Chassis Design of a Hydrogen Powered Car

May 2023 - Present

Affiliate: Hydrogen Car Team, University of Calgary

Skills: SolidWorks, Finite Element Analysis, Material Research

As part of the chassis sub-team, we have been responsible for researching, designing, and integrating a new chassis for a hydrogen-powered car—the load-bearing framework of the vehicle. This chassis serves as the fundamental structural component, supporting the weight of the vehicle body, driver, and all integrated components while ensuring structural integrity and safety. A key design requirement is that the roll bar must withstand an applied 700 N force to meet the safety standards necessary for competition in the Shell Eco-Marathon. This project places a strong emphasis on durability, structural efficiency, and aerodynamic performance, ensuring that the vehicle maintains optimal strength-to-weight balance while adhering to race regulations.

Leveraging my expertise in SolidWorks, I developed multiple chassis models, iterating through various designs to optimize structural performance while incorporating key factors such as weight distribution, rigidity, and manufacturability. These iterations have led to the current chassis model, which balances structural robustness with aerodynamic efficiency. To enhance our design, I conducted extensive material research, evaluating different lightweight and high-strength materials that would provide the best strength-to-weight ratio for the chassis. This research was complemented by Finite Element Analysis (FEA), where we tested various load conditions to assess the structural integrity and impact resistance of our design.

The following simulations demonstrate how the chassis responds to various load scenarios, ensuring its ability to withstand real-world forces:

Roll Bar Strength Test: An FEA test was performed by applying a 700 N force to the roll bar to simulate potential rollover impacts. This test is crucial in validating the structural stability of the roll bar to meet competition regulations and protect the driver.

Frontal Impact Test: To assess the chassis’s crashworthiness, a 700 N force was applied to the front of the car, simulating a head-on collision with an obstacle. The results help determine stress concentrations, potential failure points, and necessary reinforcements to improve occupant safety.

Rear Impact Test: Another FEA simulation was conducted with a 700 N force applied to the rear of the chassis, replicating a scenario where the vehicle is struck from behind. This analysis provides insight into how well the frame can absorb impact energy and whether reinforcements are required to minimize structural deformation.

With the FEA results providing critical insights into our chassis design, the next phase focuses on iterative optimization based on simulation findings. This involves strengthening weak points while maintaining weight efficiency to ensure structural integrity without unnecessary mass. Additionally, we will refine our material selection, taking into account factors such as manufacturing feasibility, cost, and sustainability to identify the most effective material for the chassis. Alongside these improvements, we will initiate manufacturing process research, exploring the best fabrication techniques and ensuring that parts procurement aligns with our design goals. This project has been an excellent opportunity to apply mechanical design principles, simulation techniques, and real-world engineering considerations, resulting in a highly functional and competitive chassis design for the Shell Eco-Marathon.

Wind Turbine Hub Mechanical Design

March 2023 - December 2023

Affiliate: Laboratory for Turbulence Research in Aerodynamics and Flow Control

Skills: SOLIDWORKS, Mechanical Testing (Tensile, Compression, Fatigue), 3D Printing

I designed, fabricated, and tested a modular wind turbine hub capable of accommodating blade configurations ranging from 2 to 12, allowing for versatile experimentation with different aerodynamic setups. The project began with conceptual sketches, followed by 3D CAD modeling to ensure a robust design that could securely house various blade configurations while integrating seamlessly with sensors for future data acquisition, including encoders and force transducers.

A key challenge was developing a reliable attachment mechanism to prevent blade detachment during operation, ensuring both structural integrity and ease of assembly. Since the hub needed to accommodate multiple blade configurations, I explored various clamping and locking mechanisms that could securely hold the blades under different loading conditions without excessive wear or deformation. To address this, I performed theoretical calculations to determine the optimal clamping force required to resist centrifugal forces during high-speed rotation. These calculations factored in the expected aerodynamic loads, material stress limits, and potential vibration-induced loosening.

Beyond force analysis, material selection played a crucial role in ensuring durability and manufacturability while keeping fabrication cost-effective. I considered multiple polymer and composite materials for 3D printing, prioritizing strength-to-weight ratio, impact resistance, and thermal stability. Given the availability of printing materials, I evaluated PLA, ABS, PETG, and reinforced nylon for their mechanical properties and how well they would withstand tensile and torsional stresses. PLA, though easy to print and dimensionally stable, lacked the necessary toughness. ABS offered better impact resistance but required more controlled printing conditions. PETG provided a balance between durability and ease of fabrication, while reinforced nylon, though superior in mechanical strength, had a higher cost and required specialized printing setups. After conducting a cost-benefit analysis, I selected PETG for the primary hub due to its balance of strength, flexibility, and cost efficiency, while reinforced nylon was used for a secondary hub optimized for high-load testing scenarios.

