considering styling input (CAD A-surface), manufacturing feasibility and packaging study. • Worked on the design of a common Bus body shell structure for 3 different applications thereby reducing the shell weight by 9%. Engineering design calculation for bus shell structure concept design followed by high level design. • Design and development of destination board mounting brackets for Intermediate Commercial Vehicle buses (ICV) to improve the vibration frequency. Worked on a robust design and alternate mounting methodology thereby increasing the vibration frequency by 28%. • Interact with multiple discipline teams such as cab body electrical, marketing, production and suppliers. • Responsible for prototype build of Bus Body and integration with chassis through support in production plant. • Resolve packaging issues with chassis components through concept model preparation and feasibility studies. • Engineering analysis of existing field failure through DFMEA and root cause analysis. • Design review for appropriate material selection, cost reduction, design for assembly (DFA), design for manufacturability (DFM), design for serviceability (DFS) and comparison with Indian Bus body standards. • Preparation of CMVR layouts and homologation layouts. • Design release through iLEAP and ENOVIA.

Mechanical Engineering Intern

2016 - 2017

• Responsible for testing thermostats from various suppliers in 4 Cylinder diesel engine test beds. • Performed static and dynamic tests on thermostats to ensure engine is maintained at an ideal temperature range (95̊C -102̊C). Plotted the results and compared with the ideal behavior curve for identifying any deviation in performance. • Utilized root cause analysis methods like Fishbone diagram to predict the engineering reasons for deviation in the behavior of thermostat. • Identified a fault in the thermostat by introducing an alternate method, by performing the dynamic test in fully open condition, the engine temperature still remained above 102̊C indicating a its faultiness.

Suspension and Transmission team Lead

2016 - 2016

• Was responsible for Design of suspension components such as the A arm, upright and performed finite element analysis to find its mechanical response. • Used Lotus suspension analysis software to identify suspension hardpoints and obtained input for A-arm and upright design. • Finalized the transmission system and performed hand calculations to find the transmission efficiency and performance at gradient and unfavorable road conditions.