Christopher Colarusso Email & Phone Number

Detroit, MI

Troy, Michigan, United States

• Co-led the development of novel steer-by-wire steering gear including system sizing, torque reduction/amplification mechanisms, concentric motor integration, anti-rotation mechanisms, sealing parameters, grease.
• Designed/authored prints for a novel cycloidal transmission
• Technical expert for vehicle dynamics tuning of force feedback actuators on in-house HIL stand

Dearborn

• Authored functional requirements for the implementation of CAN message authentication (CMA) in power steering control modules including initialization, key provisioning, signal ratings, DTC setting, etc., using AUTOSAR.
• CMA subject matter expert for lower steering application teams and partnered suppliers, providing implementation support through all program milestones for initial vehicle programs slated for message authentication
• Performed device transmittal changes for lower steering CAN message databases via Siemens Teamcenter
• Conducted Super Duty steering sizing testing to validate engineering specification targets by driving instrumented trucks through a series of maneuvers and processing the data by building custom MATLAB scripts in order.

Dearborn, Michigan, United States

• Designed and integrated a novel linear position sensor into a prototype steer-by-wire rack and pinion system that was in a latter design phase and led the steering lab bench test integration and troubleshooting of.
• Led design work on the input shaft/sensor assembly for a build-to-print electric recirculating ball steering gear for F250/F350 Super Duty trucks, along with torque/angle sensor selection and initial powerpack target.

Dearborn, Michigan, United States

• Led the development of Ford’s first steer-by-wire engineering specification for lower steering gears
• Performed on track testing and calibration development of supplier prototype steering systems, with the goal of matching production vehicle steering characteristics and minimizing inherent system flaws
• Created and executed a low friction testing plan based on SAE, ISO and internal vehicle dynamics steering tests to assess and characterize supplier gear performance and algorithms during winter testing
• Planned and conducted internal customer clinics to develop ingress/egress requirements and steering wheel overtravel events

Dearborn, Michigan

• Designed components and assemblies for the second generation of an in-house hydraulic recirculating ball steering gear for F450/F550 Super Duty trucks using a combination of tolerance stackups, Catia v5 (for CAD, FEA.
• Developed an atomic level DFMEA linking all dimensional tags to specified quality requirements based on failure mode severity, contribution to tolerance stack-ups, etc.
• Reviewed evidence book data and assessed capabilities in Minitab with Ford Asia Pacific colleagues and Tier 1/2 suppliers
• Coordinated bench testing, internal leakage studies, BOB/WOW trials, Tinius Olson testing, etc., with in-house testing lab
• Led similar design work on the first iteration of an in-house flexible manual rack and pinion gear architecture, including a novel roll formed swage ring for bearing retention and components/assembly of the input.

Ontario, Canada