I then conducted mechanical testing to validate the hubs structural integrity under dynamic conditions, ensuring it could withstand the forces experienced during turbine operation. The testing phase included tensile, fatigue, and impact tests to evaluate material performance and attachment stability. For tensile testing, I prepared standardized test specimens from both PETG and reinforced nylon to assess their ultimate tensile strength and elongation under load. Using a universal testing machine, I applied axial loads to simulate the forces the hub would experience when subjected to high rotational speeds and varying wind conditions.

Blade Attachment for Tensile Testing

Tensile Testing

Fatigue testing was performed to determine how well the hub material could endure cyclic loading over extended operational periods. By subjecting the hub to repeated stress cycles, I analyzed its resistance to microfractures and structural degradation, ensuring long-term reliability. Impact testing was also conducted to evaluate how sudden force applications, such as abrupt wind gusts or rapid braking scenarios, would affect the hubs integrity.

To compare experimental results with theoretical predictions, I analyzed the failure points, deformation patterns, and stress distribution within the hub. This data allowed me to refine the design, optimizing blade attachment reinforcements and adjusting material thickness where necessary. Finally, after successful validation, I assembled the complete turbine system, integrating the hub with various blade configurations. The final setup was prepared for real-world performance testing in both wind tunnel experiments and field conditions to assess its aerodynamic efficiency and overall mechanical stability.

Interior Console Redesign
of a Gas to Electric Converted Vehicle

June 2023 - Present

Affiliate: Relectric Car Team, University of Calgary

Skills: SolidWorks, 3D Printing, Rapid Prototyping

As part of the interior console sub-team, our focus has been on designing and integrating a new central console for the vehicle, which serves as the primary control interface in the front and center of the interior. The goal is to replace the outdated console with a modernized design that accommodates the infotainment system and other critical controls while prioritizing user convenience, functionality, and aesthetic appeal. This redesign is crucial for improving the driver and passenger experience, ensuring that the updated console seamlessly integrates into the existing interior.

To achieve precise measurements and a streamlined design process, we partnered with Rapid3D to obtain a 3D scan of the car interior. This scan was imported into SolidWorks, providing an accurate digital representation of the existing console layout. By leveraging these high-fidelity scans, we can design with greater accuracy, minimizing measurement errors and reducing the need for extensive manual fitting and in-person adjustments. This approach significantly enhances efficiency in the design and prototyping process.

Currently, we are on our second prototype iteration, refining the console’s dimensions, fit, and structural integrity. Research is ongoing to determine the optimal materials for the console, ensuring that the final product balances durability, weight, cost, and aesthetic quality. Material selection is especially important given our plans to incorporate a faux leather finish, which will enhance both the visual appeal and tactile experience of the console. The next steps will involve finalizing the installation process and completing the coating application, ensuring that the new console is seamlessly integrated into the vehicle’s interior while meeting all functional and ergonomic requirements.

Predictive Modeling and Blade Element Momentum (BEM) for Performance Optimization of Wind Turbines

March 2023 - December 2023

Affiliate: Laboratory for Turbulence Research in Aerodynamics and Flow Control

Skills: MATLAB, Fluid Mechanics, Numerical Methods, Aerodynamics, Data Analysis/Visualization

Developed a MATLAB-based wind turbine performance analysis tool using Blade Element Momentum (BEM) theory to optimize aerodynamic efficiency and power output predictions. I discretized the turbine blade into multiple elements and applied iterative momentum and energy balance equations to compute thrust, torque, and power coefficients across varying wind speeds and Tip Speed Ratios (TSR). By incorporating one-dimensional wake analysis, I accounted for axial and tangential induction factors, refining the accuracy of aerodynamic force estimations.

To improve model accuracy, I integrated real-world wind turbulence effects and Reynolds number-dependent airfoil characteristics, dynamically adjusting lift and drag coefficients to model flow separation and stall conditions. I also implemented Prandtl’s tip loss correction to capture radial flow effects and mitigate overestimation of aerodynamic forces near the blade tips. Using convergence algorithms, I iteratively solved for flow angles and optimized lift-to-drag ratios, ensuring numerical stability and efficiency.

To enhance the tool's usability and provide visual insights into turbine performance, I developed a plotting function that generates graphical representations of key performance parameters, such as Power Coefficient (Cp) versus Tip Speed Ratio (TSR), Thrust Coefficient (Ct) versus TSR, and Torque versus Radius. These plots were critical in evaluating the turbine's aerodynamic efficiency and identifying design parameters that maximized power output. The use of curve fitting allowed for smoother and more interpretable visualizations of performance trends, making the analysis more accessible for optimization and decision-making.

