Dmitry Yudovsky - UCLAyudovsky.bol.ucla.edu/ProjectPortfolio.pdfProblem Statement Purpose: Bubbles form in a high pressure chem-delivery line. These are ... Dmitry Yudovsky, Project

Dmitry Yudovsky, Project Portfolio, 2006

Dmitry Yudovsky

Project Portfolio,Fall 2002 through Spring 2006

2

Project Portfolio

� UCSD, MAE156B, Winter 2006� Z-Microsystems Server Cooling. Corporate Sponsored Project

� Lawrence Livermore National Laboratories, Summer 2005� Numerical Optimization of High Pressure Containers

� Applied Materials, Inc; Electro Copper Plating Group, Summer 2004� Bubble removal from Liquid Delivery System

� Applied Materials, Inc; Chemical Mechanical Planarization Group, Summer 2003

� Metrology Unit Validation � Improvement to Factory Automation Software Development Process

� San Diego Supercomputer Center, Spatial Information Systems Laboratory � GIS HTML Viewer

� UCSD Structural Engineering, Powell Lab, Professor Elgamal, Structural Health Monitoring Laboratory, Ongoing Projects

� Satellite Based Structural Healthmonitoring of the Vincent Thomas Bridge� Remote Structural Healthmonitoring of Voigt Bridge


Lawrence Livermore National Laboratories.

Manufacturing and Materials Engineering Division

KDP Crystal Mitigation Machine for the National Ignition Facility (NIF)Architecture and HMI Development

Summer, 2006

4

Lawrence Livermore, 2005. Page 1

Purpose

Background

Challenges

Method Choose

Problem Statement

5

data

HMI

interfacesensors

actuator

DXC-390

Pressure switches

amplifier

USER2: Stepper motorServo motor2 linear drives

MDIG Code

Lawrence Livermore, 2005. Page 1System Integration

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Lawrence Livermore, 2005. Page 1Methods – Software architecture

Event driven architecture, object based.

World Event

Status Variable

Faulted?

Change Event

Fault Check

GUI

Key strokeMotor velocityInterlock breachSystem event…

Fault Event


UCSD, Mechanical and Aerospace Engineering Course

156B

Z-Microsystems Server Cooling ImprovementCorporate Sponsored Project

Winter 2006

8

UCSD MAE 156B Project. Page 1

SPONSOR:Z Microsystems • Leading The Evolution In “Field-Ready” Computing.• Design & Manufacturing of Rugged Computer Hardware.

PURPOSE:Sealed Computer Module (SCM) is overheating. Develop a cooling system that is passive and rugged. It must keep the internal temperature at 25ºC above ambient

9

Proposed Design

Air DamHeat Sink

Old Design

Thermal Pad

Top Cover

Thin Grease Layer

Aluminum Block

IMPROVEMENTS

• Eliminates About 50% of The Thermal Resistance Interfaces.

• Doubles The Effective Surface Area Of The Top Panel And Localizes It Above The CPU.

• Modifies Top Panel To Increase Airflow

ADVANTAGES

• Passive Cooling

• Does Not Require Refrigerants or Liquids.

• Has Zero Degrees Of Freedom

UCSD MAE 156B Project. Page 2HARDWARE CONFIGURATION

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SIMULATION RESULTSHeat Sink Optimization for fin spacing (A) and thickness (T) . Coded in Matlab.

1 2 3 4 5 6 7 8 9 100.1

0.12

0.14

0.16

0.18

0.2

0.22

0.24

a - spacing (mm)

Res

ista

nce

C/W

Resistance vs. fin spacing for servarl fin widths

0.1mm

0.6mm1.1mm 1.6mm

Resistance Decreasing

Spacing Increasing

Sweet Spot


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TEST RESULTS

At 100% system load and 23ºC ambient temperature:

• SCM internal temperature rises by 23ºC from ambient

• CPU core temperature rises 34ºC

Spec requirement met

PROTOTYPE -5 00 0 5 00 100 0 1500 200 020

25

30

35

40

45

50

55

60

Time (se c on ds)

Tem

pera

ture

(C

elci

us)

Temperatue vs. Time


Lawrence Livermore National Laboratories.

New Technologies Division

Numerical Optimization of High Pressure Containers

Summer, 2005

13


PurposeOptimize cylindrical, multilayered high pressure vessels for ultra-high speed wind tunnel

BackgroundVarious techniques exist for raising the overall strength of vessels (such as cannons, or canisters). This includes increasing the strength (and cost) of materials, shrink fitting concentric shells, and over straining (autofrettaging) shells. An optimal assembly with shrink fitting and autofrettaging can be found.

