Projects
Parallel Systems Internship
Parallel Systems is a startup creating electric and autonomous rail vehicles, aiming to phase out trucks carrying cargo on the road and thereby reducing emissions and traffic. I was a Vehicle Engineering Intern on the mechanical engineering team, and was assigned several hands-on projects related to design, testing, and validation.
Image Source: Parallel Systems
Project #1: Brake Controller Enclosure Gasket Redesign
Background
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Old gaskets in brake controller enclosure had to be trimmed by hand because they were flimsy and would get compressed to the point of protruding too far out.
Goal
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Redesign gasket and corresponding geometry to achieve adequate compression and seal against water/other ingress.
Enclosure
Old gasket
Project #2: Lug Calculator Validation
Background
A lug calculator was designed by my teammate to find margins of safety for a lug/clevis/pin/bushing assembly, with inputs including FOS, external loads, geometries, & material properties.
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Goal
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Validate lug calculator spreadsheet’s outputs & functionality with FEA on Ansys Workbench.
Project #3: Strain Gage Kit and Testing
Background
No streamlined in-house strain gaging setup existed at Parallel.
Goal
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Develop kit for strain gaging on test vehicle instrumentation and test articles. Determine whether pricier gages and adhesives perform better. Write out procedures, including for DAQ usage.
Teammate's initial experiment - strain on soda can
Project #4: Brake Pump Pressure Testing
Background
Brake pumps failed to reach the minimum pressure of 1200 psi (which they’re rated to) during initial testing, when Parallel's manufacturing partner measured 800 psi.
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Goal
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Validate 800 psi rating by measuring max pressure provided to the axle by the hydraulic brake pumps when fully energized to 12 V.
Brake tray
Project #5: Charging Harness Restraint Mount
Background
Charging harness of vehicle would be left as a coiled heap on the top deck.
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Goal
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Design a mount or restraint to secure the harness since it will remain on the vehicle both when stationary and in motion.
Side Project: Brain PCB Stand
Background
Parallel's electrical engineers were using an unstable makeshift stand for working on the brain PCB, which is an integral component for vehicle commands and functionality.
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Goal
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Design a stand to prop up the PCB and the complementary Jetsin module (when attached), leaving space for fans to blow air and cool the Jetsin.
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Results
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Designed a version of the stand without tabs to mount fans, and then one with tabs to mount 4 small fans and with cutouts in the base. 6 units were 3D printed and put to use, more came later.
Brake tray