To validate the model’s predictive accuracy, I compared computational results against experimental wind tunnel data and industry-standard performance curves. This analysis provided key insights into optimal turbine design parameters, contributing to performance optimization and efficiency enhancement of horizontal-axis wind turbines.

Interactive Country Analysis Program
for Safety and Sustainability Rankings

May 2023 - August 2023

Affiliate: SHIFT Critical International

Skills: Python, Pandas, MS Suite

I developed an interactive Python program designed to analyze and present comprehensive research findings on global safety and sustainability rankings. This program provides users with the ability to select continents and countries, offering detailed insights on factors such as forced and child labor, human rights risks, and the industries contributing to such issues. The tool was built to enable the extraction, processing, and documentation of Environmental, Social, and Governance (ESG) data from over 120 countries, empowering stakeholders with real-time access to up-to-date sustainability and safety rankings.

The program leverages Python's powerful data manipulation library, Pandas, to efficiently manage large datasets, with a primary focus on an Excel dataset that I used for retrieving accurate and reliable country-level statistics. I implemented automation to streamline the data retrieval and analysis processes, which significantly reduced manual data handling and improved the efficiency of generating ESG insights.

In addition to data processing, I created intuitive data visualization dashboards using Matplotlib, Seaborn, and Plotly. These visualizations include heat maps, statistical graphs, and trend charts, designed to convey complex ESG trends effectively to users. The visual approach helped communicate global patterns in forced labor, sustainability practices, and human rights risks in a clear and accessible manner.

I also conducted a quantitative analysis of ESG metrics at the country level, identifying key patterns, correlations, and insights that could support strategic decision-making. These findings were presented to the company's founders, providing actionable insights for shaping policies and addressing sustainability concerns within their global operations.

One of the key outcomes of this project was the successful automation of the ESG reporting process. By automating data collection, analysis, and visualization, I was able to significantly reduce the time spent on manual processing, allowing for quicker access to crucial sustainability insights. This streamlined reporting process not only enhanced operational efficiency but also made it easier for users to access and act on ESG data, ultimately supporting SHIFT Critical International's commitment to sustainability and ethical business practices.

Through this project, I gained valuable experience in data automation, visualization, and analysis, while also contributing to the promotion of sustainability and human rights at a global scale.

Optimization of Beam Equilibrium and Structural Integrity Through Energy Minimization

March 2023 - April 2023

Skills: MATLAB, Structural Analysis, Computational Mechanics, Finite Element Analysis, Simulation of Physical Systems

I developed a MATLAB program to evaluate the structural integrity of trussed beams, simulating the motion of a flexible 2D beam under external forces, including gravity and internal elasticity. The program was designed to optimize the beam's design and performance by determining its equilibrium state through energy minimization techniques. I began by initializing the beam structure, creating a series of nodes and segments, and establishing their connectivity. I then visualized the beam’s initial configuration and its connectivity matrix to get a clear understanding of its structure.

Afterward, I focused on calculating the beam’s equilibrium state by minimizing the total energy, which combines gravitational potential energy and elastic strain energy. To do this, I used optimization techniques to adjust the node positions, ensuring the beam adhered to realistic boundary conditions. I compared the initial and final energies of the beam to confirm that the system had reached a more stable configuration.

For evaluation, I examined how different stiffness values affected the beam’s energy and stability. I found that the beam's maximum stiffness was 790, beyond which it would either break or become unstable. Additionally, I explored the segment length required for the beam to appear nearly horizontal, finding that segment lengths of 8 m and 100 m yielded similar results.

This project allowed me to apply energy minimization techniques to analyze and optimize structural systems, providing insights into the behavior of beams under different conditions. It also gave me a deeper understanding of how to design and evaluate structures for stability and performance in real-world engineering applications.

Automated Water Bottle Filament Cutter for 3D Printing

March 2024 - Present

Skills: Arduino, Mechanical Design, Microcontrollers, Sensors, Motors, Gear Mechanisms, Testing & Debugging

MORE PICTURES TO COME :D

I am currently designing and implementing an Arduino-controlled automated system that converts water bottles into usable filament for 3D printing applications. This innovative project integrates multiple components, including sensors, motors, and a gear train mechanism, to automate the cutting process, providing a precise and efficient solution for creating filament from recycled plastic.

The system is controlled by an Arduino microcontroller, which coordinates the operation of the motors, sensors, and cutting mechanisms. I have integrated a set of sensors to monitor the position of the water bottle, ensuring accurate cuts are made each time. The motors drive the gear train, which is responsible for rotating the water bottle and guiding it through the cutting process.

As part of the design process, I focused on developing a gear train mechanism that ensures the water bottle is securely held in place during cutting, while also optimizing the motor speed to ensure smooth and consistent operation. This design minimizes the risk of jams or errors, making the system both reliable and user-friendly.

