Head of Mechanical Engineering

Head - Mechanical Engineering

Responsibilities

Drive Train System Engineering

• Lead the design and optimization of mechanical drive train systems, including main shafts, bearings, gearboxes, and couplings to ensure robust performance under variable loads.
• Conduct dynamic load simulations using tools like ANSYS and Romax to predict fatigue life, vibration characteristics, and resonance conditions.
• Oversee torque transmission system integration with rotor nacelle assemblies for high efficiency and minimal wear during operational cycles.

Blade Structural Integrity

• Direct the application of composite materials like carbon fiber and epoxy resins to achieve optimal strength-to-weight ratios and durability under extreme environmental conditions.
• Oversee finite element analysis (FEA) for blade structural integrity, addressing fatigue cracking, shear deformation, and delamination.
• Establish and validate blade testing protocols, including static and fatigue tests, to ensure design assumptions align with real-world performance.

Thermal and Vibration Analysis

• Develop heat dissipation strategies for components like bearings and gearboxes under high-load conditions.
• Implement noise, vibration, and harshness (NVH) mitigation techniques, including vibration damping materials and acoustic emission reduction designs.
• Validate thermal and vibrational performance through prototype testing and field trials.

Subsystem Integration and Interface Management

• Lead the integration of mechanical subsystems, ensuring alignment of gearboxes, main shafts, and rotor dynamics with nacelle designs.
• Collaborate with cross-functional teams to resolve interface challenges, such as misalignment, load distribution, and thermal interactions.
• Oversee interface testing to verify subsystem compatibility and operational efficiency.

Material Science and Application

• Guide the selection of advanced materials, such as high-strength steel and composite alloys, to enhance reliability and corrosion resistance.
• Establish and implement material testing protocols, including corrosion resistance and fatigue testing.
• Introduce lightweight material alternatives to improve turbine efficiency and reduce costs.

Reliability Engineering and RCA

• Develop reliability engineering frameworks, setting benchmarks like Mean Time Between Failures (MTBF) for mechanical subsystems.
• Lead root cause failure analysis (RCFA) for mechanical failures, such as gearbox fatigue and blade structural issues, and implement corrective actions.
• Establish proactive maintenance schedules based on operational data to enhance subsystem durability.

Testing and Validation Protocols

• Oversee load simulations, fatigue tests, and field trials to validate mechanical system performance.
• Manage instrumentation systems for strain measurement, displacement monitoring, and thermal analysis during prototype and field tests.
• Document testing outcomes to support certifications and design validation processes.

Compliance with Technical Standards

• Ensure mechanical designs meet international standards, including IEC 61400, for safety, fatigue, and durability.
• Lead certification audits with global authorities like TUV and DNV-GL to validate structural and operational reliability.
• Align designs with regulatory requirements for environmental sustainability and safety.

Advanced Manufacturing and Process Innovation

• Drive innovation in manufacturing techniques, including additive manufacturing for prototyping and CNC machining for high-precision components.
• Optimize traditional processes like casting and forging to improve efficiency and reduce material waste.
• Explore automation opportunities in assembly lines to enhance consistency and throughput.

Cross-Functional Collaboration and Leadership

• Lead multidisciplinary teams to integrate mechanical designs with electrical and SCADA systems, addressing challenges in real-time.
• Foster a culture of innovation and technical excellence by encouraging adoption of best practices and emerging technologies.
• Provide strategic insights to senior leadership on design enhancements, manufacturing scalability, and cost optimization.

Key Stakeholders - Internal:

• Head - Engineering
• Lead - Mechanical Drive Train
• Lead - Blade Process Engineering
• Lead - Gearbox & Tooling Engineering
• Lead - Load Simulation
• Head - Electrical Engineering
• Head of Manufacturing
• Head of QA
• Head - Safety
• Head - System & Business Excellence

Key Stakeholders - External:

• Regulatory Bodies
• Certification Bodies
• External Consultants
• Government Agencies
• Major Suppliers (e.g., nacelle and blade components)
• Component Testing Facilities
• Industry Standard Organizations

Qualifications

Educational Background:

• BE or ME in Mechanical Engineering, with a focus on structural design or manufacturing.

Work Experience:

• 12+ years in mechanical system design and integration, focusing on drive trains, blade structures, and subsystem validation. Experience in material selection and advanced manufacturing is essential.

Industry Knowledge:

• Deep understanding of FEA, reliability engineering, and standards like IEC. Proficiency in innovative manufacturing techniques and durability optimization is required.