ASME Channel Islands Professional Chapter Engineer of the Year Donald Geoff Carter January 20, 2016

Transcription

1 ASME Channel Islands Professional Chapter Engineer of the Year Donald Geoff Carter January 20, 2016 Dennis Horwitz, Chair

2 Engineer of the Year Donald Geoff Carter President and Founder, Link Engineering & Design Professional Engineer (P.E.) ASME Member, Former Section Chair Innovative, practicing lead design/mechanical engineer since 1996 B.S. and M.S in Mechanical Engineering, Cal State University Fresno 4 patents issued and 2 pending Specialist in space deployable mechanisms and structures Numerous space achievement awards Telescopic booms, Coil-able booms, Articulated Booms, Solar Array Wings Precision Mechanisms and Structural Analysis Built his own home in Santa Paula over 8 years

3 Donald Geoff Carter Education and Professional Development

4 Donald Geoff Carter Career Chronology

5 Donald Geoff Carter Career Highlights Flexible leadership skills wearing many diverse hats for each phase of the program: concept, design, analysis, procurement, build, testing, and management. Lead Design Engineer bringing several high profile space flight projects such as, STP-SIV, NuStar Adjustment Mechanism, NPOESS Solar Array and the JMAPS Solar Array from concept to deliverable. Notable experience in the space structures industry designing Telescopic Booms, Coilable Booms, Articulated Booms, Solar Array Wings, military APU packaging, precision mechanisms and structural analysis. Bringing high volume products to the marketplace for large OEM s and awarded three US Patents for superior product innovation. Developed the mechanical structure and kinematic mechanisms for Star Wars Darth Vader robotic toy arm, which received the Educational Toy of the Year award at the International Toy and Hobby Show. Received service awards such as Perfect Attendance three simultaneous quarters, and an A3 Performance award coupled with stipend for completing project ahead of schedule and under budget. Successful projects include a very diverse list from consumer products to space flight hardware.

6 Donald Geoff Carter Engineering Expertise design projects completed Project Manager/Lead Design Engineer Managing manufacturing and assembly lines for product development/launch Working in multi-functional team environment Conducting preliminary and critical design reviews Liaise with overseas manufacturers and customers Feasibility studies / cost savings analysis GD&T, ANSI Y14.5, DOD-STD-100 standards. Precision mechanism design/kinematic analysis Design for assembly/manufacturing Failure analysis Electric motors and pumps OEM high volume injection molding, die casting and metal stamping parts/products CNC and sheet metal design Rapid prototyping - with plastics and metals Instructed Pro/E training classes for other engineers Pro Engineer Expert - ( hours experience) Pro Mechanica Structure - stress/thermal analysis & simulation Microsoft Excel, Access, Word, Power Point, Project Solid Works, AutoCAD and MathCAD Ansys Workbench 16

7 Donald Geoff Carter Volunteer Work

8 Link Engineering And Design You are bound only by the grips of your imagination Link Engineering And Design Donald G. Carter, PE

9 About Link Engineering And Design Product Development and Engineering Firm Founded in years in consulting Machinery Mechanisms Aerospace Automotive Agriculture Food industry Dedicated to bringing your projects to completion

10 Link Services Mechanical Engineering Systems Engineering Electrical Engineering Industrial Design Stress / Thermal Analysis Drafting / Modeling

11 Clients Consumer Products Network / Computer Aerospace Toys

12 Software CAD ProE - Mechanica Solidworks - Cosmos MS Office Suite Word Excel PowerPoint Project MathCAD

13 Project Portfolio Consumer Products / Toys

14 Toys: Darth Vader Arm Customer: Uncle Milton Toys Educational Toy of the Year Award! Robotic Arm with gripping action, articulating wrist and elbow. Complete Design / Build Mechanism Design Structural Analysis

15 Toys: Interceptor AeroX Launcher Remote control tank with integrated plane launcher. Click on the picture Design / Build Mechanism Design Two independent gear trains. Clutch Design Launch Mechanism Structure Design / Analysis Customer: Estes Rockets

16 Enclosure: Power Strip Description: This power strip provides both AC and switchable DC power with over load protection. Design / Drafting / Build Analysis Rapid prototyping Electronic Packaging Custom electronic switches New high voltage contacts Customer: Maverick Power Systems Inc.

