Embedded Files
Mechanical Engineering Co-Op @ QSA Global
Mechanical Engineering Co-Op @ QSA Global
Jul 2022 - Dec 2022
Jul 2022 - Dec 2022
QSA Global is a nondestructive testing products company specializing in radiology and radioactive elements.
I was in responsible for fulfilling engineering requests and product/tool documentations.
My days were spent between SolidWorks and working hands-on for projects aiding manufacturing and developing new testing fixtures.
Pipe Trolley Image Stabilizer
Pipe Trolley Image Stabilizer
My main project for my 6-month experience was the pipe trolley image stabilizer. I was tasked with designing a system that could attach to our x-ray units to allow for stable recording. I could go to my engineering managers for problem-solving and communicate with other departments, but besides that, I was in charge of the concept, modeling, prototyping, testing, and release of this product. There was a need for this project because, before, users would carry large units and try to record x-ray images steadily for hours a day. The images would be inconsistent, and the unit was heavy and awkward to hold. This project would alleviate the weight and allow for smooth and consistent image recording. I chose to include this project in my portfolio because it demonstrates my responsibility in carrying out major assignments and highlights my skills and knowledge in CAD, prototyping, testing, and engineering teamwork.
Objective
The purpose of the project was to design a product that could carry the weight of our new x-ray units and roll along industrial pipes of various conditions and sizes.
Requirements:
Supports 50 lbs (weight of units and user pressing against the system).
All parts and sourcing costs fit within budget.
Handle the extreme temperatures of the usage locations.
Accommodates pipes from 4" to 20" in diameter.
Does not impair image quality when recording.
What I did
Firstly, I had meetings and discussions about quantifying the requirements for the project.
We talked with industry workers to receive input on what they would like to see and talked with other departments to clarify timelines and finances.
Next, I created a template on SolidWorks so I could simulate how different design concepts would look in action and check if they fit the requirements, as well as remain unobtrusive.
I made sure the foundation of my concept could apply to pipes 4" to 20" in diameter because that factor differentiates the project from other competitors.
The concept came to be 2 legs with 4 joints that could be adjusted for different pipe sizes. The dimensions were chosen so there will be no obstruction to the unit's performance. I discussed with machinists to learn what was feasible and machined some parts.
Simulation
Wheel Hub V1
Concept Hub V2
3D Printed Hub V4
Once the basic shape was formed, I focused on the wheel hubs. They had to be cost-effective and the geometry had to prevent the whole system from tipping over.
I compared omni-wheels, big nylon wheels, and rubber skate wheels. Rubber wheels provided much-needed grip.
Physical 3D prints were made and combined with machined and spare parts to create the prototypes.
Initial feedback was received, and changes were made to the design. The hubs needed to be simpler to save machining costs and the back wheels had to be pushed back to keep the center of gravity straight.
The hub has extra holes to incorporate pneumatic wheels for when the pipe's conditions are rough and beaten.
Rendering of Image Stabilizer with Pneumatic Wheels
The other major part to rethink was the legs connector. It needed to be easy to manufacture and lock the trolley steady.
My design was one part that utilizes a Picatinny connection that came with the x-ray unit. It slides the trolley onto a rail and locks in with a spring plunger.
Once we had a concept we'd like to finalize, I gave a presentation with cost breakdowns, and CAD and physical models to pitch the idea.
After there was a product we liked, I ordered professionally machined parts from Xometry and McMaster-Carr.
We assembled multiple prototypes and tested them in-house. After adjustments were made, we sent them for field tests for customer feedback.
Design Process of Legs Connection
Results
The project was deemed a "game changer" by customers and QSA employees.
Final adjustments to be made by the time I left. The product was planned to release as an incentive bonus for customers ordering QSA's revamped x-ray units.
I increased my skills in CAD, rapid prototyping, and team communication.
1st Prototype made of spares parts and PLA
Final Prototype Attached Underneath
Stabilizer Set and Ready
1670270109462.mp4Customer Field Trial in Norway
Page updated
Google Sites
Report abuse