Sparky the Firefighter

Work In Progress

In the heart of my senior year at the University of Delaware, as a mechanical engineering student with a passion for aerospace, I've taken on an invigorating challenge: resurrecting the Indian River Fire Company's animatronic dog and firetruck. This project is not just a repair job; it's a revival of a community icon that has been silent for too long.

The task at hand is complex. We're dissecting and reworking a system that's a blend of early '90s technology and layers of modifications. This animatronic firetruck, with its myriad of features like a differential drive, actuated movements, and a remote audio system, is a puzzle of engineering marvels. But it's a puzzle I am actively solving.

Currently, I'm deep in the trenches of this project, wrestling with tangled wires and outdated components. The key challenge? Upgrading the obsolete 75MHz transmission system to a more reliable 2.4GHz transmitter, ensuring longevity and efficiency. Simultaneously, I'm troubleshooting and replacing the central electronic controller, the heart of this animatronic machine.

This undertaking is more than a university project; it's a commitment to reviving a vital tool for community engagement and fire safety education. Every step in this process is a learning opportunity, aligning perfectly with my interests in engineering and problem-solving. As I progress, I'm not just applying theoretical knowledge from my coursework; I'm gaining invaluable hands-on experience that's shaping my future as an engineer.

I'm dedicated to seeing this project through to the end, ensuring that the Indian River Fire Company's animatronic mascot returns to its role as a beloved and functional part of their community outreach. Stay tuned for more updates as I continue this challenging yet rewarding journey.

ASAE AIRCRAFT

THIS PROJECT IS BEING WORKED ON ACTIVELY MORE INFORMATION WILL BE ADDED LATER, STAY TUNED.

The SAE International Aero Design East Advanced Class competition, scheduled for March 8-10, presents a challenging yet stimulating opportunity for engineering teams to innovate in aerospace technology. The primary objective of this competition is to design a multifaceted system capable of simulating wildfire combat operations. This involves deploying a Ground Transport Vehicle (GTV) from a Powered Autonomous Delivery Aircraft (PADA), which in turn is released from a larger Primary Aircraft (PA). The PA also carries a water payload, integral to the mission's success.

The scope of the project revolves around designing, building, and operating a vehicle system that meets these complex requirements. This encompasses various engineering and design tasks:

Fuselage Design and Integration: The fuselage, serving as the central body of the aircraft, must house all control mechanisms, support the payload, and connect the wings and tail. It is also responsible for carrying the PADA. The design includes manufacturing landing gear and wing integration, ensuring internal accessibility for control system installation and payload removal.

Wing and Tail Engineering: The wings are crucial for generating sufficient lift for takeoff, considering the aircraft's weight. The tail aids in stability, countering the moments acting on the aircraft. Control surfaces like ailerons and flaps are essential for steering and altering the center of lift.

Primary Aircraft (PA) Requirements: The PA must carry a 4lb water payload and the PADA, capable of releasing it mid-flight.

Powered Autonomous Delivery Aircraft (PADA): The PADA carries parts for the GTV and must autonomously navigate to two types of targets—one marked by GPS and the other by color.

Ground Transport Vehicle (GTV): This manually controlled vehicle carries a water payload and is assembled post-delivery by the PADA.

Testing encompasses three modules: the Ground Station with a Data Acquisition System (DAS), the PA/PADA, and the GTV. The DAS includes mission planning software and altimetry tools, while the aircraft systems incorporate Pixhawk Flight Controllers, Radiolink AT10 Transmitters, and specific safety measures like SAE power limiters and arming plugs. The GTV, based on a commercial STEM RC Car Kit, must transport 2lbs of water to a designated target.

Construction involves assembling pre-manufactured components, primarily sourced from RC hobby sites and online marketplaces. Mounting these components requires a combination of Velcro and fasteners, particularly for high-torque elements like servo motors and engines. The design also incorporates extended wiring with shrink-wrapped extensions and precise positioning of parts.

