Table of Contents Bio
Education
Design Study Ensemble Module System
Samples of work Automotive Battery Block & Module Design Automotive Battery System Design Flow Bench Design Tooling Design Drafting Senior Capstone
Overview Mirror Module Final Assemble Results
Contact Information
Jamison Micah Pezdek
Bio
Jamison Micah Pezdek
Born: August 6th, 1986 Hometown: Wynantskill, NY Professional 6 years battery / automotive Experience: 1 year product design 8 months medical device
Education
• Masters of Science, Computer Systems Engineering Focusing in Computer Aided Design
• Class of 2012
• Coursework in CAD Design, C++ and Java Programing, Manufacturing, Energy Systems, and Human Factors
• Bachelors of Science, Mechanical Engineering • Class of 2009
• Minor in Business
Jamison Micah Pezdek
Design Process
Jamison Micah Pezdek
Design Requirements
• What is the problem?
• When is it needed?
• What is the cost?
Brainstorming
• What have we done in the past?
• What are the issues with the current design?
• What is required?
• What features would the customer appreciate?
• What rules can we break?
Concept Development
• What will it look like?
• What do we need to add?
• Do we know enough about the problem? What is the science behind it?
• Do we have a backup?
• Develop a new block design that has a higher energy density, for the same cost
• Timeline: 2 years
• Module assembly often consists of torqueing many small screws in a tight space
• There was no defined system for packaging the existing blocks
• Why do blocks need to be welded?
• Integrated HV Connection System • Training to understand electrical point
connections • Backup Welded Design
Design Process Continued
Jamison Micah Pezdek
Prototype
• What do we want to try?
• What areas should we focus on?
• How does it work?
Test
• What do we need to test?
• Do we need certifications?
• Where will it be used?
• How will the customer use it?
Analyze
• Did it work like we wanted?
• Did it break? Where?
• Did we think of all the possible outcomes
Redesign
• What didn’t we think of?
• What did the testing tell us?
• Can we make it effectively?
• Has all of the customers' requirements been met?
Test
• Did we test enough before?
• What has changed?
• Did things improve?
Ready For Production
• Get parts ready for production
• Is the supplier making parts like we expect
• Are all of the tolerances correct?
• Prototyping with 3D Printer, Soft Tooling. • Check for fit and form
• Automotive Standards • Electrical Resistance • Government Standards
• FEA • Design Validation
Testing
• DFMEA • Design Reviews • Failure analysis
• DFM • DFA • Added features to enhance
customer experience • Added features to enhance
reliability
• Further testing to verify redesign
• Load testing to verify FEA data.
• Vibration testing
• Hard Tooling • FAI • PPAP • Process Validation Testing
Final Result
“The flexibility of the Ensemble system allows customers to design, build and test a prototype pack in a fraction of the time it would typically take for a fully custom solution. Next, the production quality components used in the initial prototypes greatly reduce the pack qualification effort needed to launch into mass production. Finally, the same highly-reliable standard components used in the prototype and development stages support a cost-effective launch of low, medium and high volume packs without the need for expensive tooling or a complex assembly line. Ensemble provides clear value from project inception through high volume pack production.”
—Darren Bischoff, Director of Business Development and Marketing for Boston-Power
Jamison Micah Pezdek
Automotive Battery Block & Module Design
Jamison Micah Pezdek
Swing Key Block e-Taxi Module e-Bus Module Ensemble Module System
Battery System Design Automotive
Jamison Micah Pezdek
e-Taxi Pack e-Bus Pack Saab 9-3 Sedan Chinese Consumer Sedan
Flow Bench - Testing
Jamison Micah Pezdek
Used for forced cooling testing • Machined, COTS, 3D printed and
formed plastic components • Achieves uniform flow rate across the
test chamber • Swappable parts so flow rate can be
increased if the needa
Tooling
Jamison Micah Pezdek
Membrane Cutter: Modification to an Arbor Press
Epoxy Drying Station Electronics Enclosure
Design Approach
Get as much information up front.
CRD, PRD
Design with simplicity and manufacturability in mind.
Have we done this before?
What are the real problems that need to be addressed?
Incorporate DFx early in the design.
DXF addressed material availability
DFX addressed design for assembly and manufacturability.
Tackled difficult design issues as a team in a room setting.
Brainstorming in a room is much more effective then through emails.
touch freezing device •Used for sample preparation in quick freeze deep etch microscopy
•Device rapidly cools biological samples (10,000°C/sec) resulting in vitrification
•Use of a linear motor and laser curtain prevent mechanical deformation
Jamison Micah Pezdek
mirror module •Major component of touch freezing device
•Houses four copper mirrors, held under liquid nitrogen
•Inclusion of T-type thermocouples allow for monitoring of mirror temperature
•T-6061 Aluminum Alloy: Ideal for low thermal expansion
Jamison Micah Pezdek
final assembly •Most machined parts were done in house.
•The Mirror Module was sent out to an outside machinist.
•Construction and Assembly took about three to four weeks
Jamison Micah Pezdek
results •Preliminary results were very favorable
• Device effectively vitrified the leading edge of the samples, ensuring quality images
•Tests prove design as a working prototype.
•Device is currently in use at Northeastern University
•Water Droplet Test
Jamison Micah Pezdek
contact
Cell: (518) 810-7736
E-mail: [email protected]
Address: 15 Wensley Street Boston, MA 02120
Jamison Micah Pezdek