Projects

And im proud of it!

SIGMA Compact






Background

I was hired by Frese A/S to work in their R&D department as an R&D engineer to develop new valves for HVAC systems. I developed the new generation of dynamic balancing valves, hence forward called SIGMA Compact.

Resumé

Frese A/S had a desire for the development of a new generation of dynamic balancing valves. They wanted the new generation to include their Compact technology, built in isolation, and a number of other features. As the project manager I was responsible for developing this new product, covering everything from design, to prototyping, to economics, to manufacturing.

Skills used

  • -Project Management
  • -CAD
  • -Hydraulics
  • -Vibrations
  • -Economics
  • -Documentation




Description

To start with I was introduced to the previous generation of the product and the various functionalities and features that Frese A/S wanted in their new valve. I quickly discovered that they expected me to be the project manager on the entire R&D project. After having gone through a number of designs, the economics of the project was covered with the manufacturing department before everything was presented to the stakeholders. After a few changes, the project was approved, and manufacturing and testing of brass and plastic prototypes began. The flow range of the product was the main focus of the development of the valve throughout the majority of the project, but when I started nearing the deadline, the marketing department changed the main focus to the minimum needed startup pressure, which changed certain parameters of the project. The design was changed to ensure that the valve didn't exceed the required minimum startup pressure, which unfortunately meant that I was unable to live up to the deadline. In the end, the product was launched after a pilot batch was manufactured and tested by myself. I took 5 pieces of each size of the pilot batch and conducted a full release test on them. After the launch of the product, the project was concluded with the addition of scales, knobs, and housings for sales of the valve in the US.

Brazilian Oil Ship

Background

During my time at AVN I had hundreds if not thousands of tasks. Most of these were minor sales and purchasing. Some were problem solving and design, especially through CAD. A few were larger projects, such as the one described here.

Resumé

Emerson was designing ship gates for 2 FPSO's (Floating Production Storage and Offloading vessels) for Petrobras in Brazil. They hired us to supply the hydraulic system.

Skills used

  • - Customer Relations
  • - Design
  • - Hydraulics
  • - CAD
  • - Purchasing

Description

At first the customer (Emerson Process Management) simply requested a quotation on hydraulic accumulators. The specifications were later upgraded to stainless steel. Later on, after having inquired into the use of the accumulators, they finally asked us to quote and then supply two complete hydraulic units. During the process I had direct contact with the customer and visited them on occasions to discuss the desired product. At first, rough scetches of the design were created, which were followed by 3D CAD drawings and hydraulic diagrams and calculations. These were used to purchase the relevant components that were used in the manufacturing of the two large hydraulic units. During the purchasing of the various components, I was in contact with a variety of suppliers in order to get the most favourable prices and quality, in order to ensure the lowest cost on the project.

Robovator

Background

I wrote my thesis on a project I did for a small engineering company that focused on automatic agricultural machinery.

Resumé

F Poulsen Engineering was developing an automatic weeding machine, and one of the components of the machine was a hydraulic block that controlled the weeding arms. My thesis was on the design of this hydraulic block.

Skills used

  • -Morphology
  • -Dynamics
  • -Hydraulics
  • -CAD
  • -Economics
  • -Documentation




Description

As with any other projects, the morphological process brought me through five major designs to solve the problem. I decided to focus on a solution that used an internal piston, cogs, and a sinus sequence for the motion of the weeding arms. Dynamics were used to calculate the force that was applied on the weeding arms from various sources and directions, which in turn were used to design the cogs that would rotate and thus move the arms. A hydraulic diagram was created for the block along with a CAD design. With all this in place it was easy to create an economic assessment of the product. The project was finalized with documentation, which included a manual, maintenance, and assembly.

Dose Indicator Barrel

Background

During my internship, I worked with a group of engineers to maintain and optimize the production line of Novo Nordisk's insulin pen. Here you can read about one of the issues we encountered on one of the production machines

Resumé

During the assembly of the NovoPen4, a plastic drum with numbers was inserted into the pen. For some reason, the drum was mashed into the pen and the whole product destroyed.

Skills used

  • -Troubleshooting
  • -Problem Solving
  • -PLC programming

Description

At first we were informed that a machine in the production line was discarding almost every product. When we investigated we noticed that the pen was crushed. Analysing the samples revealed that it was due to the number drum being mashed into the product. We therefore investigated the machine that inserted the number drum. Using high speed cameras we discovered that the machine was doing what it was supposed to, but that the components were a few millimetres to close. This was due to the fact that new holders for the product had been inserted and these were about an inch larger. Using PLC programming we changed the machinery codes to compensate for the new holders.

Vacuum Container

Background

During my time at university, I was given four larger projects for various companies. Here you can read about a project I did for Danfysik.

Resumé

Danfysik had a vacuum tank that required an automatic open/close system that could fit into the small workshop where the container was being used.

Skills used

  • -Morphology
  • -Mathematics
  • -Hydraulics
  • -Dynamics
  • -CAD




Description

The technological concept was created by going through various ideas using a morphological approach. Six possible designs were created and the hydraulic solution was chosen. Through the use of basic mathematics, the available space was calculated in order to define the open/close sequence of the design. Using dynamics, the various dimensions of the components for the system was created so that it could hold the 1.5 ton lid. As the design used four hydraulic cylinders for the open/close sequence, there was a number of hydraulic calculations and diagrams that were created. Finally, the whole project was created in Solidworks to give a 3D solution to the customer.