ERS, Inc. - Program Evaluation
(2017-2018)

Goal: To provide a recommendation for a client with the intent of determining the impact of financial incentives for smart thermostats (e.g. - Ecobee, Nest, Honeywell Lyric, etc.) targeted towards home owners.

Background: While working at ERS, we had a client that requested us to design and implement a study, then report our findings. I was a member of a team that focused on certain parts of a program evaluation for the client. Our team was tasked with the assignment of designing and implementing a comprehensive survey in order to assess heating and cooling energy use behaviors for a cohort of home owners. The survey took into consideration both qualitative and quantitative methods of gathering data which was then analyzed and presented to the client.

Methodology: The first steps within our scope of work was to filter through a provided cohort of home owners and determine their eligibility for participating in the study based on a set of criteria. This was executed in conjunction with the development of a comprehensive survey with a goal of most accurately evaluating energy usage (gas or electric) behaviors within a 3 hour time frame per visit, and 2 visits per year for each eligible home.

The survey included qualitative questions such as the home’s building envelope sealing quality, building material insulation types and the home owner’s satisfaction of their current heating and cooling system. The quantitative survey questions included assessments such as system energy consumption to heat and cool the home, measurements of building envelope area, room temperature with relative humidity data and behavior data provided by the home owner.

In order to most accurately calculate the energy consumption of various heating and cooling systems, data loggers were deployed on site to verify the duty cycle. Using nameplate ratings and data collected from the loggers on various heating and cooling systems, we could more accurately calculate total energy consumption for systems that operate on sensor based controllers.

After data was collected from a full heating and cooling season (1 year total) the data was aggregated for each home and statistical analysis was performed. Before compiling and reporting our findings from the study, the final step was to create a total normalized energy consumption for heating and cooling of each home. Unlike other calculations used to determine energy consumption, these formulas were derived from assumptions based on the qualitative data gathered from the survey questions.

MeyeSpot - A Revolutionary Weather Station
(2016-2017)

Goals: (1) Create an opportunity for outdoor sports enthusiasts to remotely survey a specific area of interest for activities to ensure a high quality experience. (2) Enable a highly accurate and localized weather forecasting strategy that can predict weather up to 14 days in advance.

Background: MeyeSpot, LLC was formed by Hans T. (CEO), Chris V. (CPO) and Ian D. (CTO) to address 2 market opportunities as mentioned above by creating a weather station. Our competitive analysis has shown that there are other companies creating similar products, but the MeyeSpot team found them to be cost prohibitive, unable to sustain outdoor conditions and lacking features to address our target market. Nearly all personal and commercial weather stations on the market were found to be lacking a camera. The ability to visualize the weather was found to be desirable for outdoor sports enthusiasts.

To address another concern, our team hypothesized that applying finite element methods (FEM) for ground based weather station data and implementing statistical analytics with existing weather satellite and weather radar data can increase the accuracy and prediction window for weather forecasting. This hypothesis is possible by creating a low cost weather station that can be installed, function and communicate with minimal location restrictions. A proof of concept (POC) was designed and constructed to demonstrate the feasibility and functionality of this weather station.

Methodology: A survey was introduced to a representative audience of our target market that aided with the selection of our product’s features including the product image. Using the survey results, a list of end user product features and specifications was created to satisfy the need’s of our target market. Several sketches were drawn to confirm the look of our product. A simple schematic was then drafted, reviewed and designed to aid with the creation of our bill of materials (BOM).

After researching options for product sourcing and analyzing the cost of goods sold (COGS), our team identified a strategic opportunity to lower our COGS while creating an additional revenue stream. This opportunity involved the development of our own anemometer and wind vane sensor and was ultimately decided worth pursuing after confirming difficulties with sourcing a financially viable option. We successfully designed, 3D printed and tested a fully functional anemometer and wind vane that utilized the Hall Effect to output useful data and estimated a total COGS savings of up to 15%.

Most of the remaining sensors and hardware were assembled and housed within a prefabricated polycarbonate case that we modified to allow for more accurate temperature and relative humidity readings. The entire POC weather station was controlled with a Raspberry Pi board using python scripts and was powered by a solar photovoltaic module with a backup battery.

IESI, Inc. - Solar PV Facility Design
(2011-2016)

Goal: Design engineering drawings, procure materials for and construct a solar photovoltaic (PV) energy generation facility per client specifications.

