Engineering Project Portfolio

JACOB CONSENZ

SENIOR MECHANICAL ENGINEERING STUDENT

GEORGE FOX UNIVERSITY

JACO B .CONS E N Z @ G M A I L .COM | ( 5 0 3 ) 8 9 9 - 8 9 6 0

Table of Contents

FLIR Systems Projects

• Gimbal Flipping fixture Summer 2016

• Cord Harness ECR Summer 2016

• Coplanar Fixture Summer 2016

• FOD Detection Enclosure Summer 2016

• BRITE Star II Gimbal Mock-up Summer 2016

FLIR Systems:Gimbal Flipping Fixture

Objective:◦ Design a fixture which will allow FLIR gimbals (of various configurations) to be

attached to a pair rotating forks. This will allow the gimbal to be easily mounted, then turned upside down during assembly

Project Overview:◦ Fixture Designed based on the needs of the service department

◦ Close coordination with assembly-level technicians◦ Incorporated design language of other FLIR fixtures◦ Designed primarily for fit with other components and ergonomics

Skills Employed:◦ SolidWorks 3D modeling◦ 2D technical drawing creation◦ Static stress analysis using computational tools◦ Testing of tolerances and fits with other components◦ Design for ergonomics◦ Compliance with AS9100 Quality Management Standards

FLIR Systems:Cord Harness ECR

Objective:◦ Develop a solution to better secure cord harnesses within FLIR products

Project Overview:◦ Cord harnesses were previously secured with tape; a more permanent and reliable

solution was needed.◦ ECR (Engineering Change Request) conducted on existing part: added additional

mounting features for wire clips to secure cord harness◦ Determined all BOM (Bill of Materials) of sub-assemblies affected by ECR

◦ Created test assembly in SolidWorks to ensure that there were no interferences introduced from adding the wire clips

Skills Employed:◦ Coordination with manufacturing technicians◦ SolidWorks 3D Modeling◦ Testing of tolerances and fits with other components◦ Creation of Official documentation

◦ ECR Submittal◦ Revision change for all parts affected◦ Work Instruction updated

◦ Compliance with AS9100 Quality Management Standards

FLIR Systems:Coplanar Balance Fixture

Objective: ◦ Design a Fixture that will allow a FLIR Imager to be coplanar balanced prior to

shipping.

Project Overview◦ Fixture designed so that Imager could be placed on a desktop workstation and

worked on.◦ Clearances made to allow tools to reach key fasteners on Imager side brackets so

that the Imager could be coplanar balanced.◦ Assembly Work Instruction update to include use of new fixture

Skills Employed:◦ SolidWorks 3D modeling◦ 2D technical drawing creation◦ Compliance with AS9100 Quality Management Standards

FLIR Systems:FOD Detection Enclosure

Objective:◦ Design a fixture to aid in the detection of FOD (Foreign Object Debris) in FLIR

thermal Imagers

Project Overview:◦ FOD (in the form of dust particles) must be removed from camera lenses in order to

adhere to image quality standards◦ FOD on the lenses appears most prominently when the imager is heated◦ The fixture ramps imager up to operating temperature for FOD detection.◦ Work Instruction written to accompany fixture and detail its use◦ Use of fixture and work instruction was permanently incorporated into FLIR’s

manufacturing process

Skills Employed:◦ Analysis of manufacturing process◦ Rapid fixture design using 80/20 T-slot material◦ SolidWorks 3D modeling◦ 2D technical drawing creation◦ Construction of physical enclosure◦ Compliance with AS9100 Quality Management Standards

FLIR Systems:BRITE Star II Gimbal Mock-up

Objective:◦ Create an accurate representation of a FLIR BSII gimbal unit for use in testing

assisted lifting machinery prototypes.

Project Overview:◦ Service department had need of assisted lifting equipment in order to prevent

worker injuries.◦ Third party supplier was to design lifting equipment and needed an accurate model

of FLIR’s product on which to conduct testing of their prototype.◦ An older FLIR gimbal (BS I), along with 3D printed components would be used to

accurately represent the current model of gimbal (BS II)◦ 3D models and 2D drawings were consulted to identify all differences between the

current and older gimbals◦ Older gimbal with 3D printed components were sent to a lifting equipment supplier

for testing.

Skills Employed:◦ Coordination with suppliers◦ Analysis of technical documents◦ SolidWorks 3D modeling◦ 3D printing◦ Compliance with AS9100 Quality Management Standards