I have been testing and debugging various components of the system, including the sensors and motors, to ensure proper alignment and functionality. Through iterative testing, I have optimized the motor speed for cutting efficiency and refined the sensor alignment to enhance the precision of each cut. Additionally, I have ensured that the system can handle various types of plastic bottles, adjusting the settings to accommodate different thicknesses and materials.

The project has progressed steadily, with key milestones including successful integration of the Arduino system with the sensors and motors, as well as the development of an effective gear train mechanism. I have also conducted multiple tests to fine-tune the system's performance, ensuring that the filament produced is of consistent quality and suitable for use in 3D printing.

So far, the system has shown significant potential in reducing waste by repurposing plastic bottles into filament, offering an environmentally friendly alternative to traditional filament production methods. The project has allowed me to further develop my skills in mechanical design, microcontroller programming, and automation, as well as my ability to troubleshoot and optimize complex systems for real-world applications.

Key progress so far includes: Successful integration of sensors, motors, and gear mechanisms. Optimized motor speed for reliable cutting performance. Iterative testing and debugging to refine system reliability and user experience. Development of a functional prototype that is capable of converting water bottles into 3D printing filament efficiently.

This project aligns with my passion for sustainability and innovation, and I look forward to completing the final stages of testing, optimizing the system, and eventually sharing a working model that can help reduce plastic waste through 3D printing technology.

Elliptical and Compound Mechanism Analysis

November 2023 - December 2023

Skills: MATLAB, Kinematic Analysis, Mathematical Modeling, Kinematic Machine Simulation

For this project, I developed a MATLAB program to simulate and animate a four-bar linkage mechanism, demonstrating both elliptical and compound motion through two interacting closed kinematic chains. The mechanism involves four links: r1, r2, r3, and r4, where r2 acts as the input crank. The primary objective was to analyze the displacement of two control pistons over time as the crank angle (θ₂) evolves, providing a dynamic visualization of the mechanism's behavior.

The program begins by ensuring that the input link parameters satisfy the conditions dictated by Grashof’s Law, which determines if a four-bar linkage is valid. Specifically, it checks whether the shortest link (r2) is smaller than the sum of the other links' lengths. If this condition isn't met, the program halts to prevent invalid simulations. The program then calculates the angular step (astep) based on the length of the input crank (r2) and the desired number of cycles (n). This step size determines how fine the crank angle (θ₂) is sampled over time. Using these inputs, the code generates an array of theta values, which represent the crank angle's progression across multiple cycles. The heart of the simulation lies in the iterative loop, where the program calculates the positions of the links and joints based on trigonometric relationships using the crank angle. The mechanism consists of a primary linkage system formed by r2, r3, and r4, along with a secondary linkage system that introduces a phase shift. This phase shift is essential for simulating the compound nature of the motion, producing a more complex and realistic representation of the mechanism’s movement. The positions of the pistons are calculated over time and stored in arrays, capturing the x and y coordinates for each piston’s position at each timestep. These arrays then drive the animation, dynamically updating the mechanism’s configuration as it progresses through each cycle.

The animation loop works by updating the configuration of the linkage mechanism at each timestep. As the program iterates through each crank angle, the angles of the links are recalculated, and the corresponding x and y positions of the pistons are plotted in real time. The animated plot provides a visual representation of how the pistons move in relation to the crank angle. Users can observe the periodic nature of the pistons’ motion, highlighting the compound elliptical behavior driven by the interlinked chains. The animation also allows users to adjust the speed and number of cycles, offering flexibility to explore the motion in greater detail or at a faster pace. By adjusting parameters like link lengths and crank angle, the user can immediately see how these changes affect the overall motion, making it a highly interactive and insightful tool for understanding four-bar linkages.

At the end of the simulation, the program generates a graph that displays how the angles of the r2 crank link change over time. This graph illustrates the periodic motion of the crank, providing further insight into the motion dynamics of the mechanism. The graph highlights key characteristics, such as the frequency of oscillation and the impact of different parameters on the system's behavior. It serves as a valuable tool for analyzing the performance of the four-bar linkage system and its response to various inputs.

This technical breakdown of the simulation and animation process highlights how the mechanism's motion is driven by precise angular calculations and real-time updates. By visually representing the motion of the pistons and providing a graph of the crank angle's progression, the program enables engineers to better understand the dynamics of a compound elliptical mechanism. This is particularly useful for applications like engines and pumps, where precise motion control is crucial. The tool not only aids in theoretical analysis but also offers practical insights that can be directly applied to real-world mechanical systems.

Lied Op. 42, no. 13

Composer: Alec Rowly

ft. my dog Miko :D

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A Little Story

Composer: Valentin

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