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Academic Portfolio

Under Maintenance July 2024, check back soon ;)

Throughout my academic and professional career I have provided large contribution to projects involving:
Complete project management oversight over design, fabrication, and analysis of a finalized MVP

Quality testing methodologies including DOE & ANOVA Gage R&R
Creation of MATLAB image rendering tools
SolidWorks and SpaceClaim 3D computer aided designs
ANSYS structural analysis
ANSYS topology optimization

Sample CAD/Structural Analysis

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GymPals

Product Launch & Go-to-Market Strategy (Product Management Course)

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Tension Monitoring System

(Sponsored By Quabbin Wire and Cable Co.)

Abstract

The Quabbin Wire Tension Monitoring System team has been tasked with the design and fabrication of a repeatable, pulse reducing, cost effective, and operator friendly tension rendering system that will utilize a displacement sensor to track vibrations in a cable as it is moved off a reel and onto a payoff machine for twisting and stranding. In practical application, an operator will use a hand-held tension roller that utilizes a load cell, transducing compressive force to be used as an electrical signal. With the proposed design, tension monitoring will be streamlined, removing the need for an operator as well as error that is produced by introducing forces such as friction from the roller to the cable. In addition, the project will serve as a tool to guide further development into adaptive systems such as a tension braking system, where speed reduction of the payoff motor will reflect active tension measurements. Our team seeks to begin fabrication of the tension monitoring system in February, followed by continuous testing for repeatability and reproducibility as compared to a conventional system through the design of experiment model. By May of 2022, the finalized system will be applied to the company sponsor's key payoff machine with adaptive capabilities to be used on a variety of secondary payoff machines. 

Method

Using the standing wave oscillation (forced vibration) obtained from a variety of gauge wire being stranded, the tension can be solved with the natural frequency using Fast Fourier Transform. Afterwards, tension can be derived from a series of calculations.

Model Of System

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Recreation of Cable Pulley System

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Orientation of Cable

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Sample Analysis with following assumptions:

  • natural frequency derived from vibration

  • wire

    • gauge length​

    • density

    • mass

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Key Specifications, including but not limited to the following:

  • Omittance of operator by providing live tension measurements through LCD display

    • Button's guide stepper-motor to alternate position based on wavelength​

  • Repeatable method off measuring tension​

    • Tension measurements are tracked within a +-0.1 lbf accuracy and results are provided continuously ​

  • Eliminate and or reduce pulsing and tension variation​

    • Observing natural frequency of vibration response​

  • Simple display​

    • LCD display is simple enough such that operators can see tension results with a quick glance ​

  • Universal ​

    • Our proposed design should be useable on all payoff machines within Quabbin​ Wire and Cable Co.

  • Variability in stand​

    • Stand should be able to adjust vertically as well as encasement/pulley system pivoting to allow all angles of attack of wire​

  • Cost​

    • Budget provided to our team of $1000 per conductor​

  • Lightweight/portable device​

    • If the device is to be moved around Quabbin's facility, it should be easy to carry

​

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Personal Contributions (Team Lead)

  • Conducting meetings with sponsored company regarding project scope and direction, weekly AOI reports, and timeline

    • MS Project​

  • Evaluation of system, including DOE tested against contemporary hand-held compression roller method, single sample t-tests​​​​

    • Statistical software including Minitab​

  • Influence over all design modifications with justification

    • CAD including SolidWorks 3D Drawings​

  • Developing C/C++ Code to work with the following computation and hardware:

    • FFT and tension computation, Arduino, LIDAR-Lite v4 sensor, LCD hardware​

  • Management over bill of materials

    • Correspondence with machine shop and suppliers​

​

Enclosure for SMG Pressure Sensor
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(Sponsored By Sensata Technologies)

Available in dropbox are files related to design specification and restraints. The project consisted of multiple redesigns for a pallet and plastic insert used to capture SMG pressure sensors with a limited degree of freedom. The pallet itself milled out of Aluminum 6011 due to it's strength to weight ratio, where weight was a substantial grading metric in the project. Topology optimization and static structural analysis were preferred to select optimal weight and geometry. Machining limitations that included cost, time, tool changes, and milling thresholds were all taken into consideration.

Portfolio: List

Design of Motor Gearhead

The goal of the project was to successfully design and iterate a motor gearhead to be used in an industrial motion controller without bending or surface failure, fall within gear case sizing (22mm +/-), maintain a reduction ratio of 12, and maximize the life of the gear given that it will be ran for a total of 1,000 hours at 99% reliability. Preset conditions such as standard pressure angle, operating conditions, motor power, and tensile and hardening properties for steel were provided. Other variables such as pitch, number of gear stages, and reduction ratios could be altered to ensure the above criteria was met.

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Design of Motor-Brake System

Some key specifications off this project included:

  • Created scaled sketches of a Maxon 35L 12W motor assembly as well as a disk and single short-shoe brake configuration.

  • Provided justification for choice of motor-brake system that optimized time to stop and minimum clamping force required.

  • Created a BOM which included purchases of spring and solenoid for activation and deactivation of disk brake.

Design of Electronic Pill Dispenser

Some key specifications of this project included:

  • Automated dispersion of pill(s) at said time and date

  • Cartridge opening done by CNC axis 

  • Cartridge reusability

  • Sensory features for remembering when it is time to take medication

  • Padlock to avoid temperament 

MATLAB Rendering to Achieve Primary Function

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