Date post: | 08-Jan-2017 |
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Highlights● New product development
● High tolerance machining
● Sheet metal
● Aluminum extrusion
● Cosmetic surfaces
● Rapid prototyping
● Plastic Injection Molding design
● Over-molding
● Production drawings and documentation
● Welding
● Working with suppliers to explore new technologies
● Fixture Design
● Overlay and labeling design
● Cable design / Ultrasonic Welding
● Product support● Investigation of product issues● Manufacturing support
● Cost reduction
● Design challenges
● Personal woodworking projects
New Product DevelopmentTest and Measurement – PXI Modules● Inception to Production● High tolerance machining● Sheet metal● Aluminum extrusion● High voltage/high current● Quoting ● Supplier selection● BOM creation/product life cycle● Overlays● Verification testing● Assembly fixtures● Test fixtures● Work instructions● Production hand-off
New Product DevelopmentSlot Machine Topper● Adjustable monitor stand ● Sheet metal design● Rivets● Painted exterior surfaces ● Ensures proper grounding
New Product DevelopmentAccessory Cables● Cosmetic surfaces● Material selection● Supplier selection● Supplier support with new processes● Shielding● Over-molding● Plastic injection molding● Verification testing● Labeling
New Product DevelopmentRapid Prototyping● Target practice Deuling Tree● Solid model● Metal fabrication● Welded● Tested● Start to finish in 12 hours
New TechnologiesUltrasonically Welded Cable shells● Never before used on cable enclosures at National Instruments
● Allowed quick change from over-mold to injection molded plastic
● Conducted research● Developed process working directly with supplier
● Selected tooling● Selected materials● Trained Mechanical Engineering team
Product Support
Game Floor Kiosk Conversion● Conversion from Solidworks to Creo 2.0
● Created over a hundred solid models and production drawings
● Integrated new auto-latching door design
● Welded parts
Product SupportRoot Cause Analysis of Coin Jams● Designed test setup● Created LabVIEW program to count coins and measure time between cycles
● Recreated jams in house● Discovered root cause ● Updated design ● Conducted reliability testing
Manufacturing Support
Production hand-off● Developed assembly processes● Created detailed assemby instructions● Developed assemby fixtures● Trained manufacturing team
Manufacturing Support
Fixture Design● Reflow oven fixture● Assembly fixtures● Gluing fixture● Cable solder fixture
Design Challenges
EMI Gasket● Adding gasket to front panel proved to be more difficult than anticipated
● Conducted brainstorming meetings
● When no feasible solution discovered, re-evaluated which constraints could be adjusted
● Longer connectors allowed for enough material in panel to capture EMI gasket
Design Challenges
Connector Block Assembly Bow● Integral part to RF product● Tightened connectors caused deformation ● FEA used to predict behavior of next revision
Cost Reduction
Working with Vendors● Changed to less expensive vendor
● Designed out high cost features
● Material change● Re-used parts on multiple products
● New parts verification
Personal ProjectsPower Generating Exercise Bike Prototype● Alternator to generate electricity while you exercise
● Created LabVIEW VI to measure power output and speed
● Presented results at company tech fair● Created a second revision
Personal ProjectsBeekeeping● Beehive stand with moats to prevent ant invasions● Queen Castle for queen bee production● Custom honey label with beeswax seal on lid, won first place at county competition
Personal ProjectsTeardrop Trailer● Built onto 4' x 8' trailer● Battery plus inverter power supply
● LED lights● Powered fan vent
Personal ProjectsUnderground Tornado Shelter● Integrated door frame built into concrete floor
● 10'x16' shop built on top● Shelter roof supports 2 feet of wet soil
Personal ProjectsUnderground Tornado Shelter● Custom welded steel door weighs 750 lbs● Concrete filled to provide extra strength
Personal ProjectsUnderground Tornado Shelter● Lift assist provided by two gas springs● Integrated bolt locks
Personal ProjectsUnderground Tornado Shelter● Custom ship ladder with integrated hand rails● Magnetic door lock ● Bottle jack for backup door lift
Personal ProjectsUnderground Tornado Shelter● Small kitchen● Water heater● Shower● Macerating Toilet