In summary, this project represents a comprehensive endeavor in aerospace engineering, demanding a synthesis of design, mechanical, and electronic skills. It not only tests the team's ability to innovate within stringent constraints but also provides a real-world application scenario, mirroring the complexity and demands of modern aerospace challenges.

Pill Bottling System

Overview

In this detailed portfolio project, I will guide you through the development of a compact pill bottling machine designed for small-batch vitamin and supplement manufacturers. This project was to design, manufacture, and test a compact, automated pill bottle filling system for small batch manufacturers that includes conveyance, pill filling, and capping operations.

Project Introduction

Motivation

Background

Conceptualization and Design

Concept Development

Final Design

Detailed Overview

Bottle Dispensing System

The initial bottle dispensing and conveyance system consisted of a crank-rocker mechanism as well as a conveyor belt. A motor would rotate a crank arm which would move a pusher to translate the bottles onto a conveyor belt. The conveyor belt would then carry the bottles to the rotary table. This first prototype underwent two important changes for the final design. The first is the replacement of the original crank-rocker mechanism that would push the bottles out and dispense them. Instead, a simpler linear actuator will be used to push the bottles out of the chute. This would take up less space and be more efficient. The second change to the original design was the elimination of the conveyor belt between the bottle dispenser and the rotary table. By removing the intermediate step of the conveyor belt, the team simplified the design and improved its reliability. The conveyor belt was able to be removed because it essentially served no purpose since the bottles could be dispensed directly into the rotary table. This not only removed the uncertainty of bottles falling on the belt but also made the system more compact and space efficient. Additional beam break sensors were added to the rotary table to allow the bottles to spin to the exact location needed.

Pill Dispensing System

Bottle Capping System

Testing and Failure Analysis

Testing Approach

Conclusion and Future Work

Reflection

Next Steps

Wooden Bike

Objective

The primary objective of the Wooden Bike Frame Challenge, a key component of the Statics course at the University of Delaware, was to design and build a functional and safe wooden frame bike, specifically a "balance bike" similar to the historical "Dandy Horse". This project not only aimed to revitalize the tradition of mechanical engineering in bike design but also to showcase the innovative maker skills of the students. The end product was expected to be a full-scale prototype, foot-propelled, and capable of supporting an adult user. This task was not just about building a bike; it was about merging historical design with modern engineering techniques, emphasizing creativity, practical skills, and technical knowledge.

Requirements

The project's requirements were stringent and multifaceted, focusing on both the design process and the final product. Key requirements included:

1. Material and Construction Constraints : The bike frame had to be constructed entirely from 1/2" thick plywood, using a limited amount of 1/4-20 hardware. The major frame pieces had to be cut from a single 4 ft x 4 ft plywood sheet using a CNC router, with manual carpentry allowing for minor modifications.

2. Integration and Safety : The incorporation of a pre-fabricated front steering column and 26" wheels was mandatory. The bike had to safely support a 200 lb user with a Factor of Safety (FOS) of 1.5.

3. Portability and Functionality : The design had to ensure that the bike could be disassembled to fit into a standard travel bike bag, with no brakes or drive systems, being purely foot-propelled.

4. Cost-Effectiveness and Aesthetics : The design needed to be economical, lightweight, easy to assemble, comfortable, stylish, and fast, meeting various user-centric priorities.

Skills Used

PID Controller

OBJECTIVE

Design a PID vehicle speed trajectory controller for a scaled (1:25) robotic car, which is used at the Information and Decision Science Lab’s Scaled Smart City (IDC). The car can be modeled using the simplified representation where m = 0.434 kg is the mass of the car, b represents the viscous friction, F is the force applied to the car, and v is the speed of the car. To achieve the correct step response the requirements are that the overshoot must be below 25%, the settling time must be below .2 seconds, and have less than a 10% steady-state error.

DESIGN

To determine the PID controller values, the first step is to identify the system. Given a diagram of the forces acting on the car seen in Figure 1, the equation of motion, seen in Equation 1, was derived.

Where v represents represents the velocity of the system, F is the force required to push the mass (m), and b is the viscous friction acting on the mass. Once we obtained that equation of motion, we used Laplace transformations to create a transfer function of the system. The open loop transfer function derived can be seen by Equation 2.

