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ASME Channel Islands Professional Chapter Engineer of the Year Donald “Geoff” Carter January 20, 2016 Dennis Horwitz, Chair [email protected]

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Page 1: ASME Channel Islands Professional Chapter · ASME Channel Islands Professional Chapter ... Solar Arrays for spacecraft Mechanism design for ... Concept / Design / Drafting

ASME Channel Islands Professional Chapter Engineer of the Year

Donald “Geoff” Carter

January 20, 2016

Dennis Horwitz, Chair

[email protected]

Page 2: ASME Channel Islands Professional Chapter · ASME Channel Islands Professional Chapter ... Solar Arrays for spacecraft Mechanism design for ... Concept / Design / Drafting

Engineer of the Year

Donald Geoff Carter

President and Founder,

Link Engineering & Design

Professional Engineer (P.E.)

ASME Member, Former Section Chair

Innovative, practicing lead design/mechanical engineer since 1996

B.S. and M.S in Mechanical Engineering, Cal State University Fresno

• 4 patents issued and 2 pending

• Specialist in space deployable mechanisms and structures

• Numerous space achievement awards

• Telescopic booms, Coil-able booms, Articulated Booms, Solar Array Wings

• Precision Mechanisms and Structural Analysis

• Built his own home in Santa Paula over 8 years

Page 3: ASME Channel Islands Professional Chapter · ASME Channel Islands Professional Chapter ... Solar Arrays for spacecraft Mechanism design for ... Concept / Design / Drafting

Donald Geoff Carter

Education and Professional Development

Page 4: ASME Channel Islands Professional Chapter · ASME Channel Islands Professional Chapter ... Solar Arrays for spacecraft Mechanism design for ... Concept / Design / Drafting

Donald Geoff Carter

Career Chronology

Page 5: ASME Channel Islands Professional Chapter · ASME Channel Islands Professional Chapter ... Solar Arrays for spacecraft Mechanism design for ... Concept / Design / Drafting

Donald Geoff Carter

Career Highlights

Flexible leadership skills wearing many diverse hats for each phase of the program:

concept, design, analysis, procurement, build, testing, and management.

• Lead Design Engineer bringing several high profile space flight projects such as,

STP-SIV, NuStar Adjustment Mechanism, NPOESS Solar Array and the JMAPS

Solar Array from concept to deliverable.

• Notable experience in the space structures industry designing Telescopic Booms,

Coilable Booms, Articulated Booms, Solar Array Wings, military APU packaging,

precision mechanisms and structural analysis.

• Bringing high volume products to the marketplace for large OEM’s and awarded

three US Patents for superior product innovation.

• Developed the mechanical structure and kinematic mechanisms for Star Wars Darth

Vader robotic toy arm, which received the Educational Toy of the Year award at the

International Toy and Hobby Show.

• Received service awards such as Perfect Attendance three simultaneous quarters,

and an A3 Performance award coupled with stipend for completing project ahead of

schedule and under budget.

• Successful projects include a very diverse list from consumer products to space

flight hardware.

Page 6: ASME Channel Islands Professional Chapter · ASME Channel Islands Professional Chapter ... Solar Arrays for spacecraft Mechanism design for ... Concept / Design / Drafting

Donald Geoff Carter

Engineering Expertise

• 80-100 design projects completed

• Project Manager/Lead Design Engineer

• Managing manufacturing and assembly lines for product development/launch

• Working in multi-functional team environment

• Conducting preliminary and critical design reviews

• Liaise with overseas manufacturers and customers

• Feasibility studies / cost savings analysis

• GD&T, ANSI Y14.5, DOD-STD-100 standards.

• Precision mechanism design/kinematic analysis

• Design for assembly/manufacturing

• Failure analysis

• Electric motors and pumps

• OEM high volume injection molding, die casting and metal stamping parts/products

• CNC and sheet metal design

• Rapid prototyping - with plastics and metals

• Instructed Pro/E training classes for other engineers

• Pro Engineer Expert - (18000+ hours experience)

• Pro Mechanica Structure - stress/thermal analysis & simulation

• Microsoft Excel, Access, Word, Power Point, Project

• Solid Works, AutoCAD and MathCAD

• Ansys Workbench 16

Page 7: ASME Channel Islands Professional Chapter · ASME Channel Islands Professional Chapter ... Solar Arrays for spacecraft Mechanism design for ... Concept / Design / Drafting

Donald Geoff Carter

Volunteer Work

Page 8: ASME Channel Islands Professional Chapter · ASME Channel Islands Professional Chapter ... Solar Arrays for spacecraft Mechanism design for ... Concept / Design / Drafting

