shyam vadakkanchery

Highly experienced Simulation and Control Systems Engineer with over 7 years of expertise in Model-Based Software Development (MBSD), HIL/SIL/MIL testing, and embedded systems validation across the automotive, avionics, and power electronics sectors. He has a strong background in developing and validating safety-critical control algorithms, particularly for fuel cell systems, powertrain applications, and flight control systems.

He is proficient in tools such as MATLAB/Simulink, TargetLink, Polyspace, BTC Embedded Tester, and Veristand, and has hands-on experience with OPAL-RT, CAN protocols, and Python-based automation. Shyam has contributed to major projects at ZeroAvia, Mercedes-Benz R&D (via Tata Elxsi), and DRDO, demonstrating strong analytical skills, technical leadership, and a commitment to high-quality engineering standards.

Work Experiences 

Simulation & Test Engineer (Nov-2022 to present) PROJECT SCOPE: - Architecture & Development of the LTPEM and HTPEM fuel cell power generation system plant models for validation and certification of control algorithms.  BOP (Balance of Plant) model developed for Fuel-cell in Simulink/Simscape environment, including various sensors (Temperature & Pressure, Humidity), Actuators & Electrical Signals for closed loop and open loop Validation of Control Algorithm.  Utilized data-driven methods to develop the Anode (Gaseous Hydrogen), Thermal, and Cathode subsystem Plant Models and validate the control algorithms in the MIL and HIL Test.  Develop test case as per SRD & validate in HIL, Analyse & Debug CAN interface data using PCAN Analyzer.  Validated various critical state machine and subsystem for the Fuel cell controller algorithm using MIL Test.  In charge of the development and maintenance of the Hardware-in-Loop-Simulation (HIL) Test Rig and wiring harness utilizing the OPAL-RT Platform.

 Specialist MBD - Control Development TATA ELXSI Ltd (May-2020 to Nov- 2022) 

PROJECT SCOPE: - Oversee the internal development and validation of diverse HVAC functions for various vehicle models. Lead a team of five members, ensuring effective task allocation and timely project completion. (Jan-2022 to Nov-2022) 

PROJECT SCOPE: - Development and validation of Level 2 Monitoring software for Powertrain applications conducted internally for multiple car lines. (May-2020 to Dec-2021) 

 Performing requirement analysis and software development with MATLAB, Simulink, and Targetlink, while complying with ISO 26262 standard.  Assessment of Modelling Guidelines with the MXAM Tool and the generation of code automatically via Targetlink.  Implement Static Code Analysis using Polyspace Code Prover.  Conducting MIL-SIL Back-to-Back Tests and Analysis with the BTC Embedded Tester.  Requirement-driven functional unit testing employing Time Partition Testing (TPT). SENIOR ENGINEER – Control Validation (March-2019 to April-2020) 

PROJECT SCOPE: - Outline the procedure for SIL testing utilizing TPT, conduct coverage analysis, and ensure the maintenance of the traceability matrix for different Engine Management software modules.  Validation of EMS Software through Software-in-Loop (SIL) Testing utilizing TPT.  Created MATLAB scripts to improve the efficiency of test execution. 

 SENIOR RESEARCH FELLOW (July 2015 – Feb 2019) DEFENCE RESEARCH & DEVELOPMENT ORGANIZATION Bangalore, India PROJECT SCOPE: - Design and implementation of a Flight Control Test System tailored for various Avionic Line Replaceable Units (LRUs) employed in the medium-altitude long-endurance (MALE) unmanned aerial vehicle (UAV) being developed by Govt of India.  Development and up gradation of Flight control computer (FCC) control law as per latest Functionality Requirement.  Development and up gradation of Mathematical model of 6-DOF as per latest Functionality Requirement & Air Frame Update.  Development of avionics subsystems, including Sensors and Actuators, utilizing MATLAB/Simulink in accordance with the Requirements Specification.  The design and implementation of a Hardware-in-Loop Simulation (HILS) Test Rig leveraging OPAL-RT and National Instruments (Veristand).  Automation script developed in Python for conducting Hardware Software Integration Testing (HSIT) on Avionic Line Replaceable Units (LRUs)  Assessment of Static and Dynamic Functional Validation for Different Avionics Line Replaceable Units in Stand-Alone and Integrated Modes 

ELECTRICAL ENGINEER (March 2013 - March 2015) INSTITUTE FOR PLASMA RESEARCH Gandhinagar, India PROJECT SCOPE: - Design and development of multiple safety-critical power electronics circuits within the Lower Hybrid Current Drive Division involve the utilization of a Klystron (microwave tube) to heat plasma in an experimental Tokamak. This process enables the generation of consistent plasma discharges lasting approximately 500 milliseconds, achieving plasma currents exceeding 75,000 A at a central magnetic field strength of 1.5 T.  Developed HVDC switch with a rapid response time of under 5 microseconds, supporting 5kV and 100A, consisting of series-connected SCRs paired with a triggering circuit and gate driver configuration.  Designed a high voltage power supply unit capable of 230AC/5kVDC output, featuring a current range of 0-3mA. This unit includes 10 kV isolation, current monitoring capabilities, an active overcurrent trip interlock, and a configurable variable trip point setting.  Designed a Soft Start Circuit utilizing Triac and 555 timers for the power supply of a Tetrode filament, operating at 7V and 20A.  Developed a High Current Pulse Generator (30A. 50sec). TESTING & COMMISSIONING ENGINEER (June- 2012 - February 2013) 

KERALA STATE ELECTRICITY BOARD (KSEB) Kerala, India  Perform Type Testing, Routine Testing, and Special Testing on High Voltage Equipment such as Power Transformers, Current Transformers (CT), and Potential Transformers (PT) in substations with voltage levels between 33kV and 220kV  Perform Tan DELTA measurements and insulation resistance assessments for Power Transformers, CTs, and PTs.  Execute various tests on circuit breakers, including insulation resistance tests, high voltage tests, contact resistance tests, and timing tests. 

TESTING & ANALYZING ENGINEER (Sept- 2010 - February 2012) TRANSFORM ELECTRICALS Kerala, India  Engaging in the testing and analysis of new power supply designs, which include fixed and variable voltage configurations, along with transformer-based and solid-state (SMPS) systems.  Executing transformer testing for ratings up to 250 KVA, which involves load testing, no-load testing, and insulation resistance testing.  Managing production operations, supervising staff, and being accountable for the upkeep of progress reports.

Bachelor degree in Electrical & Electronics engineering