ChallengesMultivariable optimization problem with many non-linear constraints. Numerically, negative radii might be great, but the solution must be kept realistic.

Method ChooseGradient projection method. Find steepest descent and project it on the set of active constraints.

GeometryMaterials

Thermal loadingPressure loading

Autofrettagetreatment

Gradient Projection

Stress Analysis

Optimal geometry

Problem Statement

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Geometrical configuration of problem

… more shells

1 2 n N-1 N…

r2 rn rn+1 rN rN+1r1

d1 dn-1 dn dN dN-1

r = radius d = interference or radius mismatch

P1 PN+1

sym

met

ry

Po

Pi

r1

r2

unit length

axisymmetric


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Numerical Optimization Using Gradient Projection Method

� Definitions� Active set: the set of currently enforced constraints� Inactive set: set of constraints that, when violated, become active

� Process1. Find cost function gradient2. Select active constraints3. Project gradient onto active set4. Go down projection

gn(x)=0

Iterative downhill search

Breach step

Projected gradient

Ineq

uality

cons

traint

gn(x)<0

gn(x)>0


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Graphical User Interface Lawrence Livermore, 2005. Page 4

prop

rieta

ry

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Calculation Results

1 1.2 1.4 1.6 1.8 2 2.2 2.4 2.6 2.8-0.5

0

0.5

1

1.5

2

2.5

3

factor of safety

log(

cost

)

Relative log of cost vs. factor of safety

doubling FS about increase cost by ~10

Multilayered pressure vessel. Optimal cost varies with given require factor of safety. Obviously the cost increases, but here we see that in increases exponentially. The y axis is normalized cost on a log scale.

Adding a temperature gradient during operation imposes an added stress to the assembly. We see that by greatly heating the inside of the assembly, a total diameter must be made in order to sustain the thermal stress gradient.


0

100

200

300

400

500

600

0

100

200

300

4000.5

1

1.5

T innerT outer

Log

Out

er r

adiu

s


Applied Materials, Electro Copper

Plating Group

Bubble removal from Liquid Delivery System

Summer 2004

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Problem Statement

� Purpose: Bubbles form in a high pressure chem-delivery line. These are detrimental to the subsequent process.

� Background: Degassers are commercially available however these bubbles are caused by a chemical reaction, not dissolved gas. So a bubble trap is required.

� Challenges: Waste, startup time, and installation and maintenance costs mustbe minimized. This would be an upgrade to existing systems.

� Method: Utilize the disparity between liquid to surface interaction.

Applied Materials, 2004. Page 1

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Bubble Trap Concept

2rpFpressure π=

delivery

clea

n liq

uid

waste

bubblesfloat up surface tension

pressure force

rFsurface πσ 2=

Find r to balance the two

Ideal bleed hole case

σ ≈ 0 for gas


21

Bubble Trap Implementation

L

pRQwaste

∆µ

π=8

4

µ very small for gasses

Ended up using long, very thin inner diameter tube. Friction (and some surface tension) effects counteracted the pressure force and allowed liquid to bleed at a prescribed rate, but gas to escape very quickly.

Hagen-Poiseuille:


Exit to atmospheric pressure

rLF zshear πτ 2=

2rpFpressure π=


Applied Materials, Chemical

Mechanical Planarization Group

Metrology Unit Validation

Summer 2003

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� Purpose: Applied Materials CMP leads the world in wafer planarization. However, it only makes a crude, in process metrology unit to test the quality of the polishing. External metrology must be performed; this is done by third part units. CMP System Integration was validating two competitors. My function was to test to stability, functionality, and compatibility of the this unit with our CMP hardware and software.

� Challenges: � Two teams from different corporate cultures� Third party unit still in beta phase� Time constraints

� Accomplishments: � Prepared and implemented test scenarios� Found and helped fix many bugs

Problem StatementApplied Materials, CMP, 2004. Page 1

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CMP ProcessApplied Materials, 2004. Page 2

wafers container

polishing process 1

polishing process 1

polishing process 1

polishing process 1

clea

ning

pro

cess

metrology validation

front end back end

back-end processes

pass

ed

failed

crude in-process metrology occurs during polishing

Unit of interest


Applied Materials, CMP Group

Improvement to Factory Automation Software Development Process

Summer 2003

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� Purpose: Optimize the software development (SW) process dealing with factory automation (FA).

