Embedded Files
SOLIDWORKS
SOLIDWORKS
As a member of Terps Racing Baja, and through the completion of ENME272 (Introduction to Computer Aided Design), I have gained experience working with SOLIDWORKS modeling tools and Finite Element Analysis. Below are some of the projects I have worked on using SOLIDWORKS.
Terps Racing Baja | Integrated Constant Velocity Joint and Overrunning Clutch Housing
CV-Clutch Housing
CV-Clutch Housing
During the 2021-2022 academic year, I worked with two other members of the Terps Racing Baja team to fully design a single housing for both the constant velocity joint and overrunning clutch for the front drive shaft of our Baja vehicle. The image on the left shows two of our housings located on the front drive shaft assembly.
Fully designed housing made to be CNC machined. The majority of the housing is Aluminum. A steel ring is also present in the housing to interface with the clutch components and helps prevent excess wear while in use.
Section cut to highlight inner geometry and steel ring. Also visible are the acrylic and aluminum rings to retain clutch components inside the housing.
Finite Element Analysis was performed on the housing to view stress concentrations and ensure it met the required safety factor of 1.5. The forces were applied at locations that match the real-world loading cases.
Over-Terrain Vehicle Project
For ENES100 (Intro to Engineering Design), students work with 7-8 classmates to design and construct an OTV (Over-Terrain Vehicle) which must autonomously complete a specified mission and navigate an obstacle course. I led the claw and CAD development for my group. We utilized Fusion360 for CAD since it easily enabled collaboration and file sharing between myself and other members as we designed our OTV. Our mission was to determine whether a block was foam or plastic, then classify its weight as either heavy, medium, or light. Below are some of the components and assemblies I worked on during the project.
Final Assembly
Master Assembly
Components
Claws (Material Identification)
Claws (Material Identification)
In order to identify the material block, my group decided to use claws. In addition to the weight of the block being random, the dimensions could vary by 10mm and we would not know which block we were being tested with. We initially thought about measuring the distance our claws closed to determine the material since the foam would deform, but not the plastic, however, the variability of dimensions eliminated this idea. To successfully determine the material, I wrote an Arduino program to measure the current draw of the servos as they closed around the block. In order to accomplish this, I measured the voltage across a resistor connected to the servos actuating the arms. By looking at the relationship between voltage and time as the claws closed, I was able to determine that the voltage increased rapidly when closing on the plastic block, but gradually with the foam block. Using this relationship, my code enabled our OTV to autonomously determine the material of the block.
Weight Classification
Weight Classification
Classifying the block as heavy, medium, or light weight was accomplished by transferring the weight of the block onto a load cell. As shown in the video, after the claws closed on the block, the block was lifted by a third servo shown in the assembly to the left. This servo was attached to the chassis of our OTV via a load cell which enabled us to determine the weight of the block when it was lifted off the ground.
Manufacturing
3D Printing
3D Printing
Manufactuing our OTV involved a number of different technologies and tools. The majority of our chassis plates were manufactured using a laser cutter which ensured the dimensions and hole/notch placements matched that of our design in CAD. Most of the claw components were 3D printed. Other tools and machines such as a belt sander and drill press were used to construct and shape components which could not be 3D printed or laser cut.
Laser Cutting
Laser Cutting
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