Principal Engineer — Power Electronics

Defined the features and requirements of the BMS system and defined the software architecture.

Developed the utility functions (bootloader driver, CCP driver) and the low-level driver of the LCU board in C code and integrated the driver in the MATLAB-Simulink MBD environment. Software (both handwritten C code and MATLAB auto-generated code) was tested and debugged.

Developed battery plant models (voltage and thermal) in MATLAB Simulink. Created a mathematical model of the battery system using a single-pack simulation model provided by the supplier. Extracted internal resistance and open-circuit voltage (OCV) curves through testing and calibrated the model using real-world data.

Built an integrated battery model for multiple modules, matching actual truck configurations. Proposed a dynamic current distribution algorithm based on the mathematical model to optimize the trade-off between simulation speed and accuracy. Validated the model against real truck data.

Enhanced a resistance-based dynamic charging strategy to improve state-of-charge balancing during the charging process and refined the algorithm for better integration of the battery system into the DC bus.

Developed new plant models for the vehicle’s high-voltage (HV) loop, including the battery, inverter-motor system, Power Distribution Unit (PDU), brake resistor, and fuel cell. Created torque loop models—such as the gearbox and inverter-motor—and integrated them with the HV loop models.

Defined clear interfaces between plant models, thermal plant models, Vehicle Control Module (VCM) control modules, and other simulation components to ensure seamless system integration.

Integrated VCM control logic into the comprehensive vehicle simulation model, utilizing MATLAB scripts to automate and dynamically incorporate ongoing updates, supporting continuous development of VCM algorithms.

Leveraged the simulation model to optimize power management algorithms (fuel cell power commands, brake resistor control, motoring/regeneration power commands) and energy management algorithms (state-of-charge control).

Developed the control algorithms and software of the hydrogen system control unit (HSU sub-system: fuel cell module, DC/DC, hydrogen supply, coolant system) and the fuel cell module control unit (FCU sub-system: anode, cathode, ventilation, coolant, and electronics sub-system control, interface, housekeeping) in the MATLAB-Simulink MBD environment.

Developed torque-management algorithms (pedal, traction motor), power-management (fuel-cell module, HV battery, traction motor, and vehicle load), and limp-mode (HV battery failure) algorithms of the vehicle control unit (VCU) in the MATLAB-Simulink MBD environment.

Developed a MATLAB-Simulink plant model of the FCEV system (VCU, fuel-cell module, traction motor, vehicle physical model, HV battery, and driving cycle generator) for power management function development and customer demonstration.

Coordinated with hardware and system teams to develop test procedures and evaluate the test results on both bench and dyno to validate the hardware, the control software, and the system performance to meet customer requirements.

Integrated (the VCU, hydrogen control unit, fuel cell module) and commissioned (in-vehicle calibration, parameter tuning, and on-site software optimization) more than 600 fuel cell trucks (first 50 trucks on-site, the others remote).

Drafted the commissioning guide, calibration book, and troubleshooting book and launched several training sessions for the local engineering team.

Led the electrical part design (CAN communication structure, safety sensors/actuators deployment, test controller, and GUI development) of two fuel-cell test labs.

Developed the customer interface, DC-bus current control algorithm, limp-mode (HV battery failure, DC-bus voltage control), and CAN diagnostic strategy; optimized torque-control algorithm, DC-bus current estimation algorithm, and system performance in special operating conditions in the MATLAB-Simulink MBD environment.

Coordinated with customers to understand requirements, perform tests, and draft test reports to support vehicle tests (on-site and remote) and mass production. Coordinated with customers and other suppliers (VCU, HV battery, and DC/DC) to develop new features (auto active discharge, DC-bus current control) to meet customer requirements.

Tested and calibrated the BSG motor on both bench and dyno to validate the hardware, the control software, and the system performance to meet customer requirements.

Integrated and commissioned mule cars on-site and remotely, providing vehicle test support (test results analysis, performance evaluation, failure root cause troubleshooting).