After deriving the open loop transfer function, the block diagram (Figure 2) involving the PID controller (Equation 3) was used to develop the closed loop transfer function seen by Equation 4.

Where Y(s) represents the output velocity of the system, R(s) represents the input velocity of the system, V_o(s) is the open loop output velocity, and F_o(s) is the open loop force required to push the car.

From the transfer function (Equation 4), identifying the characteristic equation was next. The characteristic equation derived can be seen in Equation 5.

To determine the PID controller values, the first step is to identify the system. Given a diagram of the forces acting on the car seen in Figure 1, the equation of motion, seen in Equation 1, was derived. To arrive at the gain values, the next step in the process was to compare the denominator of the ideal transfer function shown below in Equation 6.

To finally achieve the gain values for the system, the viscous friction needed to be identified. The open loop transfer function (Equation 2) was analyzed in MATLAB to obtain a step response resembling that of Figure 3 shown below.

Using the found value of viscous friction (b = 4.5) and comparing it with the characteristic equation, it was found that the gain values of the system are D = 0, P = 35.43, and I to be 3436.

The results gathered from the Information and Decision Science Lab’s Sealed (1:25) Smart City conclude that the PID gain values were not accurate to achieve the desired overshoot, settling time, and steady-state error. When going to test the values the car overshot the ideal speed by 53%, did not settle for 1 second, and had a steady state error of 0.50. Testing in MATLAB the overshoot was predicted to be 19%, and the settling time was 0.1 seconds, with no steady-state error. The two speeds tested were 0.4 m/s and 0.3 m/s and for both the response settled around 0.6 m/s.

The ideal step would have no overshoot and settle at 0.4m/s. Looking at the ideal step response graph, you can see how the gain values are scaled. The ideal and real charts both have an approximately similar rising time, which could be caused by a similar ratio of the proportional term to the integral term, with the only difference being the lack of a derivative term in the real trial.

Moving forward, what should be redone is the analysis of the original transfer function and a reworking of the algebra behind achieving the gain values. The conclusion of this term project proved the importance of each of the terms in the PID control. The zeroed derivative term allows for an extreme amount of overshoot since the controller has no damping force. Therefore, moving forward, team 9 is going to re-evaluate the given problem and find a correct solution that incorporates the derivative term.

3D Printed Props

Life Sized Greatsword

I finished a 3D printed Greatsword from "Elden Ring." Using my Ender 3 Pro, it took a week to print all 28 parts, fitting within the printer's 220x220x250mm capacity. Post-print, I spent another week on assembly, reinforcing the structure with three galvanized steel rods. I designed the model in Blender, choosing a 0.2mm layer height and a 0.6mm nozzle for the right balance of strength and material efficiency. At six feet, it's to scale, hefty, and despite its size, it's assembled to handle like it belongs in the game—minus any fantasy features.

StormBreaker

Utilizing my Ender 3 Pro, I meticulously 3D printed a full-scale replica of Stormbreaker from the Avengers series. The entire piece was printed in multiple sections over the course of a week, designed specifically to fit within the printer's maximum capacity of 220x220x250mm. After printing, I dedicated an additional week to assemble the parts, inserting a steel rod through the center for stability and a realistic weight. The model was crafted in a CAD program with precise attention to the intricate details of the weapon, choosing a 0.2mm layer height for a fine finish, and a 0.6mm nozzle to ensure structural integrity. To complete the look, I applied a metallic spray paint to the axe head and a dark wood finish to the handle, achieving a movie-accurate appearance that feels like it's straight out of the hands of Thor himself.

Lord Of the Rings

In the latest foray into 3D printing, I've turned my attention to the iconic rings from the Lord of the Rings series, fabricating two replicas with my reliable Ender 3 Pro. The process involved careful calibration to accurately capture the subtle engravings and contours of each ring. Over a couple of days, these rings were printed with a 0.2mm layer height for fine detail, using a 0.4mm nozzle to ensure the engravings were clear and precise. Post-printing, the rings were finished with a smoothing technique to eliminate any layer lines, then one was colored in a vibrant green and the other in a muted ivory using specialty filaments to mimic the distinct tones of the legendary artifacts. These pieces are not only testaments to my 3D printing skills but also a nod to the craftsmanship of fantasy jewelry making.

