Chengbo Li

A UC Berkeley graduate student studying Mechanical Engineering with concentration in Product Design

Design of Flywheel System for Hybrid Vehicles – Capstone Project

ObjectiveDesign a high power energy storage system to maximize regenerative braking energy capture and reuse for hybrid vehicles.

1.3D CAD modeling by SolidWorks

2.High Volume Manufacturing

3.Material Selection

4.Bearing Selection and Sealing System Design

5.Design for Manufacturing

6.GD&T

Flywheel Diameter versus Rotating Speed (Left); Flywheel Thickness, Diameter versus Rotating Speed (Right)

Flywheel Sizing Analysis

Design of Flywheel System for Hybrid Vehicles – Capstone Project

Top housing

Cap

Stator

Retaining ring

Bearing

Spacer

Seal

Middle housing

Shaft

Fly wheel

Bottom housing

Design of Flywheel System for Hybrid Vehicles – Capstone Project

Design of Flywheel System for Hybrid Vehicles – Capstone Project

Flywheel Failure Analysis Rotor Distortion Analysis

Key Slots Failure Analysis Flywheel Distortion Analysis

Redesign of the Lubrication System

Design of Flywheel System for Hybrid Vehicles – Capstone Project

Die Reconstruction ProjectObjectiveThe goal of this project is to use a new tool path generation approach called ‘C-Space Approach’ to rebuild a wax die using High Speed Machining. This method could provides gouge and collision free tool paths, balanced cutting loads and smoother cutter movements

Inverse tool-offset surface (ITO-surface) Construction of C-space for 3-axis machining

Die Reconstruction Project

1 Laser scan the original die to obtain surface geometrical data(coordinates)2 Use ITO and TPO algorithm to generate tool path(coordinates) for milling(MATLAB)3 Transform tool path to NC-code and use it to mill the wax die(CNC)This method used ‘global’ data to achieve :Gouge-free machiningUncut handlingCollision avoidanceChip-load levelingCutting-load smoothing

Design of transfer robot based on MCU

System based on AT89S52 microprocessor, a self-line-patrol robot which could take goods from position A to position B following the black line. After the delivery of the first item, it will go back to the original position and starts to move the next one until it finishes all of the items.

Objective:The goal of this project is to design and build a prototype transfer robot that can carry goods to certain locations following certain paths automatically.

Used 4 infrared QTI sensors .2 close ones are for keeping the robot one line2 rear ones are for speed control

Designed (SolidWorks) and machined the body and holder of the robot

Selected the server motor and other standard parts

Used C programing language on Keil uVisionto complete the task

Design of transfer robot based on MCU

Skills used:machining, milling, planning, grinding, rolling, sand-casting, stamping, wire-electrode cutting and cutting and bench work

Manufacture of a metal model of sailing boat