� Background: FA for a complex machine requires keeping track of 1000’s of events, status variables, errors, logging variables, and controllable variables in the operating system of the machine. Naming and numbering of these data variables requires careful planning; no two events can have the same logical address. At Applied Materials CMP SW, a software package simplifies the actual C++ coding by generating most of the header files and event handling functions. The input to this preprocessor is a syntax based language, GCD, where each datum is defined. The file was, in turn, generated from other files written by different members of the SW team in Excel, Perl, VB, or just text. This decentralized process was very cumbersome and slow.

� Solution: Create a one-source database (DB) that the entire SW team could share. The DB would be locked to one user at a time to prevent collisions, control number ranges, and allow for easy import from and export to any standard or user defined format.

Problem StatementApplied Materials, CMP, 2004. Page 1

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Software development processApplied Materials, CMP, 2004. Page 2

Data (Variables, events, status reports, etc.) stored in different media (Excel, text, etc.). These require data specific converter to create a GCD file. GCD file in then compiled to C++ code.

Old Processdata converter

Events

GCD fileGCD

Preprocessor

Status Variables

Error variables

…

update C++ codeC++ Code

Data is stored in a database that sits on a network drive. Variables can be imported from GCD file. GCD file is generated with one click.

GCD fileGCD

PreprocessorC++ Code

New Process

MS Access Database on

networkEvents, Status variables, etc.

data, converter, importer

Import capability


San Diego Supercomputer Center,

Spatial Information Systems

Laboratory

GIS HTML Viewer Development

Spring 2002

29

� Purpose: Develop a web-based graphical user interface for a Geographical Information System (GIS) database.

� Background: GIS is a useful tool for decision making. It facilitates the graphical representation, superposition, and spatial querying of data.

� Method: Use XML, JavaScript, and DHTML to accomplish the said goal.

Problem StatementSDSC, 2002, Page 1

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GIS database

Browser, JavaScrpit,

DHTML

Map generator

GIS = Geographic Information System

SQL

Vector data

XML

Images, data

User interacts with GIS database through an HTML viewer. This viewer must be portable over many platforms. And it must be pretty.

GIS OverviewSDSC, 2002, Page 2

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Old Style ViewerSDSC, 2002, Page 3

static toolbar with limited featurs

layer list is unstructured

query results in pop-up window

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New Style ViewerSDSC, 2002, Page 4

dynamics and hierarchal layer list

dynamic legend

minimize/move features added to windows


UCSD Structural Engineering

Department, Professor Ahmed

Elgamal

Satellite Based Structural Healthmonitoring of the Vincent Thomas Bridge

Ongoing

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� Purpose: Build a a remote structural health monitoring system. Prove that off-the-shelf components can be used to do remote data gathering.

� Schematic:

RemotePC

sensors

DAQinternet

satellite dish

FTP LocalPC

Data processing

Data processing

Data processing

Project Overview – Vincent Thomas BridgeUCSD Structural Engineering, Page 1

Data flow schematic

On bridge In lab

35

� Sensors:� Temperature, surface, and air� Camera� Accelerometer

(red dot indicates approximate location)

� Extensive Collaboration� UCSD Structural Engineering� CalTrans� Hughes Network Systems� San Diego Super Computer Center

� Potential� New, more complex testbeds� Temperature to frequency response correlation

Project OverviewUCSD Structural Engineering, Page 2

http://healthmonitoring.ucsd.edu/

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� Data for May 2005 through February 2006

Results – Thermal DataUCSD Structural Engineering, Page 3

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Sunrise Single Frame

Results – Camera DataUCSD Structural Engineering, Page 5

http://healthmonitoring.ucsd.edu/vtb/remote/vtb_remote_imaging.jsp


UCSD Structural Engineering

Department, Professor Ahmed

Elgamal

Remote Structural Healthmonitoring of Voigt Bridge

Ongoing

39

UCSD Structural Engineering – Voigt Bridge

� Purpose: Monitor Voigt Bridge with accelerometers and a camera

� Methods: A camera is used to determine the location of a vehicle on a bridge. A network of accelerometers monitors the excitation cause by this vehicle along the bridge. Thus we know the location of the load and the excitation.

UCSD Structural Engineering, Page 1

http://healthmonitoring.ucsd.edu/voigt.jsp

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Vehicle Tracking over Voigt Bridge UCSD Structural Engineering, Page 2

99 100 101 102 103 104 105 106 107 10850

100

150

200Location vs. f rame

frame number (seconds*.35)

loca

tion

on

brid

ge (

feet

)

28.0629MPH

Documents

Dmitry Yudovsky - UCLAyudovsky.bol.ucla.edu/ProjectPortfolio.pdfProblem Statement Purpose: Bubbles form in a high pressure chem-delivery line. These are ... Dmitry Yudovsky, Project