R&D- Senior Design Engineer at Warpp Engineers Pvt Ltd. (2024-06 – Present)
Senior design engineer focused on power converter design, embedded systems, and PLC-based automation.
- Designed and tested a 125W buck converter and a half-bridge DC motor speed control system. Implemented LM3524, LM555, TL494 and self-oscillating based buck, boost and forward converter topologies.
- Designing of buck boost converter based on LM5118 achieved 92% efficiency over wide loading conditions.
- Developed common-mode and differential-mode filters for PLC-based systems, including simulation, PCB design, and testing.
- 16 KW LLC converter-based induction heater, magnetic design, gate drivers, filters, and snubber circuits.
- Designed monitoring system for IoT, to scale down 70V / 400A using LV25 Hall effect current sensors and LM324 op-amps.
- Developed analog voltage-controlled interfaces for PLC-integrated welding systems using HCNR200 and LM358 op-amps for precise current and voltage regulation.
- Design of optocoupler-based level shifters for DC motor driver application.
- Designed TRIAC-based solid-state relays with zero-crossing optical drivers and optimized snubber circuits.
R&D- Senior Design Engineer at Warpp Engineers Pvt Ltd. (2024-06 – Present)
Achievements
- R&D- Representative in managerial meetings, improving technical communication and incorporating real-time client feedback into design iterations.
- Performed DFMEA, DFM in PCB design process, BOM, assembly and testing minimized defects by 80%
- Expertise with PLC based automation systems, assessing client requirements, selecting optimal hardware including PLC, HMI, VFD, servo drives, stepper drives, stepper motors and conducting thorough simulations and testing.
- Reduced R&D support calls by 30% through training programs and detailed documentation including schematics and troubleshooting manuals.
- Increased PCB testing efficiency by 50% by developing JIGs, reducing testing errors by 25%
- Accelerated BOM and ISO documentation by 40% through AI tool integration and subordinate training.
- Played a key role in cross-functional collaboration, supporting programming teams, supervising control panel design, and leading on-site commissioning and troubleshooting.
Avionics Executive | Advisor at Drone Development Team (2022-06 – 2024-06)
- Designed and evaluated avionics systems for an RC plane with a payload capacity of 6 KG.
- BLDC Motor, ESC, li-po battery sizing and flight time analyses using eCalc online software.
- Collaborated effectively with multidisciplinary teams to achieve AIR 5 in DDC 2023.
- Optimized wire harnessing, reducing overall weight by 240 grams, improving efficiency and flight performance.
Internship at Western Railways (2023-01 – 2023-01)
EMU Virar Crashed
- Gained practical insights into trip inspection and periodic maintenance procedures for EMU.
- Studied the role and application of power electronic converters in railway traction systems.
