Philips Co-Op
Aug. 2020 - Dec. 2020
Projects Assigned
During my time at Philips, I was assigned two major projects (sustaining and process improvement) and two smaller side projects. My sustaining project was twofold, entailing force characterization and investigative testing on ECG patient modules, with the latter addressing two different issues. My process improvement project dealt with designing and assembling a cable bending test fixture for Philips to use for future cable testing. As for the side projects, they entailed reworking engineering drawings and finalizing reports.
Major Projects Results
Sustaining Project
For the sustaining project, I performed several tolerance analyses on the ECG patient modules (seen below) using a 3D PTC Creo model to understand the effects of tolerance stack-up, calculating both the worst-case tolerances and the Root Sum Squared (RSS) tolerances for each analysis. I then used the nominal dimensions and RSS values in those analyses to calculate a theoretical force the user would need to exert to promote module battery ejection. I also sent out a few modules for 3D Computed Tomography (CT) scanning to compare the nominal dimensions used for the tolerance analyses to actual dimensions from the scans to determine if any significant variance was present between the two.
After comparing dimensions and calculating forces, I conducted experimental testing using a force gauge and height gauge to compare the theoretical, calculated forces to actual, experimental forces. Additionally, I performed investigative testing to solve other sustaining issues with the modules, and I provided suggestions on how the modules and certain assembly processes can be improved to reduce the likelihood of these issues from occurring again. As I worked on these projects, I would schedule and lead bi-weekly Microsoft Teams meetings with the Mechanical Team to share my progress and receive feedback on how I should continue moving forward. Towards the end of the Co-Op, I co-led a technical review with my mentor to showcase my efforts, results, and next-step suggestions for the project.
Process Improvement Project
For the process improvement project, I was tasked with designing and assembling a cable bending test fixture within a five-week timeframe with an electrical engineer (who handled the controls side of the fixture). We held several brainstorming sessions in which we shared ideas and concepts, and I hand-drew four conceptual designs, stemming from those brainstorming sessions. I then used PTC Creo to assemble two of those conceptual designs into a more formal assembly, which I then presented to the Mechanical Team along with an estimated cost for each fixture. Additionally, I carried out motor research and requested quotes to find the optimal motor for our application based on a torque calculation I carried out. Once our final design was approved, I used our BOM to organize and send out POs to obtain the parts we needed for the assembly.
During the assembly process, I used machinery such as a drill press, band saw, and disc sander to modify aluminum extrusion and create the fixture. After three long days of assembly, we were able to showcase the fixture to the Mechanical Team on Microsoft Teams using a PowerPoint presentation. We were able to meet the deadline, and below is an image and videos of the fixture in action. The fixture can currently rotate a minimum of 1 cable per clamp (5 cables maximum) to a bend angle of any degree between 0-90° with 1° step sizes. Depending on the size of the cable, the clamps can accommodate more than 1 cable per clamp, potentially rotating a maximum of 15 cables at a time (although the motor may need to be upgraded if this maximum amount is reached).
Shortcomings & Lessons Learned
During the conceptual sketching phase for the cable fixture, I noticed that I was leaning more towards intricate designs rather than simpler ones. I was associating simplicity with a lack of effort and sincere thought while associating complexity with intelligence and critical thinking. Although this may be true in some instances, in most cases it is not, which is something I realized with this experience. As my partner and I decided to commit to one of the more complex designs, going so far as to assembling the fixture on PTC Creo, we began to come across several practicality issues. We ended up presenting the idea; however, there was not enough confidence on our end to get approved and begin purchasing parts. We ended up discarding the idea and going back to my original idea, which was much simpler.
Interestingly enough, because we had brainstormed so many ideas before returning to the original idea, we were able to approach that first, original idea with a fresh perspective, which led to implementing several pieces of the other conceptual designs into it. Although the first design did present its own set of issues, they were much easier to resolve than those of the other design. Unfortunately, I cannot provide the conceptual sketches to compare the two designs; however, the lesson I learned remains: simplicity is key. If there is a simple alternative, usually that is the best and the most efficient way to approach any design project. There is still merit in exploring other ideas and brainstorming to completely exhaust the design space and evaluate all potential solutions. However, when it comes time to decide and commit to a concept, the simplest design that fulfills the design requirements will save time, money, and stress compared to those that are more complex.
Overall Experience & Skills Attained
Throughout the entirety of the Co-Op, I was responsible for leading bi-weekly Microsoft Teams meetings to share with the Mechanical Team my progress on the sustaining projects, which gave me a sense of responsibility and ownership over my work. These presentations helped me further develop my communication, presentation, and leadership skills in a professional setting. Additionally, the sustaining project presented several opportunities for critical thinking and evaluation in order to understand the mechanics of the ECG patient modules and uncover why certain issues were occurring. This entailed the use of equipment such as a force gauge and a height gauge to gather quantitative data on certain aspects of the modules.
For the process improvement project, I exercised divergent thinking via the many brainstorming sessions for the conceptual designs, and I was also responsible for researching similar, existing designs, researching information on motors and considering which would work best for our application, hand-sketching, using PTC Creo to assemble designs, create a BOM, and send out POs. I was also able to assemble the fixture using machinery such as a drill press, band saw, and disc sander, and I learned the importance of designing for manufacturing and assembly since doing so will save time and effort when it comes time to bring a design to life. Overall, this was an incredible learning experience, and I thank the entire Mechanical Team for being so patient and kind to me throughout the entire process!