Link Engineering And Design

“You are bound only by the grips of your

imagination…”Donald G. Carter, PE

Link Engineering And Design

Page 9: ASME Channel Islands Professional Chapter · ASME Channel Islands Professional Chapter ... Solar Arrays for spacecraft Mechanism design for ... Concept / Design / Drafting

About Link Engineering And Design

Product Development and Engineering Firm

Founded in 2014

15+ years in consulting Machinery

Mechanisms

Aerospace

Automotive

Agriculture

Food industry

“Dedicated to bringing your projects to completion”

Page 10: ASME Channel Islands Professional Chapter · ASME Channel Islands Professional Chapter ... Solar Arrays for spacecraft Mechanism design for ... Concept / Design / Drafting

Link Services

• Mechanical Engineering

• Electrical Engineering

• Stress / Thermal Analysis

• Systems Engineering

• Industrial Design

• Drafting / Modeling

Page 11: ASME Channel Islands Professional Chapter · ASME Channel Islands Professional Chapter ... Solar Arrays for spacecraft Mechanism design for ... Concept / Design / Drafting

Clients

Consumer Products Aerospace

Network / Computer Toys

Page 12: ASME Channel Islands Professional Chapter · ASME Channel Islands Professional Chapter ... Solar Arrays for spacecraft Mechanism design for ... Concept / Design / Drafting

Software

CAD

ProE - Mechanica

Solidworks - Cosmos

MS Office Suite

Word

Excel

PowerPoint

Project

MathCAD

Page 13: ASME Channel Islands Professional Chapter · ASME Channel Islands Professional Chapter ... Solar Arrays for spacecraft Mechanism design for ... Concept / Design / Drafting

Project Portfolio

Consumer Products / Toys

Page 14: ASME Channel Islands Professional Chapter · ASME Channel Islands Professional Chapter ... Solar Arrays for spacecraft Mechanism design for ... Concept / Design / Drafting

Toys: Darth Vader Arm

Robotic Arm with gripping action, articulating wrist and elbow.

Complete Design / Build

Mechanism Design

Structural Analysis

Customer: Uncle Milton Toys

Educational Toy of

the Year Award!

Page 15: ASME Channel Islands Professional Chapter · ASME Channel Islands Professional Chapter ... Solar Arrays for spacecraft Mechanism design for ... Concept / Design / Drafting

Click on the picture

Toys: Interceptor AeroX Launcher

Design / Build

Mechanism Design

Two independent gear trains.

Clutch Design

Launch Mechanism

Structure Design / Analysis

Customer: Estes Rockets

Remote control tank with integrated

plane launcher.

Page 16: ASME Channel Islands Professional Chapter · ASME Channel Islands Professional Chapter ... Solar Arrays for spacecraft Mechanism design for ... Concept / Design / Drafting

Enclosure: Power Strip

Design / Drafting / Build

Analysis

Rapid prototyping

Electronic Packaging

Custom electronic switches

New high voltage contacts

Customer: Maverick Power

Systems Inc.

Description: This power strip

provides both AC and switchable DC

power with over load protection.

Page 17: ASME Channel Islands Professional Chapter · ASME Channel Islands Professional Chapter ... Solar Arrays for spacecraft Mechanism design for ... Concept / Design / Drafting

Sports: Face Mask - Baseball

Concept to product.

Industrial Design

Analysis

Mechanism Design

Ergonomics

Customer: Grounder Guard

Description: A lightweight removable

safety mask for youth baseball. Mask

pivots out of way when not in use. It

can withstand a 70mph baseball

direct hit.

Page 18: ASME Channel Islands Professional Chapter · ASME Channel Islands Professional Chapter ... Solar Arrays for spacecraft Mechanism design for ... Concept / Design / Drafting

Network Encrypting Router and Key

Low part count – combined multiple components

Passive cooling Industrial design Ruggedized Key Fob

x.o.ware (Injection Molded Enclosures)

Page 19: ASME Channel Islands Professional Chapter · ASME Channel Islands Professional Chapter ... Solar Arrays for spacecraft Mechanism design for ... Concept / Design / Drafting

Samsung Tablet Cradle

Adapt existing tablet for medical use Multifunctional assembly

In and out of operating room

Ergonomic docking features for ease of use Maximize screen area Industrial design

Arthrex California Technology(Injection Molding)

Page 20: ASME Channel Islands Professional Chapter · ASME Channel Islands Professional Chapter ... Solar Arrays for spacecraft Mechanism design for ... Concept / Design / Drafting

