Projects

Encoder Mount Redesign

Background:

Previous encoder mount was unstable, resulting in inaccurate measurements and wasted materials

Took measurements of encoder mount parts while the machine was not in use

Redesigned the mount using Solid Edge

Weak points:

Two photo eyes were mounted separately, allowing them to move independently

A bad bearing resulted in the encoder arm pivoting horizontally

The parts were too thin and would deflect when a board passed through, causing the machine to jam and break parts

Changes made:

Made the mount one piece

Used a shoulder bolt as the bearing to allow for less wobble in the arm

Increased the thickness of parts that might deflect

Results:

Decreased errors and scrap rate from 4,800 parts per day to 80 per day

Improved productivity by reducing the number of shutdowns

Increased encoder mount and machine longevity

Plant Process Engineering Intern - Pella Corp.

Pit Stop Pipe Replacements

Background:

Managed 5+ projects during the three-day plant-wide shutdown

Followed ASME B31.3 code for projects

Pitched changes to appropriate managers

Main Project:

Replaced a carbon steel line of pipe with 316 stainless steel because of corrosion in the old pipe

Selected pipe fittings and valves that were compatible with the ethanol process stream

Created work scopes for contractors, prioritizing safety

Coordinated work between contracted welders, NDE specialists, and scaffold builders, as well as the Valero operators and managers

Updated P&IDs using AutoCAD

Results:

The new pipe will last significantly longer than the previous pipe

Completed the installation on time and within budget

Zero accidents occurred

Renewables Engineering Co-op - Valero Renewables

IREC Recovery Preparations

Background:

Stepped into the recovery team lead position after the previous team lead unexpectedly quit

Design and Manufacturing:

Created a parachute descent rate calculator on Excel to determine ideal parachute size

Designed parachute gore template using SolidWorks

Manufactured two 9 ft toroidal parachutes with a team of five people

IREC Preparations:

Wrote a progress report

Created a checklist and recovery integration procedure to allow for faster integration without forgetting steps

Ensured all recovery systems were prepared for launch (correctly packed parachute, line cutters, and reefing avionics)

Results:

Successfully launched and recovered the rocket

Placed 5th in the 10k COTS division and 8th overall at IREC

Taught the future recovery team lead how to prepare all recovery systems

Rocketry Club at Iowa State University