Joshua Cunningham Email & Phone Number

Fremont, CA, US

Principal Lead of PowertrainOversee and manage Terraline’s Powertrain resources, ensuring alignment with development schedules, budgets, and management expectations, while serving as a key representative for all vehicle powertrain initiatives.

• Founded Rogue Tuning, a high-performance hardware and software development company for the Porsche 944, and 944 Turbo automobile.
• Reverse-Engineered the engine control computer from a Porsche 944/911.
• Rewrote the firmware for the Porsche 944 engine management allowing the usage of different sensors, and increased functionality.
• Wrote time critical interrupt-driven operating system in assembly.
• Designed multiple PCBs to include real-time decryption equipment and time critical automotive solid-state ignition coil control.
• Developed products from concept to delivery for improving the Porsche 944 engine performance and safety.

Calgary, Alberta, CA

• Lead Inverter Controls EngineerGuided the Controls group in developing advanced motor control solutions utilizing Exro's innovative open-winding motor and inverter topology for primary mover on-highway applications.
• Architectural Innovation: Led major architectural overhauls to address safe-shutdown requirements, innovating methods that integrated and streamlined the entire derating and safety system.
• Intellectual Property: Pioneered Exro’s first software patent, enhancing inverter reliability through novel techniques.
• Functional Safety (FuSa) Leadership: Served as the internal FuSa advisor, introducing redundant measurement systems and rationality checks to bolster safety.
• Toolchain Migration: Spearheaded the transition from Ansys SCADE to MATLAB/Simulink, re-architecting the control software for enhanced performance and scalability.
• Innovative Proposals: Conceptualized and proposed a proof-of-concept control scheme for on-board charging using the Exro inverter and motor.

Phoenix, Arizona, US

• Lead Engineer responsible for development of a high-voltage (800v), high-power (600kW) inverter drive system. Intended usage in class-8 heavy-duty trucks.
• Designed a variable-frequency iFOC control in Simulink for a high-speed interior permanent magnet synchronous (IPM) motor.
• Developed SiC MOSFET & Si IGBT junction temperature and loss model heavily used for module selection on the new inverter design.
• Directed base-software-team (BSW) effort in setting up inverter software scheduler architecture; including loop timing, ADC & Resolver read timing, PWM generation – both continuous and discontinuous patterns.
• Investigated multiple dyno manufactures, selected, and procured a 600+ kW, 1250Nm, 14krpm dynameter.
• Worked with industry leader to develop a custom DC-Link capacitor and DC-bus plates to achieve <25nH of stray inductance (IGBT module + DC bus + DC-Link Cap).

• Principal Software Engineer responsible for research & development of Field Oriented Control for a low-voltage (24-48v) inverter drive system. Intended usage in forklifts and lift trucks.
• Designed a unified FOC control method for multiple motor topologies, including AC induction (ACIM), surface permanent magnet synchronous (SPM), interior permanent magnet synchronous (IPM), and wound-rotor synchronous.
• Designed MOSFET junction temperature prediction model to aid inverter thermal design requirements, and real-time inverter thermal limiting.
• Designed open-loop scalar control (Volts/Hz) for automatic motor parameter identification functionality.
• Built simulation of the inverter power-stage to provide MOSFET switch dead-time requirements, DC bus ripple rms voltage and current, DC-link capacitor sizing, and capacitor technology required.

Longmont, CO, US

• Primary motor control software engineer responsible for pushing the state-of-the-art of UQM brushless AC traction motor and inverter drive systems.
• Developed and implemented Safety-Critical vector-control (FOC) software for 20 – 250kW three-phase permanent magnet synchronous motor traction systems.
• Designed and implemented variable PWM frequency functionality to improve inverter efficiency and losses. As a result, the UQM traction system stall time improved from <1s to ∞ (motor stator temp limited).
• Designed and implemented inverter IGBT Junction temperature prediction safety function, which realized a 5x reduction in the required IGBT temperature safety margin, allowing for higher inverter power output while.
• Improved existing motor control firmware, realizing an 18% reduction in executable size, and a 31% improvement in executable loop iteration time.
• Conducted vehicle integration, testing and calibration in the USA, United Kingdom, China, and India.

Arlington, Virginia, US

• Managed a highly trained Special Operations team in Iraq and Afghanistan conflicts.
• Responsible for the serviceability and maintenance of equipment in excess of $500,000.
• Supervised the implementation and construction of multiple public works contracts worth over $2,000,000.
• Identified target audience specific marketing, including radio broadcast and newspaper with a weekly distribution of 20,000 papers.
• Gathered marketing metrics, performed analysis and trend identification on the effectiveness of US Army programs.
• Advised high-level officers on implementation of strategic goals and missions.