Ryan Jacobs. mechanical engineer. design portfolio

Transcription

1 mechanical engineer design portfolio

2 Formula SAE Student Design Project Team

3 Formula SAE Student Design Project Team Design: Fabrication: Testing:

4 Formula SAE Drivetrain Design Bearing Carrier CV joint Halfshaft Wheel Hub Differential Objective:Optimize performance, weight, cost, reliability, ease of manufacturing, and tunability. Function:Team Leader, responsible for design and manufacture of drivetrain components with a focus on system optimization. Highlights: Implemented tripod style Constant Velocity (CV) joints to save weight and enable in-house CNC machining, designed and fabricated simple mechanism to restrain halfshafts

5 Formula SAE Drivetrain Packaging Highlights: - Redesigned inboard CV joints and bearing carriers to accommodate brake calipers, rotors, and hydraulic lines - Minimized halfshaft angle within CV joint to reduce stress and optimize efficiency while maximizing chain engagement on both sprockets - Eliminated potential sources of unbalance and friction by minimally constraining assembly in concentric layout Rear Sprocket Brake caliper Differential CV Joint Brake Rotor

6 Formula SAE Constant Velocity (CV) Joint Background:CV Joints allow rotating shafts to transmit torque over a range of angles to allow for suspension travel Highlights: - Developed one-piece Tripod style inboard CV joints - Analyzed joint in FEA for acceleration and braking conditions - Incorporated brake rotors and wheel speed sensors onto exterior of inboard joint to minimize yaw moment of inertia - CNC machined from 4340steel then heat treated to HRC 50 Wheel Speed Pick-up Grease Boot Tripod Brake Rotor Splines to Differential

7 Formula SAE Halfshaft Retention Mechanism Preliminary Design Ideas: (Mirrored on Inboard) Cups Dogbone Caps Halfshaft Plates Hub Plate Halfshaft Endcap Dogbone Method Halfshaft Tappet Spring Spring Method Cap Method Plates Method Final Design Hemisphere Method: Challenge: Outboard CV joints move vertically and laterally in relation to the Inboard CV joints due to vehicle suspension geometry. This creates a desired halfshaft length which continuously varies while driving. Spring Inboard CV Outboard CV/Hub Hemisphere Joint Solution: Allow the halfshaft to plunge into one of the CV joints to account for the change in length. The hemisphere method achieves a plunging inboard joint by utilizing a male hemisphere with a concentric return spring to maintain tension on the halfshaft. Furthermore, this method minimizes components and eases assembly.

8 MIT Beaver Tail Flash Drive

9 MIT Beaver Tail Flash Drive Objective: Develop a consumer product for the MIT Museum Gift Store that embodies MIT culture Design Concept: Couple technology (USB) with MIT branding (beaver) in a product which fills a common need for MIT students, faculty, and alumni Outcome: Currently in talks with the MIT Alumni Affairs office to produce a batch of Beaver Tail Flash Drives and distribute to graduating students Functional Prototype Benchmarking Beaver Tails Cartoon vs. Realistic:

10 MIT Beaver Tail Flash Drive Idea Refinement Prototyping Created an assortment of physical prototypes to evaluate general sizing and texture Clay Models Silicone Rubber Test Piece Modeling Generated multiple variations in Solidworks to refine form, color, and cross-hatch pattern

11 MIT Beaver Tail Flash Drive Final Product Molding Utilized rapid prototyping printer to create 3-piece mold for silicone rubber castings of final Beaver Tail design with integrated flash memory PCB Final Design Silicone rubber casting with 2gb flash memory storage capacity, MIT branding, and keychain attachment

12 Compressed Air Motor Design and Development

13 Compressed Air Motor Design and Development Objective: Using a compressed air tank, propel a small cart up a 10degree incline of a set length Judging Criteria: Motors evaluated on max power output and efficiency by adding weight to the cart until motor fails to reach finish Outcome: Developed most powerful motor out of 30 entries while placing 2 nd in efficiency Air Cart Chassis Benchmarking Current Commercial Products: Piston Motor Gerotor Motor Vane Motor

14 Compressed Air Motor Design and Development Design Features: - Tri-Piston motor to eliminate dead spots without sacrificing design simplicity - Long piston stroke possesses significant torque and power advantage over smaller diameter gerotorand vane motors. - Optimized for manual machining by employing circular and square geometry and duplicating components - Press fit interfaces with locking set screws to streamline assembly

15 Compressed Air Motor Variable Timing Highlighted Innovation: -First student air motor to include separate intake and exhaust valve timing -Tune by advancing or retarding outer cylinder in relation to rotating valve -Valvingassemblies connect to cylinders through lightweight plastic tubing -Capability to adjust on-the-fly for optimum power and efficiency Exhaust Valve Intake Valve

16 Rockcrusher Design and Development

17 Rockcrusher Design and Development Objective:Design a hand-held device capable of crushing small rocks (i.e. applying a large clamping force onto a load measuring sensor) Judging Criteria: Max force output, weight, ease of use, creativity, and manufacturing cost Outcome: Generated over 5,000lbs of clamping load for the average user, a total amplification factor of over 80x Foam Hydraulic Mock-up Preliminary Benchmarking and Development: Hydraulic Press Hydraulic Test Piece Scissor Jack Scissor Jack Sketch

18 Rockcrusher Design and Development Design Highlights: - Acme screw in series with hydraulic pistons produced 80x force amplification - Simple method of user operation - Tandem o-rings on both pistons to ensure sealing - Manufactured entirely on manual mills and lathes while holding ±.001 tolerance on piston to cylinder interface Insert Sample

19 MIT Product Design Course - Storyboarding adventures in reenspeak

20 MIT Product Design Course - Storyboarding What is Greenspeak? Greenspeak is an MIT hack done by lighting up specific windows in the Green Building on campus to display a message T-shirt Graphic: User interface: Greenspeak T-Shirt Concept: Create a miniature Greenspeak interface on a t-shirt that allows the wearer to emblaze their own personal Greenspeak message on the front.

21 MIT Product Design Course - Storyboarding Wake Up Student hears alarm clock go off Check Computer Crawls out of bed to check Wired News Get Dressed Selects Greenspeak T- shirt from dresser Reprogram Shirt Types in new slogan using Greenspeak New Display Sets shirt to display MIT Head to Campus Walks to campus for class Circuits Lab Enters classroom for lab Trouble in Lab Shorts out circuit board and bangs head into desk Reprogram Shirt Changes shirt s display to reflect frustration with MIT New Display Sets shirt to display common hacking acronym IHTFP Affirmation Passerby affirms sentiment expressed through Greenspeak

22 Outside the Office

23 24Hours of LeMons Auto Racing

24 24Hours of LeMons Auto Racing Objective:Construct a racecar to compete in a 24-hour endurance race. The Catch: Your team must spend less than $500total on the vehicle An Adventure in Mediocrity Highlights: - Purchased a rusty, dilapidated Nissan 300zx off Craigslist - Stripped car of non-essentials then modified interior with self-built roll cage and racing seat -Competed on a road course in Stafford Springs, CT with 60other racecars Track Layout

25 24Hours of LeMons Auto Racing Before After Brake & Suspension Work Prepping the Interior Installing the Seat

26 Thanks for your attention. Contact me: