Projects

Generic image of satellite dish

Composite Satellite Dish

This project taught me about validation and composite layup processes

For senior design, I assisted a team of 2 peers and a local composite R&D company to design a strain based deployable satellite. Although much of the material is proprietary, the overall theme of the project revolved around innovating and manufacturing a previously designed Proof of Concept (POC).

The previous POC failed largely in three places.

  1. Reliability - The design failed after too few iterations of its full movement. As the product is design for space use, reliability is a go/no-go priority.

  2. Manufacturability - The previous iterations of the design had relied heavily on human ability with little to no tooling, spacing or layup assistance. This led to poor surface quality and adhesion issues during manufacturing.

  3. Shape - due to the reliability and manufacturing issues, the previous iterations of the design failed to hold shape as the materials shifted over time. This led to decreased strain and shape failure - an unusable product.

To improve on these design flaws, our group first researched and brainstormed a updated method for manufacturing as the Reliability issue and Manufacturability issue were related. This meant one solution likely held the key for solving two problems. We developed a working model of new tooling and, using a 3D printer, mocked up a prototype to be used as validation testing. With necessary iteration, our method was found to be effective.

Next, our group addressed the problem of shape change over time. With an ideation session with the company engineers, we were able to come up with a secondary strain operation similar to that of a tape spring. This allowed packaging to maintain within spec while allowing for the desired strength and rigidity upon deployment.

Currently, testing is ongoing to determine the next steps to be taken in this project, including full scale validation testing.

Automated Bike Lock

This project taught me about mechanical and electrical integration along with budget engineering.

For mechatronics as a junior, I helped a team of 3 peers to complete a automatic bike lock system. Our team was graded on how little money was used as part of the grade which accounts for the rough prototype seen to the left.

Using a remote control which could be attached to a set of keys, and running off of a 12 v car battery, the system was designed to interface with a vehicle as a car bike rack. It integrated a herringbone gear box which ensured that the stroke had enough power to lock around the bike. The system would pull down on the bike until a certain pressure was reached in the claw using a FSR sensor which would cut off the motor. An alarm was then set so that is the system was forcibly broken or moved when it was supposed to stay still a visible and audible response would deter theft and encourage attention from bystanders. The lights were red and blue to suggest a police response to further discourage theft.

To design this product, the team first set upon designing the actuator as this was the most important moving part and needed to be strong. This meant focusing on how to transfer the power from rotation to linear motion along the clamp. This was achieved with a screw gear.

Next, the circuit was designed to ensure safety and control of all of the parts. This started with a functional diagram to ensure all of the components were practical and purchased and quickly filtered into a circuit diagram (both seen above).

Finally, the software was developed to control the components safely with failsafes built in for power failures/disconnections - the assumption being this may happen during use on a vehicle at some point.

Deck Build

This project taught me how to run a project from start to finish.

As a self employed worker during the 2020 pandemic summer, I helped a client design, plan and construct a backyard deck off of the rear of his house. Feel free to click through the images to the right.

Starting with the design, I measured and examined the location to discuss options with the home owner. After discussion to ensure the product would be what the home owner wanted, I mocked up a couple designs at home using the correct measurements to give a good idea of what the yard would look like with the finished product. I provide both overview (as seen to the right) and dimension specific plans for approval. Research was completed with local regulations including HOA, City, County and State concerns. This ensured the construction was up to code.

After plan approval by the home owner, along with some slight modifications as desired, I created a Bill of Materials which allowed the project to start while the wood was ordered. This planning was critical because wood at this time was quite scarce which meant incorrect math would result in wasted time and money due to the significant lead time on pressured lumber.

While waiting for the wood to arrive, all the measurements and holes for pilings were prepared, along with concrete poured. When the wood arrived, the frame and joists were hung (See pictures). Next, the deck boards were added. And finally, the railings complete.

Overall, the project was a success for the both the home owner and myself. He plans to install a pergola eventually to help shade the deck.

Track Racer

This project taught me that simple is often better and about writing reports long reports.

This project was one of the first big engineering projects I completed at university. Working with 3 peers, I helped develop a track car to go around a square track. This project was one of the first open ended design problems which I was able to work on in college. The team started all the way at the beginning of the design process with only constraints. This led to research on current market products and methods and led to brainstorming by way of brain mapping, sketching, product comparison and so on. This was a great opportunity to learn the importance of failure early in design, especially in prototyping mockups. Our design went through many iterations early on; however, we struggled to successfully learn from our mistakes which led to struggles later on. We had many last minute changes to design and methods which was a good learning experience.

By the end of the project we ended up with two very separate systems - an electronic control system and a mechanical control system. This huge variation was due to early failures in our prototype testing. Originally, we looked at controlling the wheels using a sonar sensor for distance and an Arduino processor for motor control. When the sonar sensor failed to be enough, we added an infrared sensor to allow the wheels to adapt on the fly. When this failed we tried a new configuration in the software design and so on. We failed to realize that the design was failing not due to our inability to program, but our inability to actually address the problem. A few of the first few prototypes are shown to the right.

This final realization that we were solving the wrong problems led to a compete rethink of how to design the vehicle. This led to the final design - a mechanical system which used the friction of the ground and the wall to more rapidly move than our previous iterations. This is seen in the googly eyed machine to the right.

This project taught me so much about failure and the importance of prototyping for the actual solution - learning from what the data is telling you.


Please feel free to examine the project report and documentation below:

https://docs.google.com/document/d/1hmlX9OZjiOD0Sut4IXEYwYA8pL6aJj1DvFo50pykbus/edit?usp=sharing