Dr. Suresh Reddy: Engineering Leader in Electric and Hybrid Powertrains

Electric/Hybrid Powertrains & Charging Systems

Diesel electric, trolley, battery, fuel cell and hybrid electric powertrains, charging systems, components, control systems and diagnostics

Areas of experience/expertise:

• System architectures/configurations

• Systems Integration

• Moving components (motors/generators, gearing, pantograph)

• Power Electronics (inverters, converters, choppers, thyristors)

• Charging Systems - Off-board (EVSE, DC fast charge)

• Charging Systems - On-board (for storage or auxiliary battery)

• Power sources (Diesel engines, batteries, fuel cells)

• Powertrain control system architecture

• Electric Drive control systems

• Dynamic braking systems and control

• Control of AC/DC motors, generators, inverters, thyristors

• Thermal protection of electric drive components

• Powertrain cooling systems & control

• Control of power sources (engines, batteries, fuel cells)

• Modeling and simulation of systems and control

• Model based software development

• Software In the Loop/Hardware In the Loop (HIL)/Power HIL verification/validation

CAT® 795F AC Mining truck

CAT® 794 AC Mining truck

CAT® Trolley Assist System

Respective Powertrain components

CAT® 793 Battery Electric Mining truck

CAT® MEC500 DC Fast Charger

Relevant Experience/Roles (at CAT, GE, Fronius USA)

People/program/tech leadership through full development cycle:

• GE Evo series locomotive diesel engine and auxiliary systems controls, simulations, and software automation from Matlab/Simulink

• Caterpillar Inc's firs AC electric drive for mining trucks - system, rotating components, concepts/requirements for control systems and power electronics, desktop/HIL/lab simulation & validation platforms

People/program leadership for several development phases:

• Caterpillar Inc's 793F AC, MT4400D AC, 794 AC and 795F AC trolley concepts, components/system prototype build phases

• Fronius Wattpilot (EVSE) testing in lab, concepts for US market

Tech leadership/strategy for several development phases:

• CAT mining truck electric/mechanical/electromechanical drivetrain and various battery/diesel hybrid configuration concepts analysis

• CAT Marine, Oil & Gas organic growth concepts & business case

• CAT Gas compression motors strategy, concepts, collaboration

• Concepts for electric turbo assist/turbo compound for engines

• CAT concepts for electric frac pump drive, and integration with turbine gensets

• CAT Marine concepts for diesel mech/electric propulsion, power split hybrid , diesel/battery electric hybrid

• Concepts for energy transfer/charging for CAT electrification, DOE proposals for charging system, CharIN interface

• Concepts/simulations/evaluations for battery/fuel cell/ diesel/trolley/tether electric/hybrid powertrain architectures for mining/rail/construction machines

Tech oversight for several development phases:

• MEC500 DC fast charger issue resolutions

• Oversight of concepts for on board/off board chargers/EVSEs, multi-MW MCS DC fast charger, Dynamic Energy Transfer for mining equipment

Training/competency development:

• Internal electrification learning series and external custom courses coordination, including teaching, covering electric/hybrid powertrains, components and controls to 1200+ CAT employees

• Creation of talent pools in electrification by expertise area, across CAT enterprise

CAT® Gas Compression Motors

CAT® Marine Hybrid System

Electric frac trailer

E-frac mobile power plant

CAT® 793F AC Mining truck (program suspended)

CAT® MT4400D AC Mining truck (limited production)

Diesel Electric Locomotive

GE Evo Locomotive Powertrain Controls

Engine Control Unit

Control Panels

CAT® Dynamic Energy Transfer System

Fronius Wattpilot (EVSE)

Key Product R&D Experience (at Caterpillar Inc, GE, Fronius USA)

Relevant Awards

Images of products used are illustrative of Dr Reddy's research and development in various companies - they are meant to be illustrative, but not necessarily identical

Sources of images of products:

