Square Robot
For my third and final co-op, I took on the role of Mechanical Engineering Co-op. The role was both design and hands on based. I appreciated the ability to express my creative problem solving skills in a robotic application. The crossover of electromechanical and systems engineering allowed me to expand my skill set in a valuable way. The role pushed me to grow as a young engineer and advance my technical knowledge. By the conclusion of my role, I had individually released products and implemented permanent design changes to the latest generation of robots. I worked on both topside and submerged components and left feeling as though I had left a positive mark on the vehicle.
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Problem Statement:
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Design an IP68 rated system to autonomously purge and pressurize the sealed vehicle control housing. Integrate a custom PCB with Arduino control systems to coordinate pressure sensors, solenoid valves, and heat sinks within a compact system to be both portable and 120/240V compatible. Model and 3D print all necessary mounting systems to properly organize all components, pneumatic tubing, and push-to-connect union joints.
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Actions:
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Insulate a box from both water and dust to be IP68 rated. This will act as a two-way failsafe for if any pneumatic line fails, as this will contain the nitrogen to the box, preventing user asphyxiation.
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Mount all necessary components as compactly as possible. This will make the product portable and easy to ship/transport to job sites.
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Create a user feedback loop by displaying the analog readings of the pressure sensors to compare with the internal pressure readings from the vehicle control housing.
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Create 120V and 240V power adaption by using spade connectors and custom cable harnesses to modify a power adapter.
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Write a C++ script to control logic through a custom PCB to execute setpoints and control solenoid valves.
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Design and 3D print custom mountings solutions to isolate heat from PCB from sensitive components and to orient the necessary lines.
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Create a user interface with pushbutton switches and LCD menu selects to allow for easy user interaction.
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INTELLECTUAL PROPERTY
Results:​
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The system was rigorously tested and deemed usable for rollout. It has since been used on jobs sites all across North America, Europe, and Asia. The product is licensed out to partners at a rate which reduces the payback period to be negligible.
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The operator touch time is greatly reduced, as the system's autonomous cycle swapping is quicker than any human could be. Further, the operators can do other tasks while the cycles execute on their own.
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The kit offers a standardized solution for when our components are worked on by third party companies. Therefore, with known setpoints, the expensive hardware cannot be over-pressurized or too oxygen rich due to operator error. This protects Square Robot's assets from these types of accidents.
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The system offers increased safety for the operators, as it acts as an insulated barrier between the user the nitrogen, a known asphyxiant. Further, it decreases the amount of interaction users need with high pressure vessels or high voltage components.
The video below is a slow-ramped test of a vehicle housing purge and pressure cycle. Feel free to increase the playback to 2x, as the test was run intentionally slow as a preliminary gauge of success. The thruster cycling completes within 15 seconds, while the VCH at full speed executes within 1 minute.
