ryan jacobs · formula sae –student design project team ... compressed air motor –design and...

Ryan Jacobsmechanical engineer

design portfolio

Formula SAE – Student Design Project Team

Ryan Jacobs mechanical engineering

Formula SAE – Student Design Project TeamDesign:

Fabrication:


Testing:

Formula SAE – Drivetrain Design

DifferentialWheel Hub

Bearing Carrier

CV joint

Halfshaft

Objective: Optimize performance, weight, cost,


Objective: Optimize performance, weight, cost,

reliability, ease of manufacturing, and tunability.

Function: Team Leader, responsible for design and

manufacture of drivetrain components with a focus on

system optimization.

Highlights: Implemented tripod style Constant Velocity

(CV) joints to save weight and enable in-house CNC

machining, designed and fabricated simple mechanism

to restrain halfshafts

Formula SAE – Drivetrain PackagingHighlights:

- Redesigned inboard CV joints and bearing carriers

to accommodate brake calipers, rotors, and

hydraulic lines

- Minimized halfshaft angle within CV joint to

reduce stress and optimize efficiency while

maximizing chain engagement on both sprockets

- Eliminated potential sources of unbalance and

friction by minimally constraining assembly in

concentric layoutRear

Sprocket


DifferentialBrake

caliper

Brake

Rotor

CV Joint

Formula SAE – Constant Velocity (CV) JointBackground: CV Joints allow rotating shafts to transmit torque

over a range of angles to allow for suspension travel

Highlights:

- Developed one-piece Tripod style inboard CV joints

- Analyzed joint in FEA for acceleration and braking conditions

- Incorporated brake rotors and wheel speed sensors onto exterior

of inboard joint to minimize yaw moment of inertia

- CNC machined from 4340 steel then heat treated to HRC 50

Grease


Grease

Boot

Tripod

Brake

Rotor

Splines to

Differential

Wheel Speed

Pick-up

Dogbone Method

Dogbone

HalfshaftEndcap

Cups

Cap Method

Caps Halfshaft Plates Hub Plate

Plates Method

Formula SAE – Halfshaft Retention MechanismPreliminary Design Ideas:

Spring Method

(Mirrored on Inboard)

Halfshaft Tappet Spring

Final Design – Hemisphere Method: Challenge: Outboard CV joints move vertically

and laterally in relation to the Inboard CV joints

due to vehicle suspension geometry. This

creates a desired halfshaft length which


Hemisphere Joint

Spring

Inboard CV

Outboard CV/Hub

creates a desired halfshaft length which

continuously varies while driving.

Solution: Allow the halfshaft to plunge into one

of the CV joints to account for the change in

length. The hemisphere method achieves a

plunging inboard joint by utilizing a male

hemisphere with a concentric return spring to

maintain tension on the halfshaft. Furthermore,

this method minimizes components and eases

assembly.

MIT Beaver Tail Flash Drive


MIT Beaver Tail Flash Drive

Objective: Develop a consumer product for the MIT

Museum Gift Store that embodies MIT culture

Design Concept: Couple technology (USB) with MIT

branding (beaver) in a product which fills a common need

for MIT students, faculty, and alumni

Outcome: Currently in talks with the MIT Alumni Affairs

office to produce a batch of Beaver Tail Flash Drives and

distribute to graduating students Functional Prototype


Benchmarking Beaver Tails – Cartoon vs. Realistic:

MIT Beaver Tail Flash Drive – Idea Refinement

Silicone Rubber

Test Piece

Prototyping – Created an assortment of physical prototypes to evaluate general sizing and texture

Clay Models


Modeling – Generated multiple variations in Solidworks to refine form, color, and cross-hatch pattern

