Design Portfolio

Austin Young
(510) 816-2029 | younga@berkeley.edu | www.oostin.weebly.com
University of California, Berkeley | Mechanical Engineering
Next Generation Diode Cold Plate Cost Down Project

7/29/2016
 Design Goal and Requirement
Goal Requirement
 Reduce cost of existing diode cold plate to less than  Improve heat transfer and stay below the maximum
$300.00 per cold plate with increased maximum temperature limit
temperature limit for diode to 45ºC  Maintain low pressure drop between inlet and outlet
 Replace current and implement future diode cold plate  Maintain cold plate exterior dimension and holes
 Pass leak test

© 2015 Lumentum Operations LLC | LUMENTUM CONFIDENTIAL AND PROPRIETARY INFORMATION 3

 Extrusion
Design Selections Manufacturing Process
 Increase water contact area with fins for maximum heat  Save cost using extrusion versus brazing
transfer  Obtain quote by contacting Taiwan extrusion vendors
 Keep aluminum thickness above 1mm
 Extrude with fins
 Extrude with cylindrical shape
 Extrude with cylindrical shape + fins
 Connect with face seal
 Connect with radial seal

Transistor part

Cold plate body

1mm gap is too thin

for extrusion. Increase
to at least 4.50 mm Fins Cylindrical Shape Cylindrical Shape + Fins
© 2015 Lumentum Operations LLC | LUMENTUM CONFIDENTIAL AND PROPRIETARY INFORMATION 4
 Hypothetical Design Outcome
Best Mid Worst
Water Contact Area Cylindrical Shape + Fins Fins Cylindrical Shape
Heat Transfer Coefficient (h) Fins Cylindrical Shape Cylindrical + Fins
Resistance (conduction) Fins Cylindrical + Fins Cylindrical Shape
Resistance (convection) Fins Cylindrical + Fins Cylindrical Shape
Thermal Resistance (series) Fins Cylindrical + Fins Cylindrical Shape
Diode Temperature Fins Cylindrical + Fins Cylindrical Shape
Cost Cylindrical Shape Cylindrical + Fins Fins

Fins Cylindrical Shape Cylindrical Shape + Fins

© 2015 Lumentum Operations LLC | LUMENTUM CONFIDENTIAL AND PROPRIETARY INFORMATION 5
 Assembly Methods
Main Method Other Methods
 4 M3 screws  Face seal with large O-ring (Not enough O-ring groove
 2 machined aluminum water connectors clearance)
 4 O-ring's for radial seals  Machine water connectors into the transistor part

© 2015 Lumentum Operations LLC | LUMENTUM CONFIDENTIAL AND PROPRIETARY INFORMATION 6

 Induce Turbulent Flow Design
Additional Parts Turbulence
 Spring  Turbulent flow mixes water for uniform temperature
 Patented Plastic baffles  Plastic baffles maximize turbulence but costs more
than springs

Defeatured Negative Water Channels for Ansys (Springs)

© 2015 Lumentum Operations LLC | LUMENTUM CONFIDENTIAL AND PROPRIETARY INFORMATION 7

 Ansys CFD
Diode Temperature Transistor Temperature Velocity Streamline
Cylindrical

44.49°C 51.36°C
Cylindrical + Fins

41.44°C 49.32°C
© 2015 Lumentum Operations LLC | LUMENTUM CONFIDENTIAL AND PROPRIETARY INFORMATION 8
 Ansys CFD
Inlet Pressure Outlet Pressure Drop
Cylindrical

ΔP = 16.07 psi - 14.66 psi

=1.4055 psi < 11psi
Cylindrical + Fins

ΔP = 16.55 psi - 14.70 psi

=1.86 psi < 11psi

© 2015 Lumentum Operations LLC | LUMENTUM CONFIDENTIAL AND PROPRIETARY INFORMATION 9

 Cost Break Down
Original Fin
Parts and Manufacturing Process Cylindrical Cylindrical + Fins
Design
Cost ($) Cost ($) Cost ($)

Cold Plate Extruded Part 5000pcs Confidential 19.68 19.98

Machining Before Brazing ’’ - -
Post Machining of Cold Plate Extruded Part (flattening, hole drilling, plug welding, fillet) ’’ 140.00 140.00
Water Connectors ’’ 17.00 17.00
Brazing ’’ - -
M3 Bolts X4 ’’ 4.96 4.96
Transistor Part 2 ’’ 45.00 45.00
O-rings X4 ’’ 2.00 2.00
Heat treatment post brazing ’’ 15.00 15.00
Machining After Brazing ’’ - -
Leak test(water pressure and Helium leak check) and polish ’’ 30.00 30.00
Hard clear anodize ’’ - -
Chemical clean ’’ 20.00 20.00
Packaging ’’ 6.00 6.00
Quote ’’ - -
Total ’’ 299.64 299.94
Target Cost: ’’ 250.00 250.00
Saving ’’ 300.36 300.06
Saving Per Week (150 Units) ’’ 45,054.00 45,009.00
Cost X150 90,000.00 44,946.00 44,991.00

© 2015 Lumentum Operations LLC | LUMENTUM CONFIDENTIAL AND PROPRIETARY INFORMATION 10

