Intern – Mechanical Systems (Winch & Tether)
Intern or GET
Hyderabad, Telangana, India
About
The intern will work with the mechanical and systems integration teams on the design, fabrication, and testing of the winch and tether mechanisms used for launch, retrieval, and stabilization of tethered aerostat systems.
The role combines design analysis, mechanical integration, CAD modeling, and field testing, with an emphasis on structural reliability, load management, and automation support for winch control and tether handling under variable wind conditions.
The intern will gain exposure to mechatronic systems, dynamic load modeling, and aerospace-grade mechanical design practices.
Description
Design & Modeling
• Assist in the design and 3D modeling of winch drums, guide rollers, mooring frames, and tether management subsystems using CAD tools (SolidWorks, CATIA, Fusion 360, etc.).
• Perform mechanical stress, fatigue, and dynamic load analysis on tether and winch assemblies under varying tension and wind profiles.
• Support design of gear trains, braking systems, bearings, and couplings for safe operation and rapid deployment.
• Contribute to the development of lightweight structural components and portable winch housing for road-mobile configurations.
Prototyping & Fabrication
• Prepare engineering drawings and part lists for fabrication and assembly.
• Work with technicians and vendors for manufacturing, machining, and assembly of winch components.
• Participate in quality inspection, fit checks, and dimensional validation of fabricated parts.
Integration & System Testing
• Assist in integrating winch assemblies with motor drives, encoders, and tension sensors.
• Conduct bench-level and field-level tests to measure tether tension, spool dynamics, and mechanical response.
• Support development of automated tether deployment/retrieval systems in coordination with the electronics and AI control teams.
• Participate in environmental and endurance testing for load, vibration, and temperature resilience.
Tether Design & Handling
• Study tether cable materials (aramid, UHMWPE, hybrid composites) and support selection based on tensile strength, flexibility, and insulation.
• Contribute to development of tether winding profiles and tension-feedback mechanisms for stable aerostat control.
• Assist in tether maintenance and inspection protocols to ensure long-term reliability and safety.
Documentation & Reporting
• Maintain design records, test logs, and integration reports.
• Support generation of Bill of Materials (BOM), assembly manuals, and standard operating procedures (SOPs).
• Present design updates and test outcomes during project review meetings.
Requirements
Final-year or postgraduate student in Mechanical, Design, Aeronautical, Telecommunications, Electrical Engineering, or related field.
Desired
• CAD Tools: SolidWorks, CREO, CATIA, Fusion 360, AutoCAD
• Simulation & Analysis: ANSYS, MATLAB/Simulink, or SolidWorks Simulation
• Manufacturing Knowledge: Machining, welding, sheet-metal fabrication, composite materials
• Instrumentation: Load cells, strain gauges, torque sensors, tension meters
• Basic Electronics Familiarity: Sensors, actuators, and motor integration for mechatronic systems.
• Documentation Tools: MS Office, Excel, or project management platforms (Notion, Asana, etc.)