Research & Development Engineering Intern
PROJECT DETAILS
R&D ENGINEERING INTERN
2024
In this technically demanding role, I spearheaded the design and development of a robust vibration table, equipped with a driveshaft, timing belt, and idler pulley. This system was engineered to endure extreme loads and temperatures while maintaining precise orbital motion within the required displacement range.
Throughout the project, I conducted thorough stress and frequency simulations to assess structural integrity and performed degree-of-freedom stack-up analyses to ensure accurate system motion predictions. The project demanded meticulous attention to every detail, from technical drawings to materials acquisition, fabrication, machining, shipping, and final assembly of all components.
My experience extended to conducting iterative fire tests, where I helped optimize an outdated oil burner to match the performance of the FAA's NexGen burner. This required in-depth data analysis of fuel pressure, air-to-fuel ratios, and flame fluid dynamics, resulting in significant improvements.
Additionally, I fabricated a regulator control board for pressure testing, integrating control valves and pressure transducers to comply with AS6826 pressure standards. To provide clarity to the design, I created basic piping and instrumentation diagrams (P&IDs), visualizing the system layout and ensuring seamless functionality.
This hands-on role not only challenged my engineering skills but also emphasized the importance of iterative testing and real-time data analysis in achieving optimal results.
Due to company policies, I am unable to display images of the projects I worked on. Instead, I will include online images that represent similar concepts.
Nexgen Burner
"As implementation of the burnthrough rule quickly approached, it was realized that there was a serious lack of availability of the Park Oil Burner that was specified in the Rule.
The FAA sought to develop a burner that could be equivalent in performance to the Park Oil Burner and could be easily constructed from readily available materials.
Compressed air and pressurized fuel would be used to replace the functions of the electric motor and shaft-driven fuel pump, removing much of the fluctuations caused by variations in voltage supply or environmental conditions, while increasing the level of repeatability and reproducibility."
Credit: Jinrui Wang, Beihua Cong, Kai Zhang, Bailin Zheng, Investigation of the temperature field of turbulent non-premixed flame for the variable angles of inclination of NexGen burner, Case Studies in Thermal Engineering.
Vibration Table
Induced vibrations are associated with simulating in-flight engine run and general aircraft operation during fire testing.
Acceptable vibration spectrums per ISO 2685:
- Minimum 0.8mm peak-to-peak displacement.
- Non-resonant frequency closest to 50 Hz.
Both were achieved by incorporating eccentric cams with a 0.4mm offset into each bearing, creating the necessary orbital motion. The design involved over 60 components, for which I created technical drawings and sent them out for machining.
I applied principles from running and sliding fits to size the holes for brackets and the idler arm, using data from the Machinist Handbook and manufacturer specifications. Additionally, I calculated the spring rate needed for the tensioner and used belt perimeter, breaking strength, and elongation data to determine working and breaking tensions, ensuring the correct distance between shafts.
The final design met the required performance parameters and was a key part of the testing setup.