Rafi Nasrallah

Feb 2026 – May 2026

Project: Systemic resolution of a critical premature shutdown defect (at 20% SoC) and energy gauge instability during abrupt accelerations on electric scooters through a coupled Hardware / Software / Process approach.

• Digital Twin: Development of a high-fidelity virtual battery (15S2P configuration, LFP chemistry) integrating dynamic hysteresis models and a digital guard/safety architecture (IEC 62133 / ISO 26262 standards).
• Estimation Algorithms & AI: Design and implementation of a hybrid State of Charge (SoC) estimation architecture combining a physical model (ECM 3RC), an Unscented Kalman Filter (UKF), and an LSTM neural network. Development of a residual observer (AI) to compensate for unmodeled phenomena.
• Advanced Energy Management: Integration of a bidirectional active balancing system (LTC3300-1) and development of a safety supervisor (Finite State Machine - FSM) for degraded mode management and system protection.
• Hardware & Embedded Design: Designed and routed in Altium Designer a 16S Battery Management System (BMS) board based on an STM32 architecture, integrating EMC considerations, power protections, and I2C, SPI, and CAN communication interfaces.
• Validation & Robustness: Validation of algorithms via MIL simulation on a digital twin (RMSE < 2 %) and experimental validation on an instrumented HiL prototype (Arduino, High-side MOSFET).
• Quality Management (QMS): Development and implementation of a strict industrial cell qualification procedure (PR-BAT-01) inspired by the ISO 9001 standard.
• Supervision and Digitalization: Creation of a real-time industrial dashboard (MQTT, REST API) for production monitoring, complete traceability of battery packs, and KPI analysis.

Engineering Internship - SMCV

July 2025 – September 2025

Industrial Automation (PLC/HMI), Mechanical Design

Software Used: TIA Portal, Autodesk Inventor

• Injection Molding Machine: Programmed Siemens PLC (TIA Portal) and implemented HMI interfaces.
• Mechanical Arm: Designed and modeled the assembly in 3D CAD.
• Automatic Hot-Press: Designed/analysed mechanical and thermal components, sized actuators, and programmed PLC/HMI.

Internship - ONEE

July 2024 – August 2024

National Office of Electricity and Water

Software Used: OMICRON Test Universe, SIPROTEC Tools

• Conducted operational analysis of installed Siemens protection relays.
• Developed a comprehensive testing protocol for system verification.
• Executed verification and validation procedures for the testing protocol.
• Developed and finalized comprehensive technical documentation for compliance records.

Apprenticeship - Rafi Robotiques et Machineries

2020 – 2023 (3 Years)

Mechanical Repair, CNC & Robotics

• Mechanical repair of Sharmaann horizontal boring machine.
• Design and fabrication of 5-axis welding robots.
• Repair and reprogramming of CNC Lathe Machine (Siemens Sinumerik 840D).
• Reprogramming of Spring Assembly Machine (Matissar).