Industry Experience

Problem and Background

• Mesodyne is in the R&D phase of a new thermophotovoltaic (TPV) which takes energy from combustion to heat a nanophotonic material

• The thermal radiation from the nanophotonic material is captured with a photovoltaic cell

• To make a successful TPV, the heat needs to be distributed efficiently and evenly across the photonic crystal

Solution

• I wrote an object-oriented custom simulation code to converge a temperature distribution out of many input parameters

• Combined the discretization and time stepping methods that I used in CFD research with heat transfer equations

• Used the Cantera python package to calculate chemical equilibriums in the high temperature flue gas

Results

• Simulation is able to run parameter sweeps to see how changing combustor parameters effects power output of the device

• The code will help inform design decisions and estimate performance without the need for as many time consuming and expensive experiments

• Validated with experimental results

Problem and Background

• Many steps in jet engine manufacturing use a "snap" interference fit between parts

• The inside of one part must be heated to expand it so that it can be mated to the outside of another part

• The main way that heat is delivered to target areas is with induction coils

• How the coil's power level is controlled over the process, called the "recipe," was made with trial and error and took longer than needed to run

Solution

• I decided that instead of simply using guess and check I could use Ansys analysis to make the recipe run faster

• Defined a new process for Ansys thermal and structural FEA for induction heating assembly steps

Results

• Minimized process time while ensuring that the parts expanded sufficiently for assembly but had no structural damage

• Made complicated process accessible with:

  • Template files

  • Built in excel calculators

  • Step-by-step documentation

• Process under review to be added to Standard Work documentation

• New coil designs set to cut up to a half hour off of process times in two lines once funding becomes available

Problem and Background

• Tab lock washers are used inside the engine on bolts to prevent back out

• Tabs are folded to contact the sides of the bolt

• In this build, they are located in a very hard to reach location

• Before my tool, mechanics used a pair of shaved down channel locks (it is so tight that they need to be shaved to fit)

• Mechanics were frequently slipping and hurting their hands for a process time of about 45 minutes to get all of the tabs bent

Solution

• Work with mechanics to design an improved tool

• It would offer superior mechanical advantage and scoop+fold the tab in one motion

• Took many 3D printed rapid prototypes to perfect the design

Results

• Cut process time by ~60%

• Ergonomic design prevented the hand injuries common to the old process

• Patent application is being processed

• Final tool to be made out of hardened steel

My work

• Creating parts and assemblies for new product release from Argo Bikes

• Two patents in the filing process for new designs and configurations

• Files will be sent to Taiwan or China for production and assembly

• Currently working on suspension and kickstand components

• Unfortunately, most of the details and images need to be kept proprietary

Current Product

• See: https://argobikes.com/