Guitar

Branching into the realm of musical instruments, I've recently completed a 3D printed electric guitar body, pushing the boundaries of traditional design. This guitar body was printed with an Ender 3 Pro over an extensive period, carefully divided into multiple sections to optimize the printer's capacity. The design boasts a unique, voronoi-patterned framework, chosen not only for its aesthetic appeal but also for its potential acoustic properties. After printing, I assembled the sections, reinforcing the structure internally to ensure it could withstand the tension of guitar strings. The vibrant green finish was achieved through a meticulous painting process, providing a bold statement piece that blurs the lines between music and technology. This guitar body represents a fusion of engineering and artistry, encapsulating the innovative spirit of modern 3D printing.

Femur Bone Fracture Plate

Objective

The primary aim of this project is to design an innovative femur fracture plate that offers enhanced strength, durability, and compatibility with the human body. The project will involve the use of computer-aided design (CAD) software for the design phase, followed by manufacturing a prototype using advanced techniques like 3D printing. The final phase will include testing the prototype's mechanical properties and failure limits using a hydraulic press.

Fracture Plate

I designed a fracture plate prioritizing maximum comfort and optimal load-bearing capacity. My design features eight screw holes, tailored for M4 Flat Head Machine Screws, a standard in femur fracture plate surgeries. Each hole has a loose fit, a deliberate choice to give surgeons flexibility during screw insertion. The plate's sides feature scalloped edges, aligned with the screw holes. This design, which I crafted, not only enhances aesthetics but also reduces bone contact area. There are 16 scallops in total, eight on each side. Each scallop begins with dimensions of about 10.07 mm in length and 1.93 mm in height, forming an arc, then narrows down at a 70-degree angle due to a ball cut. A key feature in my design is the central channel running along the plate's length. This channel reduces the contact surface area with the bone significantly, without compromising the plate's strength. It measures about 4.03 mm in width and 0.78 mm in height, forming a continuous arc across the plate's length.

Calculation Explanation of Femur Fracture Plate

Calculations were performed using a loading force of 100N, as the patient is not going to put the full force of their body weight on a newly broken bone. The average length of a femur is 480mm, and the average break location is halfway down the femur, so those distances were used to calculate internal forces. This ended up giving a parallel distance of approximately 62.12mm. The critical point of the fracture plate would be in the middle, right where the fracture is, as all other places have both the support of the bone and the plate, so it is unlikely that they will fail first. The main concern for the plate was deformation from bending, so that is what was determined by the calculations. The total stress calculated was 588.894MPa for 100N, and 4711.913MPa for 800N, although hopefully the patient would have something so they would not need to put the full force on their broken leg.

Coding Project 1: Heat Transfer Plate

The primary objective of this project is to develop a robust and accurate numerical model using explicit, two-dimensional finite difference methods to simulate and analyze the temperature distribution within a 30x30 cm square plate of aluminum (2 cm thick) under given boundary conditions. This model aims to predict the temperature variation across the plate both spatially and temporally, starting from an initial uniform temperature of 20°C.

A diagram detailing the boundary conditions of the aluminum plate as provided by the project prompt. The applied flux is applied evenly across the entire side surface and the detailed surface temperatures also describe their entire respective surfaces.

