Generac Power Systems
● Calculated the exhaust air thrust and performed FEA on different designed patterns on the exhaust of PWRcell.
● Designed a set of experiments to analyze the airflow simulation and temperature distribution of the battery pack.
● Revamped the design of bracket assembly of PWRcell and simulated each component under varying conditions.
● Investigated the stress concentration regions and made necessary changes for industrial production.
● Designed a functional elongated hexagonal perforated panel for an aesthetic look on the exteriors of the PWRcell.
Perforated Panel
●Industrial design values flair and functionality. Perforated panels offer a valuable combination of aesthetics and practicality.
●Including a perforated panel is a smart way to influence acoustics by serving as a tuned resonant absorber, which absorbs sounds at a specific frequency
●A perforated plate adds a layer of filtration for larger debris and animals.
Exhaust Air-diode
● Analyzed the existing symmetrical flapper diode assembly and determined the redundancies
● The existing assembly is heavy, and flappers don't open equally
● Simulated the airflow for the existing air diode and determined that the issue occurs because of the way it is pivoted.
● Calculated the air thrust, normal force, and the angle of opening to diffuse the exhaust air
● Designed various exhaust diodes to simulate the flow distribution and compared the results
● Fabricated and experimented with a prototype to validate the simulation results
● Investigated multiple hinge types and listed them based on their reliability and functionality over the time
● Developed a semi-annular snap for easy installation and moderating the angle of opening
Interior air flow and temperature distribution
● Revamped the existing interior sub-structure to improve the interior airflow and temperature distribution of the PWRcell.
● Reverse-engineered Tesla's Powerwall 2 for comparison and re-designed the interior sub-structure.
● Scope of work includes design of bracket assembly, in-depth CFD flow simulations of air and thermal flows, exhaust louvers, and selection of fasteners and struts
● Factors like wind speed, seismic response, and spectral response coefficients were considered.
● Designed all brackets in sheet metal and performed in-depth structural and finite element analysis on individual components and the assembly to detect the higher stress concentration regions.
● Decided the placement of the exterior bracket sub-assembly based on the center of gravity of the entire system.
● Investigated the plausibility of the manufacturability on an industrial scale and made necessary changes
● As a result, I have completely re-designed the interior structure and taken it to production after passing all the required tests.
