Mechanical Design (Tolerance Stackup Analysis)

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TECHNICAL LEAD - MECHANICAL DESIGN

PRIMARY PURPOSE OF THE ROLE

The person contributes to the hardware mechanical engineering activities required to design, develop and qualify an Interface test adaptor (ITA), Functional test Fixture for Electronics Unit Under Test (UUT) / Printed circuit board assembly, Special purpose machines, Precision tooling Systems (Assembly fixtures, etc.), Standard 19-inch rack systems, enclosures and/or hardware building blocks associated with it. Provide technical guidance to the team on topics relevant to mechanical design.

KEY RESPONSIBILITIES AND TASKS

• Collaborate (Local and Global) with multidisciplinary teams (Electronics, Industrialization, Manufacturing, Project management, Quality, Etc.) to design and/or realize the product.

• Understand customer needs and formalize the mechanical design requirements of the product / system.

• Detail necessary mechanical hardware component / sub-system requirements. Define the mechanical architecture compliant with product / system requirements.

• Support necessary estimation and planning of mechanical activities.

• Comply with applicable organization specific product design and development processes.

• Define the mechanical architecture of PCB & PCBA (Printed circuit board & Printed circuit board assembly) Define harness routing arrangements. Perform 3DCAD design of the mechanical architecture (Sheet metal and machined) and constituent components.

• Provide design solutions for thermal and vibration requirements. Perform appropriate material / finish process / component selection required for the design.

• Perform necessary design verification through any or all the following means

• Tolerance stackup analysis, Geometric dimensioning and tolerancing study

• Basic thermal and / or structural calculations

• Stability check of mechanical systems (Iso-statism and Hyper-statism)

• Material compliance analysis (REACH, RoHS, WEEE)

• Design for Environment (Temperature, vibration, EMI / EMC, etc.)

• Design for Manufacturability

• Design for Assembly

• Design for Testability

• Design for Maintainability

• Collaborate with Analysis engineer for various software-based analysis (Thermal / Structural / Vibration / shock etc.) of the design.

• Supply necessary design data and boundary conditions to perform analysis.

• Involve in technical discussion to validate the analysis results.

• Generate 2DCAD manufacturing drawings (with necessary GD&T or general tolerance controls), BOM and other documentations that constitute manufacturing data pack.

• Manage the design data (3D CAD, 2D CAD & documents) compliant with organization’s configuration management practices.

• Contribute to necessary project technical and milestone reviews (PDR: preliminary design review, CDR: Critical design review, etc.)

• Collaborate with external partners (Component suppliers, Test laboratories, other service providers, Etc.) for successful design, manufacturing and testing of the product.

• Participate in the integration and validation phases of designed system / product. Contribute to skill development and continuous improvement initiatives in the mechanical engineering discipline.                                

SKILLS REQUIRED

Essential

• 10+ Years of experience in Mechanical design using Catia tool
• Good experience in Special Purpose Machinery Design
• strong skill in Tolerance Stack up Analysis and GD&T
• Experience in ELectro-Mechanical design, Test Bench, Racks and Cabinets is added.

• Design for Environment (Temperature, vibration, EMI / EMC, etc.)

• Design for Manufacturability

• Design for Assembly

• Design for Testability

• Design for Maintainability

• CATIA or Equivalent CAD Tool -Capable of generating 3D CAD models of Part – Sheet metal & machined types, Assembly – Separable & Inseparable, BOM.

Mechanical Fundamentals:

• Simple bending / stiffness calculations.

• Tolerance stack up analysis, GD&T definitions. Component sizing / selection for dynamic assembly:

• Mechanical slides, guide pins, mechanical motion translation elements, Gripping and locking elements, etc.

• Assembly mating force, clamping force calculation. One-dimensional heat transfer calculation. Cooling Fan sizing calculation.

• Design for Manufacturing, Assembly, Testability and Maintainability concepts.

• Knowledge of general manufacturing processes and in separable assembly fabrication processes.

Industry Standards / Specifications: ANSI 14.1 or Equivalent ISO standard for GD&T definition. EIA-310: 19 Inch rack standard. [EIA: Electronics Industries Alliance]

Product design: Interface test adapter, Special purpose machines, Precision tooling Systems (Assembly fixtures, etc.),19 Inch rack system, Cabinets and Consoles.

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