MIT Beaver Tail Flash Drive – Final Product

Molding – Utilized rapid prototyping printer to create 3-piece mold for silicone rubber castings of

final Beaver Tail design with integrated flash memory PCB


Final Design –

Silicone rubber

casting with 2gb

flash memory

storage capacity,

MIT branding,

and keychain

attachment

Compressed Air Motor – Design and Development


Objective: Using a compressed air tank, propel a small

cart up a 10 degree incline of a set length

Judging Criteria: Motors evaluated on max power output

and efficiency by adding weight to the cart until motor

fails to reach finish

Outcome: Developed most powerful motor out of 30

entries while placing 2nd in efficiency

Compressed Air Motor – Design and Development

Air Cart Chassis


Benchmarking – Current Commercial Products:

Piston Motor Gerotor Motor Vane Motor

Compressed Air Motor – Design and DevelopmentDesign Features:

- Tri-Piston motor to eliminate dead spots without

sacrificing design simplicity

- Long piston stroke possesses significant torque and

power advantage over smaller diameter gerotor and

vane motors.

- Optimized for manual machining by employing circular

and square geometry and duplicating components

- Press fit interfaces with locking set screws to

streamline assembly


Compressed Air Motor – Variable TimingHighlighted Innovation:

-First student air motor to include separate

intake and exhaust valve timing

-Tune by advancing or retarding outer

cylinder in relation to rotating valve

-Valving assemblies connect to cylinders

through lightweight plastic tubing

-Capability to adjust on-the-fly for optimum

power and efficiency


Exhaust Valve Intake Valve

Rockcrusher – Design and Development


Rockcrusher – Design and DevelopmentObjective: Design a hand-held device capable of

crushing small rocks (i.e. applying a large clamping

force onto a load measuring sensor)

Judging Criteria: Max force output, weight, ease of

use, creativity, and manufacturing cost

Outcome: Generated over 5,000 lbs of clamping load

for the average user, a total amplification factor of

over 80xFoam Hydraulic Mock-up


Hydraulic Press Scissor JackHydraulic Test Piece Scissor Jack Sketch

Preliminary Benchmarking and Development:

Rockcrusher – Design and Development

Insert Sample

Design Highlights:

- Acme screw in series with hydraulic pistons produced

80x force amplification

- Simple method of user operation

- Tandem o-rings on both pistons to ensure sealing

- Manufactured entirely on manual mills and lathes while

holding ±.001” tolerance on piston to cylinder interface


MIT Product Design Course - Storyboarding

adventures in…


reenspeak

What is Greenspeak?

Greenspeak is an MIT hack done by lighting

up specific windows in the Green Building on

campus to display a message


T-shirt Graphic:


Greenspeak T-Shirt Concept:

Create a miniature Greenspeak interface on a

t-shirt that allows the wearer to emblaze their

own personal Greenspeak message on the

front.

User interface:

Wake UpStudent hears alarm

clock go off


Check ComputerCrawls out of bed to

check Wired News

Get DressedSelects Greenspeak T-

shirt from dresser

Reprogram ShirtTypes in new slogan

using Greenspeak

New DisplaySets shirt to display

“MIT”

Head to CampusWalks to campus for

class


Circuits LabEnters classroom for

lab

Trouble in LabShorts out circuit

board and bangs head

into desk

Reprogram ShirtChanges shirt’s display

to reflect frustration

with MIT

New DisplaySets shirt to display

common hacking

acronym “IHTFP”

AffirmationPasserby affirms

sentiment expressed

through Greenspeak

Outside the Office

24 Hours of LeMons – Auto Racing



Objective: Construct a racecar to compete in a 24-hour

endurance race.

The Catch: Your team must spend less than $500 total on

the vehicle

Highlights:

- Purchased a rusty, dilapidated Nissan 300zx off Craigslist

- Stripped car of non-essentials then modified interior with self-built roll cage and racing seat

- Competed on a road course in Stafford Springs, CT with 60 other racecars

“An Adventure in Mediocrity”


Track Layout


Brake & Suspension Work Prepping the Interior Installing the Seat

Before After


Brake & Suspension Work Prepping the Interior Installing the Seat

Thanks for your attention.

Contact me:

[email protected]

925.708.4529

ryan jacobs · formula sae –student design project team ... compressed air motor –design and...

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