Project Portfolio

Aerospace Pojects

Page 21: ASME Channel Islands Professional Chapter · ASME Channel Islands Professional Chapter ... Solar Arrays for spacecraft Mechanism design for ... Concept / Design / Drafting

Deployable Space Systems

Solar Arrays for spacecraft

Mechanism design for

outer space

Materials selection

Aluminum

Titanuim

Steels

Carbon Fiber

Stress analysis

Thermal Analysis

Testing

Design for severe

environments

Link Engineering And Design

Page 22: ASME Channel Islands Professional Chapter · ASME Channel Islands Professional Chapter ... Solar Arrays for spacecraft Mechanism design for ... Concept / Design / Drafting

Aerospace: NuSTAR

Complete Design

Piece Part Stress Analysis

Mechanical Characterization Testing

ATK Space Systems / Jet Propulsion Lab

Mast Adjustment Mechanism for the Nuclear Spectroscopic Telescope Array. Precision adjustment to micro-radians.

Page 23: ASME Channel Islands Professional Chapter · ASME Channel Islands Professional Chapter ... Solar Arrays for spacecraft Mechanism design for ... Concept / Design / Drafting

Aerospace: Telescoping Boom

Complete Design

Composite / Aluminum / SS

Deployable / Retractable

Accurate & Repeatable

High Stiffness

5’ – Stowed

20.5’ – Deployed

Customer: Able Engineering

Description: Structural telescoping

boom with high stiffness / torque /

push force. Completed as a R&D

project.

Page 24: ASME Channel Islands Professional Chapter · ASME Channel Islands Professional Chapter ... Solar Arrays for spacecraft Mechanism design for ... Concept / Design / Drafting

Aerospace: NPOESS

Lead Mechanical Engineer

Manage Mechanical Team

Deployment System

Synchronization System

Piece Part Stress Analysis

Design Trade Studies

Customer: ATK Space Systems

Description: National Polar Orbiting

Satellite System. Solar array wing

system. Deploys 9 accordion style

panels 4.5’ x 13.5’ x

Page 25: ASME Channel Islands Professional Chapter · ASME Channel Islands Professional Chapter ... Solar Arrays for spacecraft Mechanism design for ... Concept / Design / Drafting

Project Portfolio

Machinery

Page 26: ASME Channel Islands Professional Chapter · ASME Channel Islands Professional Chapter ... Solar Arrays for spacecraft Mechanism design for ... Concept / Design / Drafting

Machine: Enclosed Conveyor

Concept / Design / Drafting

Analysis

Mechanism Design

Material: SS 316L

13’ wide x 7’ tall x 180’ long

Weight = 80,000 lb

Manage demolition and installation

Customer: Leprino Foods

Description: Food processing

conveyor designed in Pro Engineer /

Pro Mechanica. Successfully

installed in Lemoore, Ca. 2000.

Page 27: ASME Channel Islands Professional Chapter · ASME Channel Islands Professional Chapter ... Solar Arrays for spacecraft Mechanism design for ... Concept / Design / Drafting

Machine: Rotary Cutter

Concept / Design / Drafting

Analysis

Mechanism Design

Material: SS 316L

Conducted Feasibility study

Used 4 HP rotary action to

replace 50 HP hydraulic

slicer.

Customer: Leprino Foods

Description: Food processing

product slicer designed in Pro

Engineer / Pro Mechanica.

Successfully installed in Lemoore,

Ca. 2000.

Page 28: ASME Channel Islands Professional Chapter · ASME Channel Islands Professional Chapter ... Solar Arrays for spacecraft Mechanism design for ... Concept / Design / Drafting

Eco Motors

OPOC Engine

Opposed Piston Opposed

Cylinder

2 stroke diesel

4x power density compared

to contemporary 4 stroke

engine

Electrically Controlled

Turbocharger (ECT)

Page 29: ASME Channel Islands Professional Chapter · ASME Channel Islands Professional Chapter ... Solar Arrays for spacecraft Mechanism design for ... Concept / Design / Drafting

EcoMotors – OPOC Rotating Components

Page 30: ASME Channel Islands Professional Chapter · ASME Channel Islands Professional Chapter ... Solar Arrays for spacecraft Mechanism design for ... Concept / Design / Drafting

OPOC components

Page 31: ASME Channel Islands Professional Chapter · ASME Channel Islands Professional Chapter ... Solar Arrays for spacecraft Mechanism design for ... Concept / Design / Drafting

OPOC Engine Optimization

Engine Operating

Points on

Compressor Map

Page 32: ASME Channel Islands Professional Chapter · ASME Channel Islands Professional Chapter ... Solar Arrays for spacecraft Mechanism design for ... Concept / Design / Drafting

5kW Generator using 80cc opoc™

Engine

Conceptual Sketches

Page 33: ASME Channel Islands Professional Chapter · ASME Channel Islands Professional Chapter ... Solar Arrays for spacecraft Mechanism design for ... Concept / Design / Drafting

Design / Drafting / Build

High density electronic Packaging

Thermal management

Twin throttle mechanism design

Intake manifold design

Fuel tank design

Quick release system

Customer: Advanced Propulsion Technologies Inc.

