Flex: Innovation Labs

My Second Coop Experience: Flex - Innovation Labs

My Biggest Project: Cyclic Force Application

This is the project I spent the majority of my time on at Flex. I was put in charge of it, and while I definitely asked for advice and opinions from the intelligent team of people surrounding me, I did all the work and was ultimately in charge of ensuring its completion.

Objectives:

Apply up to 800 lb repetitively
Be able to apply different amounts of force
Be able to use test area of 14" x 6"
Use in thermal chamber at temperatures ranging from -20°C to 60°C
Have an approximate cycle time of 0.5 seconds

Process:

Weights, motors, and pneumatics were all considered as methods of driving the system. Below are some images that highlight the brainstorming process:

Sketch highlighting final design

Prototype involving motor and cam

Alternative pneumatic design

Sketch of actual weights being used (was quickly found to be infeasible)

Final pneumatic design

(isometric view)

Results:

In the end pneumatics were decided to be the best course of action. However, the force applied had to be consistent, and the consistency of pneumatics at changing temperatures was called into question. To account for this, mechanical stops were used to drive the springs to a set length and therefore, a set force. In this way, the pneumatics drove the system, while springs applied the specific force. The diagram below illustrates the final product and how it works.

Diagram of Final SolidWorks Model

Final Test Fixture

Skills Gained & Lessons Learned:

Pneumatic component selection
SOLIDWORKS FEA
Arduino Programming
Manage a schedule
Clarify objectives
Design for user accessibility
Lead effective brainstorming sessions
Communicate with vendors

FEA Analysis of the Top Plate of the Fixture

Pneumatic Components Wired with AC Power

Flow Diagram for Pneumatics

A Secondary Project: PCB Housing

I designed a simple PCB enclosure with a label to identify the ports. The housing was then 3D printed for low volume production. To make this, I communicated with the electrical team to ensure that the final product was optimized for use. I improved my SOLIDWORKS skills by designing around a PCB and creating official technical drawings. I also used the 3D printer to make prototypes and ensure that the board would fit properly.

Final PCB Housing with Custom Label

Final Technical Drawing of Housing

Exploded View of Final Product

Additional Work

I also was given the opportunity to learn the basics of Zemax, an optical ray-tracing software. The project I was working on never came to fruition, but it was still a great learning opportunity. In addition, I was tasked with enhancing their drop/impact tester so that the impact mimicked that of a human landing.

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