Mining trucks - Cat press releases and product websites, Cat 795F AC, Trolley and 795F AC specalog; DC Fast charge - Cat press release; CAT Dynamic energy transfer system - CAT Press release; Diesel Electric Locomotive (illustrative) - arb.ca.gov; GE Locomotive engine control unit - parts sales websites (ebay, 100outlets.com); GE Locomotive Control panel - GE Evolution locomotives by Sean Graham White; Fronius wattpilot - Fronius press release; CAT gas compression motors - Cat press release; E-frac: Enquestenergysolutions.com (illustrative), solar turbines (SMT60) website;Marine: Marine hybrid system - Cat press release

Relevant Patent Grants

1. US11404986B2 “Torque Control Based on Rotor Resistance Modeling in Induction Motors”, Caterpillar Inc, Granted: August 2, 2022; Filed: Aug 14, 2020

2. US11384629B2 “Systems and Methods for Driving a Pump using an Electric Motor”, Caterpillar Inc, Granted: July 12, 2022; Filed: Nov 30, 2020

3. US12060877B2 “Hydraulic Fracturing Pump Control System”, Caterpillar Inc, Granted: Aug 13, 2024; Filed: Sept 18, 2020

4. US86263682 “Electric drive power response management system and method”, Caterpillar Inc, Granted: Jan 7, 2014; Filed: Sept 7, 2010

5. US8482238B2 “System and method for estimating generator rotor temperature in an electric drive machine”, Caterpillar Inc, Granted: July 9, 2013; Filed: Nov 30, 2010

6. US7918296B2 “Cooling system for an electric drive machine and method”, Caterpillar Inc, Granted: April 5, 2011; Filed: Sept 15, 2008

7. US7467619B2 “Apparatus and method for accurate detection of locomotive fuel injection pump solenoid closure”, General Electric Company, Granted: Dec 23, 2008; Filed: Sept 24, 2007

8. US7328690B2 “Apparatus and method for accurate detection of locomotive fuel injection pump solenoid closure”, General Electric Company, Granted: Feb 12, 2008; Filed: July 16, 2004

9. US7000598B2 “Bumpless crankshaft position sensing”, General Electric Company, Granted: Feb 21, 2006; Filed: May 27, 2004

10. US6507789B1 “Gear transmission condition monitoring method and apparatus”, General Electric Company, Granted: Jan 14, 2003; Filed: July 18, 2000

11. US6449564B1 “Apparatus and method for monitoring shaft cracking or incipient pinion slip in a geared system”, General Electric Company, Granted: Sept 10, 2002; Filed: Nov 23, 1998

Individual Awards

Caterpillar Inc. – Chairman Award (2007)

GE Transportation – New Engineer of the Year (1999)

GE Transportation – 6 Sigma Project of the year (1999)

GE Corporate R&D – Special Grant Award (1997)

GE – Managerial Award - DOT Proposal (1994)

Project/Team Awards

Caterpillar Inc. - ACS Product AQI (Annual Quality Improvement) Winner (794 AC Mining Truck Electric Drive System, 2013)

Caterpillar Inc. - Drivetrain Business Unit AQI Winner (Mining Truck 795F/793F AC Mining Truck Electric Drive Systems, 2011)

GE Transportation - Managerial Award (Selection and deployment of Matlab/Simulink)

Legacy Team/Product Awards

(Awarded to teams/product developments previously led by Suresh Reddy)

Project Management Institute – 2023 Project of the year – Caterpillar prototype Battery Electric Mining Truck

Caterpillar Inc. – Excellence Award - Mining Truck Electric Drive team (2017)

Relevant Patent Publications

1. US20250206176, “Electrified Machine and Charger Fleet and Microgrid Power Dispatch”, Pub June 19, 2025; Patent filed: Dec 13, 2023

2. US20250042273, “Charging System for Non-Road Electric Vehicle”, Caterpillar Inc., Pub Feb 6, 2025, Patent filed: Aug 1, 2023

3. US20240405313 “Thermal management of Battery Systems”, Pub Dec 5, 2024, patent filed May 30, 2023

4. US20120018236 “Electric powertrain for off-highway trucks”, Patent pub Jan 26, 2012; Filed: July 26, 2011

5. US20100065356 “Electric powertrain for off-highway trucks”, Patent pub Mar 18, 2010; Filed: Sept 15, 2008