Background: Our company engaged in a strategic business partnership that allowed us to enter the solar PV market. We typically focused on all aspects of these projects that included feasibility studies, civil, mechanical and electrical construction drawing designs and procurement of materials. The construction phase of our solar PV project work was subcontracted while we managed the rest of the project.

Methodology: The largest and most interesting solar PV project I worked on had a total system size of 8.4 MW DC. Typically, projects begin with the submission of an interconnection application to the local electric utility. This often happens even if a project may not be feasible. This is because the utility performs an impact study, which can take months, to their local substations and the customer is responsible for any potential costs to upgrade the substation (this can kill a project) in order to handle the added electric load. With this project, and most other projects, a land lease agreement is made with the owner and then followed by a feasibility study. The study includes details such as potential concerns, sizing limitations due to shading effects, environmental and property line buffer zones as well as any other environmental concerns. The report is compiled and concludes with estimates on total system sizing then presented to all project stakeholders.

If no major concerns are brought to our attention, the project moves forward by developing preliminary design drawings that are presented to the municipal planning board for review. Assuming all goes well, the first set of engineering drawings are designed and the construction process begins with a team of tree clear cutters that outlines the location of the solar PV array. During the clear cutting process, a complete set of engineering drawings are designed for construction along with a bill of materials (BOM). Just after the clear cutting is complete, a geotechnical survey and analysis is performed to determine the type of equipment needed to mount the solar modules.

In this case, the survey results showed an area of below grade rock that would penetrate to an aquifer if steel I-beams were pile driven into the ground. Therefore, a ballasted system was required for that area. In the case of this large project, lead-times for procuring materials were critical to the project so certain line items, such as the solar modules and mechanical materials to mount the solar modules, were ordered right away. At this point in the project, the ground is graded to support installation of the pile driven steel I-beam solar module mounting system.

As the solar module mounting system is being completed, all concrete pads are poured and electrical switch gear, inverters and other electrical equipment are installed on the concrete pads. Most of the solar modules have been delivered and are ready for installation. However, during inspection of the solar modules, a batch of approximately 10,000 were found to have incorrect mounting hole specifications. The Chinese manufacturer was contacted immediately and a team of quality engineers immediately flew out to help address the problem.

I developed 3 scenarios to rectify the situation that considered cost, time and quality. The stakeholders ultimately decided to go with an option that prioritized time and an on-site manufacturing process was designed and implemented. This yielded in the successful manufacturing of over 97% of the solar modules and the irrecoverable modules were replaced with ones supplied by the manufacturer.

After all the solar modules were mounted, the final phase of this project began. All solar modules and electrical equipment were wired according to the construction drawing specifications. Upon completion of the wiring, each sub-array was tested to confirm proper function. The test was a success, which allowed for the ceremonial interconnection of the solar PV facility to the electric utility grid.

Senior Design Project - Electric Vehicle Conversion
(2010-2011)

Goal: To design and convert a 1971 Volkswagen Superbeetle to 100% electric drive. The vehicle was designed to meet performance specifications such as maximum speed, driving range and acceleration.

Background: As the team leader, I initially proposed this project to our professor with the understanding of the level of time commitment. This project had many engineering challenges to focus on for the core design work, so we chose three. We decided to focus our efforts on power transmission from the electric motor (EM), mounting the EM and safely securing and housing the batteries. A 1971 Volkswagen Superbeetle was chosen as our host vehicle primarily due to it’s simplistic design and ease of maintenance.

Methodology: A list of performance specifications were determined based on statistics for the average American’s commute to and from work. A set of calculations were developed in excel along with a single-line diagram using CAD software to create a BOM. After the host vehicle was procured, all unnecessary parts were removed and final measurements were made before a PO was submitted for the BOM.

Both the EM mounting plate and EM load coupler were measured to adapt to existing EM and host vehicle features then these parts were designed using 3D CAD software. Considering static and dynamic loading conditions, the EM mounting plate was machined from 6061 Aluminum. The EM load coupler was machined from 1020 steel and designed to handle high stress, strain, torque and impulse forces. Prior to final installation of these parts, the EM load coupler was measured to confirm it was within an acceptable concentric tolerance for rotating shafts.