Ultra Clean Technology

Austin Young
08/2015
 Gas Box Frame Transport Cart
Purpose Requirement
 Transport Gas Box into paint spray booth for heat  Conceptualize design
treatment  Create and release 3D-models and drawings
 Search for OEM
 Create Bill of Materials
Requirement
Gas Box Frame
 Able to handle minimum of 3000lbs
 Movable (Casters with lock)
 Max Temperature 450°F
 Height Requirement (with Gas Box Frame mounted):
• 9’10’’ H X 9’8” W
• Spray Booth: 9’6” H X 9’8” W (114” X 116”)
• Length: < 40 7’11”
 3” ground clearance.
 Handle/Hitch for pulling & pushing
 Forklift tubes required
8’3” 6’11”
 Low Cost/East of Fabrication
 Design Challenges
Standoffs Handle Mounting
 Design process and selection of configurations
Pros: Easier Pros: Sturdy
alignment and Cons: Harder
less time alignment and Welded Pipe (2.07”
consuming to time ID) to locate Quick
install consuming to handle (1.9” OD) Release Pin
Cons: Less install A500 Steel Tubing (1/4”)
sturdy

Caster Selection

Pins/Lanyard
1”-8 Threads

OEM Parts-
Standoff  Handle > 450F and 2000lb each
threaded into
frame

Welded Pipe to
locate the
standoff.

Final Mounting Mechanism Machined

Standoff with Pin
 Analysis
Tip Analysis FEA
 Design process and selection  FOS ~ 2.7  Weight ~ 875lb
 Load ~ 500lb/Standoff X 7 = 3500lb  Coefficient of friction: .021
CM  Slope: 15 degrees
 Caster Radius: 3”
 Rolling Resistance: 25 lbf (F=
(mW/R)X4)
 Max Force before failure ~ 250 lbf

Max Stress<Yield

>15 degree

Deflection Deflection
 Final Elevated Gas Box Cart Universal Transport Cart
3D Models Manufactured Carts
 Gas Stick Holding Adjusting Fixture
Function: Responsibilities:
 Hold gas sticks in place for simple,  3D-Model (from 1998 2D
efficient, and accurate assembly drawings) various VCR gas stick
holding fixtures for UCT
cleanroom manufacturing line
 Robotics Bio-inspired Self-Righting Robots
Terradynamics Research at Poly-PEDAL Lab
Professor Robert Full and Chen Li
Publication: Cockroach-inspired Winged Robot Reveals Principles of Ground-based Dynamic Self-righting
Motivation
 Robots and small animals are susceptible to flipping over
 Cockroaches and small-legged robots become unstable as
they traverse through difficult terrains and beam obstacles
 Animals and insects adapted their body features through
evolutions, so can robots design

American Madagascar Discoid

cockroach hissing cockroach cockroach
 Bio-inspired Self-Righting Robots
Responsibilities
• Mechanically and electrically designed and built the
winged self-righting cockroach robot
• Tested robot using Arduino
• Model cockroach cuboid and obtain properties with
Solidworks

Bill of Materials
Part: # Used: Source Cost/unit:
Hyperion DS11 2 http://www.soaringusa.com/Hype $33.95
Servos rion-DS11-AMB-Metal-Gear-
Digital-Servo.html
Arduino Pro Mini 1 https://www.sparkfun.com/produ $9.95
3.3V cts/11114
Servo backpack 1 Laser cut in Ciber
Servo link 6 3D Printed in Ciber by Kaushik
Curved Wings 2 Vacuum formed by Chen
Threaded rod 4 inches McMaster $8.89/meter
Heim joints 2 Rc4wd.com $2.99
Liquid Super glue 2 Amazon.com $3.59
 Video Data Collections
*Double Click Videos (black boxes) to Play

Set Up Demonstration
 Analyze robot righting using MATLAB and VirtualDub  Like the cockroach, our self-righting robot can self-right
with 3 high speed video cameras dynamically by opening its wings to push against the ground,
using kinetic energy to overcome potential energy barriers.
 Arduino controlled input

If the robot opens its wings by a

large wing pitch angle and/or opens
its wings rapidly, it successfully self-
rights
https://www.youtube.com/watch?v=svnSTdRMr2g
Actuation Demo:
https://www.youtube.com/watch?v=6oXenA9inYY

Asymmetric wing opening helps the

robot right when it cannot open their
wings large enough
https://www.youtube.com/watch?v=uxZ4j7LoTbE
 Analysis and Results
IEEE/RSJ International Conference on Intelligent Robots and Systems
(Selected as a Highlighted Paper, 20 out of 840)
Cockroach-inspired Winged Robot Reveals Principles of Ground-based Dynamic Self-righting
 Bing-Bong-Belt
Project Details
 Single-motor mechanism that automatically plays
percussion instruments. (“You Are My Sunshine”)
 Project emphasizes on showing graphical and analytical
analysis with CAD animations and motion studies.
 Modular design
 Under $75

Negligible Deflection in FEA

Bing-Bong-Belt Animation
https://www.youtube.com/watch?v=W90PORHXnto
Bing-Bong-Belt Demo Day
https://youtu.be/nFzW5KkzTuA

Graph showing mallet angle over time. The mallet

rise time is slower than the fall time, which is as expected and as
designed.
 Wind Turbine
*Double Click Videos (black boxes) to Play

Responsibilities
 Cooperate with team of 5 to optimize turbine efficiency
 Optimize strongest tower structure with creativity in
mind
 Minimize cost and materials
 Obtain design skills and 3D printing understanding

Wind Turbine Demo Day

https://www.youtube.com/watch?v=L1mMU1LosWw
Thank You