Design Engineer

Job Purpose

To lead and execute the electrical, thermal, insulation, and mechanical design of Traction Transformers (Oil-cooled and Dry Type) for Metro, EMU, and Converter applications, ensuring compliance with international standards, customer requirements, and project timelines while supporting manufacturing, testing, and field performance.

Key Responsibilities

1. Transformer Design Traction & Converter Applications

• Design of Traction Transformers (Oil-cooled / Dry Type) for 25 kV AC traction supply.
• Design for Rectifier / Converter Transformers (6-pulse / 12-pulse) for SCR & IGBT-based applications.

2. Electrical Design

• Core selection and flux density optimization.
• Short-circuit force calculation and impedance control.
• Parallel winding design.
• Analysis of high dv/dt and di/dt stresses.

3. Traction-Specific Technical Expertise

• Harmonic loss evaluation.
• Eddy current and stray loss mitigation.
• Leakage reactance control and high-impedance matching.

4. Thermal Design

• Load-cycle-based kVA rating and temperature rise calculations.
• Hot-spot analysis under traction duty and overload duty cycles.
• Evaluation of non-sinusoidal current heating losses.
• Cooling system design: ONAN, ONAF, OFAF, OFWF, AN, AF.

5. Insulation Design

• Insulation coordination using paper, pressboard, and epoxy systems.
• Creepage and clearance calculations.
• Surge and impulse withstand level design.

6. Mechanical Design Inputs

• Winding clamping structure and pressing force calculations.
• Spacer design and tank design inputs.
• Vibration and noise mitigation inputs.

7. Design Documentation

• Preparation of Design Calculation Reports.
• General Arrangement (GA) drawings.
• Technical datasheets and customer documentation.

8. Manufacturing & Testing Support

• Support during core assembly and winding activities.
• Participation in heat run, noise, and impulse testing.
• Resolution of shopfloor and testing-related issues.

9. Standards & Compliance

• Design in accordance with IEC 60076, EN 50152 / EN 50329, IEC 61373, and applicable fire safety standards.

10. Field Support & Continuous Improvement

• Root cause analysis of failures and field issues.
• Identification and implementation of modern design and testing technologies.

General Responsibilities

• Maintain up-to-date industry knowledge through journals, publications, and technical training.
• Communicate proactively and professionally with internal teams and customers.
• Plan, prioritize, and manage workload to meet project schedules.
• Continuously improve internal and external customer satisfaction.
• Ensure transparent, fast, and robust communication within the team to prevent escalation of issues.
• Implement and comply with ISO 14001 environmental management protocols.
• Maintain strict confidentiality of all design data, technical information, and pricing details.
• Support the development of behavioral and soft skills of team members.
• Perform any other reasonable duties as assigned by management.

Key Skills & Competencies

• Strong expertise in traction transformer design.
• Deep understanding of power electronics interaction with transformers.
• Analytical and problem-solving skills.
• Knowledge of international standards and testing requirements.
• Strong communication and cross-functional collaboration skills.
• Leadership and mentoring capability (for M5 level).