Results

To simulate the nodes and make sure that the code is accurate we started with a 3x3 grid with the specified boundary conditions. When we tried to simulate a 4x4 grid, the code would provide a 3x3 because the way it is written, a center node is required but the data is still accurate to a 4x4 grid. The initial 3x3 graph can be found in Appendix B. Once we could be sure that the code is accurate we increased the nodes to 50x50 for the final resolution resulting in the graph

The code starts by defining the grid parameters (length and height of the plate, and grid spacing in both directions), physical parameters (thermal conductivity, density, specific heat capacity, and thermal diffusivity of aluminum), and boundary conditions (surface temperatures and heat fluxes at top and bottom, heat transfer coefficient at right, and surrounding temperature). Next, the time step is calculated based on the grid spacing and thermal diffusivity, and the number of time steps is set. The initial temperature at each node is set to the surrounding temperature, except for the center node which is set to the average of its neighboring nodes. Then, the temperature at each node is updated over time steps using an explicit finite difference method. The temperature at each interior node is updated based on the temperatures of its neighboring nodes using the heat equation, while the center node temperature is updated separately. The boundary conditions are set for each time step, and the temperature distribution is plotted at certain time steps using a mesh grid and a surface plot. Overall, the code simulates the temperature distribution in an aluminum plate with given physical properties and boundary conditions using an explicit finite difference method, and provides a visualization of the temperature distribution over time.

Coding Project 2: CFD - flow viz., flow field, and forces

The goal is to apply Computational Fluid Dynamics (CFD) tools for visualization, analysis, and quantification of flow characteristics over a chosen aerodynamic object, enhancing practical CFD application in relevant areas. This involves the selection and detailed presentation of an aerodynamic model, including rationale and specific features like airfoil type, coupled with the calculation and interpretation of the Reynolds and Mach numbers to determine flow state and compressibility. Flow visualization using tracer tools will analyze flow behavior, focusing on attachment and rotational structures. Pressure and velocity contour plots at the object's centerline will be created and interpreted to identify key features. Finally, the project requires computing non-dimensional force and moment coefficients, determining the center of pressure, and discussing its importance in aerodynamic design, ensuring individual integrity in all analyses while permitting collaboration for model selection and simulation setup.

Introduction

The study of aerodynamic properties remains fundamental to advancing the field of aerospace engineering. This project delves into an in-depth analysis of a selected aerodynamic model, examining its structural features and inherent flow characteristics. Through a series of tasks, the investigation evaluates critical parameters such as Reynolds and Mach numbers, flow tracers, flow contours, and aerodynamic forces. Emphasis is placed on visual representation of the model and its behavior, accompanied by rigorous calculations to validate the observations. The outcomes of this investigation aim to provide insights into the model's performance and potential applications in real-world aerospace scenarios.

Model Selection Description

The model central to this study is the Eppler 423 wing profile, distinguished by its unique aerodynamic characteristics. Measuring 48 inches in length and having a 14-inch chord, this wing yields an aspect ratio tailored for optimal flight dynamics. The Eppler 423 airfoil, with its superior lift-to-drag ratio, stands out as a favored selection in aerospace endeavors. The rationale behind adopting the Eppler 423 is twofold: firstly, its well-recognized standing within the aerospace sector, and secondly, the intent to delve deeper into the aerodynamic intricacies it exhibits under varied flow regimes. Utilizing a wing with a 48-inch span is strategic, ensuring that the experimental setup is both representative and primed for precise data collection and analysis. Furthermore, this wing is a key element in the ASAE senior design project, underscoring its relevance and importance in contemporary aerospace studies.

Flow Characteristics

With a Reynolds number of 372726.44, which far exceeds the general threshold of 4000, the flow characteristic is distinctly turbulent. Furthermore, the calculated Mach speed stands at 0.0391. Given this value is substantially below the standard benchmark of 0.3 for incompressibility, the flow is confidently characterized as incompressible. This comprehensive evaluation offers crucial insights into the aerodynamic behavior of the wing profile under the stipulated conditions.

