Generac Power Systems
Exhaust Air-diode
● Analyzed the existing symmetrical flapper diode assembly and determined the redundancies
● The existing assembly is heavy, and flappers don't open equally
● Simulated the airflow for the existing air diode and determined that the issue occurs because of the way it is pivoted.
● Calculated the air thrust, normal force, and the angle of opening to diffuse the exhaust air
● Designed various exhaust diodes to simulate the flow distribution and compared the results
● Fabricated and experimented with a prototype to validate the simulation results
● Investigated multiple hinge types and listed them based on their reliability and functionality over the time
● Developed a semi-annular snap for easy installation and moderating the angle of opening
Interior air flow and temperature distribution
● Revamped the existing interior sub-structure to improve the interior airflow and temperature distribution of the PWRcell.
● Reverse-engineered Tesla's Powerwall 2 for comparison and re-designed the interior sub-structure.
● Scope of work includes design of bracket assembly, in-depth CFD flow simulations of air and thermal flows, exhaust louvers, and selection of fasteners and struts
● Factors like wind speed, seismic response, and spectral response coefficients were considered.
● Designed all brackets in sheet metal and performed in-depth structural and finite element analysis on individual components and the assembly to detect the higher stress concentration regions.
● Decided the placement of the exterior bracket sub-assembly based on the center of gravity of the entire system.
● Investigated the plausibility of the manufacturability on an industrial scale and made necessary changes
● As a result, I have completely re-designed the interior structure and taken it to production after passing all the required tests.
● Led integration of MES, robotic screwdrivers, bit socket trays, and PLCs for a new manufacturing line; designed, prototyped, and implemented improved fixtures, developed comprehensive work instructions, and co-audited a successful FAT validating the process for quality, safety, data integrity, and scale-up.
● Engineered a custom EMI solution for a battery management unit to enhance shielding (5dB noise reduction), thermal venting (3°C temperature drop), and minimize PCB strain (<500 με).
● Modeled a 22kA short circuit test on a smart disconnect switch using FEA to identify critical failure zones, refined the design, and validated the prototype's resilience through physical testing.
● Executed strain gauge testing on eight PCBs to identify components exceeding IPC/JEDEC-9704 strain limits and implemented design and handling improvements to reduce strain by 22%.
● Authored comprehensive test procedures and SOPs aligned with UL and ASTM standards for PWRcell 2 & PWRcell 2 max product compliance.
● Enhanced component manufacturability by applying GD&T, tolerance stack up, DFM, and DFA techniques.
● Calculated the exhaust air thrust and performed FEA on different designed patterns on the exhaust of PWRcell.
● Designed a set of experiments to analyze the airflow simulation and temperature distribution of the battery pack.
● Enhanced the battery operating hours by 25% by leveraging the conservation of waste heat and optimal airflow.
● Revamped the wall mount bracket and reduced the overall weight by 30% and bolted joints by 50%.
● Engaged in cross-functional collaboration with international contract manufacturers to discuss and refine bracket assembly designs for mass production.