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Tesla - Design Projects: Image

Tesla

Tesla vehicles are well-known for their innovative high-voltage electronics, which have enabled record drive ranges for fully electrified vehicles. The high battery capacity in Tesla cars has enabled innovations in low-voltage electronics as well. For example, 12 volt systems in a Tesla can run for extended periods of time even when the car is stationary, since the 12 volt battery does not depend on an engine to maintain charge, but simply draws power from the high-capacity drive battery. This improves the ownership experience for Tesla customers by allowing the use of audio systems, air conditioning, and internet connectivity when the car is parked without worry of killing the 12 volt battery and needing a jump start.

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I worked on the Low Voltage Electronic Systems and Autopilot Product Design teams to improve the user experience, assembly line safety and ergonomics, and profitability of Tesla electronic and autonomous systems.

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Tesla - Design Projects: Text
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Model 3 Design Projects

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Improved low-voltage electronics in the Tesla Model 3:

  • Waterproofed body control PCBAs for extreme precipitation environments in Norway

  • Improved installation ergonomics for assembly line workers by identifying and redesigning components which were difficult to install

  • Replaced purchased housings and fasteners with Tesla-manufactured components of my own design for increased marginal profits

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Model 3 Failure Analysis

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Led root cause investigation into high-priority Model 3 failure mode (non-safety critical) causing customer complaints:

  • Ran weekly sync meetings between managers and directors from multiple departments, assigned action items, distributed meeting minutes

  • Personally performed:

    • Tolerance stackup analyses

    • Electric field strength testing

    • Prototype development

    • Test stand fabrication

    • Tests on engineering and production vehicles

  • Helped organize​​​​:

    • Metrology studies

    • Dimensional analysis reports

    • Automated tests on 6DOF robotic arm platform

    • Fab shop orders

  • Identified and implemented improvements for the Design Studio and Customer Service teams to manage problem in the short term

  • Identified and implemented improvements for the Low Voltage and Antenna Systems teams to eliminate root cause of electromechanical issue in long term

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Fremont Manufacturing Line

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Supported the rapid deployment of a new Model 3 assembly line to meet company-critical production goals:

  • Developed floor plans and material flow paths

  • Developed and deployed Python-based torque-recording software to electronics assembly work stations

  • Learned, in-depth, assembly process for a half-dozen Model 3 electronic subassemblies

    • Trained many incoming new assembly line workers on these assembly processes

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