Head - Mechanical Engineering

Purpose/Objective

The Head - Mechanical Engineering oversees the design, integration, and optimization of turbine mechanical systems, including drive trains, blade structures, and nacelle components. The role ensures compliance with international standards, manages material selection and testing, and validates subsystem performance through advanced simulations and field trials. It leads initiatives in manufacturing innovation, such as additive manufacturing and lean production techniques, to enhance efficiency and scalability. The Head - Mechanical Engineering collaborates across functions to ensure subsystem compatibility and addresses challenges in design, assembly, and operations. Additionally, it mentors engineering teams, implements reliability frameworks, and drives continuous improvements to achieve durability, operational safety, and performance objectives.

Key Responsibilities of Role

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

Technical Competencies

Advanced Manufacturing and Process Innovation-WTG,Blade Structural Integrity-WTG,Budget Management & Resource Allocation-WTG,Cross-Functional Collaboration-WTG,Drive Train System Engineering-WTG,Material Characterization-WTG,Reliability Engineering-WTG,Subsystem Integration and Interface Management-WTG,Technical Standards Compliance-WTG,Thermal and Vibration Analysis-WTG

Qualifications and Experience

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.