Standalone 5KW auxiliary power

supply for military applications. Quick

release pins to remove base power

unit for vehicle integration.

Packaging: Military Power Supply

Page 34: ASME Channel Islands Professional Chapter · ASME Channel Islands Professional Chapter ... Solar Arrays for spacecraft Mechanism design for ... Concept / Design / Drafting

EcoMotors APU – prototype build

Refined the design, added support packaging

and tailored to military needs

Page 35: ASME Channel Islands Professional Chapter · ASME Channel Islands Professional Chapter ... Solar Arrays for spacecraft Mechanism design for ... Concept / Design / Drafting

EcoMotors – ECT development

Electrically Controlled

Turbocharger

2.5 kW Electric Motor

5kW in Development

Reduce / eliminate turbo lag

Waste Heat Recovery

Page 36: ASME Channel Islands Professional Chapter · ASME Channel Islands Professional Chapter ... Solar Arrays for spacecraft Mechanism design for ... Concept / Design / Drafting

Project Portfolio

Analysis

Page 37: ASME Channel Islands Professional Chapter · ASME Channel Islands Professional Chapter ... Solar Arrays for spacecraft Mechanism design for ... Concept / Design / Drafting

Backed up with Traditional Analyses

Page 38: ASME Channel Islands Professional Chapter · ASME Channel Islands Professional Chapter ... Solar Arrays for spacecraft Mechanism design for ... Concept / Design / Drafting

Finite Element Analysis

Optimization of components

Stress

Strain

Modal analysis

Airflow (CFD)

Page 39: ASME Channel Islands Professional Chapter · ASME Channel Islands Professional Chapter ... Solar Arrays for spacecraft Mechanism design for ... Concept / Design / Drafting

Static Stress Analysis

Von Mises

Over stressed?

Under stressed?

Stiffness or strength driven?

Page 40: ASME Channel Islands Professional Chapter · ASME Channel Islands Professional Chapter ... Solar Arrays for spacecraft Mechanism design for ... Concept / Design / Drafting

Mechanism: Hitch safety device

Design / Drafting

FEA Analysis

Mechanism design

Customer: Entreprenuer

Description: A line of trailer hitch

products including de-coupling

system, forged hitch with quick

change hitch balls and dead-band

removal system.

Page 41: ASME Channel Islands Professional Chapter · ASME Channel Islands Professional Chapter ... Solar Arrays for spacecraft Mechanism design for ... Concept / Design / Drafting

Thermal Analysis

Page 42: ASME Channel Islands Professional Chapter · ASME Channel Islands Professional Chapter ... Solar Arrays for spacecraft Mechanism design for ... Concept / Design / Drafting

Reverse Engineering(2013 Mustang Intake)

Captured all ports locations / Geometry

Captured all geometry for clearance indentations

Vehicle

clearance

features

MAF Sensor

location

Breather

Ports

Page 43: ASME Channel Islands Professional Chapter · ASME Channel Islands Professional Chapter ... Solar Arrays for spacecraft Mechanism design for ... Concept / Design / Drafting

Pressure Flow Preliminary Analysis

Pressure differential of 1.6 psi overall

Flowing 1000 cfm maximum

Page 44: ASME Channel Islands Professional Chapter · ASME Channel Islands Professional Chapter ... Solar Arrays for spacecraft Mechanism design for ... Concept / Design / Drafting

Pressure Flow Animation

Page 45: ASME Channel Islands Professional Chapter · ASME Channel Islands Professional Chapter ... Solar Arrays for spacecraft Mechanism design for ... Concept / Design / Drafting

Qualities of an engineer – my opinion

Inquisitive – How did they do that? How does it work?

Imaginative – Dream big

Not afraid to try something new

Learn by doing – books are great, but the greatest

knowledge is hands on experience

Learn by failure - no one likes to fail, but the greatest

knowledge is gained from not succeeding the first

time

Persevere

Works well with others?

Link Engineering And Design