17 Sports: Face Mask - Baseball Description: A lightweight removable safety mask for youth baseball. Mask pivots out of way when not in use. It can withstand a 70mph baseball direct hit. Concept to product. Industrial Design Analysis Mechanism Design Ergonomics Customer: Grounder Guard

18 Network Encrypting Router and Key x.o.ware (Injection Molded Enclosures) Low part count combined multiple components Passive cooling Industrial design Ruggedized Key Fob

19 Samsung Tablet Cradle Arthrex California Technology (Injection Molding) Adapt existing tablet for medical use Multifunctional assembly In and out of operating room Ergonomic docking features for ease of use Maximize screen area Industrial design

20 Project Portfolio Aerospace Pojects

21 Deployable Space Systems Solar Arrays for spacecraft Mechanism design for outer space Materials selection Aluminum Titanuim Steels Carbon Fiber Stress analysis Thermal Analysis Testing Design for severe environments Link Engineering And Design

22 Aerospace: NuSTAR ATK Space Systems / Jet Propulsion Lab Mast Adjustment Mechanism for the Nuclear Spectroscopic Telescope Array. Precision adjustment to micro-radians. Complete Design Piece Part Stress Analysis Mechanical Characterization Testing

23 Aerospace: Telescoping Boom Description: Structural telescoping boom with high stiffness / torque / push force. Completed as a R&D project. Complete Design Composite / Aluminum / SS Deployable / Retractable Accurate & Repeatable High Stiffness 5 Stowed 20.5 Deployed Customer: Able Engineering

24 Aerospace: NPOESS Description: National Polar Orbiting Satellite System. Solar array wing system. Deploys 9 accordion style panels 4.5 x 13.5 x Lead Mechanical Engineer Manage Mechanical Team Deployment System Synchronization System Piece Part Stress Analysis Design Trade Studies Customer: ATK Space Systems

25 Project Portfolio Machinery

26 Machine: Enclosed Conveyor Description: Food processing conveyor designed in Pro Engineer / Pro Mechanica. Successfully installed in Lemoore, Ca Concept / Design / Drafting Analysis Mechanism Design Material: SS 316L 13 wide x 7 tall x 180 long Weight = 80,000 lb Manage demolition and installation Customer: Leprino Foods

27 Machine: Rotary Cutter Description: Food processing product slicer designed in Pro Engineer / Pro Mechanica. Successfully installed in Lemoore, Ca Concept / Design / Drafting Analysis Mechanism Design Material: SS 316L Conducted Feasibility study Used 4 HP rotary action to replace 50 HP hydraulic slicer. Customer: Leprino Foods

28 Eco Motors OPOC Engine Opposed Piston Opposed Cylinder 2 stroke diesel 4x power density compared to contemporary 4 stroke engine Electrically Controlled Turbocharger (ECT)

29 EcoMotors OPOC Rotating Components

30 OPOC components

31 OPOC Engine Optimization Engine Operating Points on Compressor Map

32 5kW Generator using 80cc opoc Engine Conceptual Sketches

33 Packaging: Military Power Supply Customer: Advanced Propulsion Technologies Inc. Standalone 5KW auxiliary power supply for military applications. Quick release pins to remove base power unit for vehicle integration. Design / Drafting / Build High density electronic Packaging Thermal management Twin throttle mechanism design Intake manifold design Fuel tank design Quick release system

34 EcoMotors APU prototype build Refined the design, added support packaging and tailored to military needs

35 EcoMotors ECT development Electrically Controlled Turbocharger 2.5 kw Electric Motor 5kW in Development Reduce / eliminate turbo lag Waste Heat Recovery

36 Project Portfolio Analysis

37 Backed up with Traditional Analyses

38 Finite Element Analysis Optimization of components Stress Strain Modal analysis Airflow (CFD)

39 Static Stress Analysis Von Mises Over stressed? Under stressed? Stiffness or strength driven?

40 Mechanism: Hitch safety device Description: A line of trailer hitch products including de-coupling system, forged hitch with quick change hitch balls and dead-band removal system. Design / Drafting FEA Analysis Mechanism design Customer: Entreprenuer

41 Thermal Analysis

42 Reverse Engineering (2013 Mustang Intake) Captured all ports locations / Geometry Captured all geometry for clearance indentations Vehicle clearance features MAF Sensor location Breather Ports

43 Pressure Flow Preliminary Analysis Pressure differential of 1.6 psi overall Flowing 1000 cfm maximum

44 Pressure Flow Animation

45 Qualities of an engineer my opinion Inquisitive How did they do that? How does it work? Imaginative Dream big Not afraid to try something new Learn by doing books are great, but the greatest knowledge is hands on experience Learn by failure - no one likes to fail, but the greatest knowledge is gained from not succeeding the first time Persevere Works well with others? Link Engineering And Design