Industrial Projects

Dynamic System Optimization/ Kinematic Analysis

Optimizing Exhaust Extraction Systems for Gasoline-Powered Pressure Washers:

In the testing environment for gasoline-powered pressure washer units, the emission of hazardous exhaust gases, such as carbon monoxide (CO), poses a significant safety risk to operators. To address this, exhaust extraction arms are used to capture and remove the exhaust from the units during testing. These arms require precise movement and positioning to accommodate varying engine sizes and test setups. I worked on two key projects to optimize the functionality and design of these extraction arms, addressing issues related to kinematics, joint mechanics, and structural stability.
  • Project 1: Kinematic Optimization of Exhaust Extraction Arm:
    • The first project involved optimizing exhaust extraction arms for an assembly line consisting of 12 test stations. Each station had an extraction arm designed with multiple aluminum tube links connected by revolute, spherical, and torsional joints. The arms' end effector, a cone-shaped receptor, needed to be positioned precisely at the engine's muffler, but the existing design lacked sufficient degrees of freedom (DOF) to accommodate the varying heights and widths of different pressure washer models.
    • To resolve this issue, I analyzed the required DOF by measuring the dimensions of the smallest and largest pressure washer models and considering the spatial constraints of the test room. I then performed a kinematic analysis, representing the arm as a serial manipulator in a 2D CAD environment. By optimizing the number of links, link lengths, and joint types, I proposed two configurations that allowed the end effector to move freely within the necessary range, ensuring effective exhaust extraction.
  • Project 2: Structural Support and Force Analysis for Sagging Revolute Joint:
    • In the second project, I worked on a similar exhaust extraction arm in a separate assembly line with different geometry. The arm experienced sagging at its topmost revolute joint, where the friction disk regulating the angular orientation of the connecting links was unable to hold the weight of the arm. This led to instability in the arm's positioning, impacting its effectiveness in exhaust extraction.
    • To resolve the issue, I explored the use of a gas strut as a support between the two links connected by the sagging joint. The challenge was to determine the necessary force for the gas strut while accounting for spatial constraints on where it could be attached. I performed an analysis to calculate the required moment and showed how the angle between the gas strut and the vertical axis, as well as the vertical distance from the joint, influenced the force requirements. This analysis provided a clear solution for selecting the appropriate gas strut and installation position to prevent the sagging of the arm.