Flow Contours

Pressure Contour

The pressure contours, characterized by the series of lines and varying colors, highlight areas of different pressure magnitudes around the airfoil. The closely spaced contour lines in some regions suggest steep pressure gradients, indicating rapid changes in pressure. This is especially evident in the region where the colors transition from green to red, denoting a swift shift from moderate to high pressure. This is likely the area where the airflow separates from the airfoil surface, creating a pressure differential. The regions of high pressure, marked by the red and orange hues, are typically found on the windward side (or the front) of the airfoil. This is where the incoming air molecules are compressed as they collide with the airfoil's leading edge. Conversely, the blue hues depict areas of lower pressure, which are generally located on the leeward side (or the back) of the airfoil. This pressure reduction on the back side is due to the air's accelerated flow, governed by Bernoulli's principle. The yellow surrounding region, with its relatively consistent pressure values, signifies the undisturbed flow away from the airfoil, suggesting that its influence on the airflow diminishes with distance. The presence of these varying pressure zones around the airfoil indicates the generation of lift. The pressure difference between the upper and lower surfaces creates an upward force, allowing the airfoil to achieve lift. The magnitude and distribution of these pressure differences can provide insights into the efficiency and stability of the airfoil in generating lift.

VelocityS Contour

The image displays a computational fluid dynamics (CFD) simulation of airflow around an airfoil. The velocity contours, indicated by the color gradient and streamline patterns, show the distribution of airspeeds. The tight clustering of lines towards the top rear suggests a high-velocity gradient, likely where the flow accelerates significantly. The red region at the top of the airfoil represents the highest velocity magnitudes, as denoted by the peak value on the color scale. This is characteristic of the flow behavior just above the surface, where the boundary layer is the thinnest and the speed is greatest before it potentially separates from the surface. The wide-spaced green contours represent areas of lower velocity magnitude, typical of the freestream velocity away from the airfoil's influence. The smooth transition of hues from green through yellow to red indicates a gradual increase in velocity as the flow approaches and moves over the airfoil. Overall, the pattern of velocity around the airfoil is a key factor in the generation of aerodynamic forces such as lift. The higher velocities over the top surface compared to the bottom suggest lower pressure on the top, according to Bernoulli's principle, thus contributing to lift. The effectiveness of the airfoil design in managing these velocities can be inferred from such simulations, which is crucial for optimizing performance for aerospace applications.

Coding Project 2: Airfoil Selection Database

The script stands out for its capability to access and analyze a comprehensive database of over 1600 airfoils, enabling a thorough and detailed comparison to select the best airfoil for specific aerospace applications. Here's an expanded view incorporating this aspect:

Extensive Airfoil Database: The script connects to an online database containing over 1600 airfoil profiles, available at 'https://m-selig.ae.illinois.edu/ads/coord_database.html'. This vast collection includes a wide variety of airfoil shapes, each potentially suited to different aerodynamic needs.

Automated Data Retrieval and Analysis: Utilizing the BeautifulSoup library, the script efficiently parses this extensive database to extract data links for each airfoil. It then processes each airfoil by extracting its coordinates and computing its aerodynamic performance based on the input parameters.

Concurrent Processing for Efficiency: The script employs concurrent.futures.ThreadPoolExecutor for handling multiple airfoils simultaneously. This approach significantly speeds up the analysis process, making it feasible to evaluate such a large dataset in a reasonable timeframe.

Optimal Airfoil Selection: After processing, the script compares the performance metrics of these 1600+ airfoils. It evaluates them based on criteria like lift-to-drag ratio, lift coefficient, and drag coefficient, ultimately pinpointing the most efficient airfoil under the given conditions.

Result Visualization and Information: Once the best airfoil is determined, the script not only visualizes its shape but also fetches and displays an image, if available. It provides additional reference information, giving users a comprehensive understanding of why this particular airfoil is optimal.

In summary, this script is a powerful tool in aerospace engineering, especially for projects like the SAE Aero Design competition. It leverages an extensive database of airfoils, applies rigorous computational methods to evaluate their performance, and identifies the most suitable airfoil for specific flight conditions and design objectives.

Last, but not least

Another exciting project I've embarked on is the creation of a dynamic and interactive website. This venture into web development has been a thrilling journey, blending creativity with technical skills. The process of coding and designing each element, from the user interface to the underlying functionality, has been both challenging and immensely rewarding. Seeing my ideas come to life on the digital canvas is exhilarating, and the experience has significantly broadened my technical repertoire. This website project represents not just a product of coding proficiency, but a testament to my passion for exploring new realms of technology and innovation.