JAMISON MICAH PEZDEK

Table of Contents Bio

Education

Design Study Ensemble Module System

Samples of work Automotive Battery Block & Module Design Automotive Battery System Design Flow Bench Design Tooling Design Drafting Senior Capstone

Overview Mirror Module Final Assemble Results

Contact Information

Jamison Micah Pezdek

Bio

Jamison Micah Pezdek

Born: August 6th, 1986 Hometown: Wynantskill, NY Professional 6 years battery / automotive Experience: 1 year product design 8 months medical device

Education

• Masters of Science, Computer Systems Engineering Focusing in Computer Aided Design

• Class of 2012

• Coursework in CAD Design, C++ and Java Programing, Manufacturing, Energy Systems, and Human Factors

• Bachelors of Science, Mechanical Engineering • Class of 2009

• Minor in Business

Jamison Micah Pezdek

Design Study: Ensemble Module System

Jamison Micah Pezdek

Design Process

Jamison Micah Pezdek

Design Requirements

• What is the problem?

• When is it needed?

• What is the cost?

Brainstorming

• What have we done in the past?

• What are the issues with the current design?

• What is required?

• What features would the customer appreciate?

• What rules can we break?

Concept Development

• What will it look like?

• What do we need to add?

• Do we know enough about the problem? What is the science behind it?

• Do we have a backup?

• Develop a new block design that has a higher energy density, for the same cost

• Timeline: 2 years

• Module assembly often consists of torqueing many small screws in a tight space

• There was no defined system for packaging the existing blocks

• Why do blocks need to be welded?

• Integrated HV Connection System • Training to understand electrical point

connections • Backup Welded Design

Design Process Continued

Jamison Micah Pezdek

Prototype

• What do we want to try?

• What areas should we focus on?

• How does it work?

Test

• What do we need to test?

• Do we need certifications?

• Where will it be used?

• How will the customer use it?

Analyze

• Did it work like we wanted?

• Did it break? Where?

• Did we think of all the possible outcomes

Redesign

• What didn’t we think of?

• What did the testing tell us?

• Can we make it effectively?

• Has all of the customers' requirements been met?

Test

• Did we test enough before?

• What has changed?

• Did things improve?

Ready For Production

• Get parts ready for production

• Is the supplier making parts like we expect

• Are all of the tolerances correct?

• Prototyping with 3D Printer, Soft Tooling. • Check for fit and form

• Automotive Standards • Electrical Resistance • Government Standards

• FEA • Design Validation

Testing

• DFMEA • Design Reviews • Failure analysis

• DFM • DFA • Added features to enhance

customer experience • Added features to enhance

reliability

• Further testing to verify redesign

• Load testing to verify FEA data.

• Vibration testing

• Hard Tooling • FAI • PPAP • Process Validation Testing

Final Result

“The flexibility of the Ensemble system allows customers to design, build and test a prototype pack in a fraction of the time it would typically take for a fully custom solution. Next, the production quality components used in the initial prototypes greatly reduce the pack qualification effort needed to launch into mass production. Finally, the same highly-reliable standard components used in the prototype and development stages support a cost-effective launch of low, medium and high volume packs without the need for expensive tooling or a complex assembly line. Ensemble provides clear value from project inception through high volume pack production.”

—Darren Bischoff, Director of Business Development and Marketing for Boston-Power

Jamison Micah Pezdek

Automotive Battery Block & Module Design

Jamison Micah Pezdek

Swing Key Block e-Taxi Module e-Bus Module Ensemble Module System

Battery System Design Automotive

Jamison Micah Pezdek

e-Taxi Pack e-Bus Pack Saab 9-3 Sedan Chinese Consumer Sedan

Automotive Pack Assembly

Jamison Micah Pezdek

Flow Bench - Testing

Jamison Micah Pezdek

Used for forced cooling testing • Machined, COTS, 3D printed and

formed plastic components • Achieves uniform flow rate across the

test chamber • Swappable parts so flow rate can be

increased if the needa

Tooling

Jamison Micah Pezdek

Membrane Cutter: Modification to an Arbor Press

Epoxy Drying Station Electronics Enclosure

Design Approach

Get as much information up front.

CRD, PRD

Design with simplicity and manufacturability in mind.

Have we done this before?

What are the real problems that need to be addressed?

Incorporate DFx early in the design.

DXF addressed material availability

DFX addressed design for assembly and manufacturability.

Tackled difficult design issues as a team in a room setting.

Brainstorming in a room is much more effective then through emails.

drafting

touch freezing device •Used for sample preparation in quick freeze deep etch microscopy

•Device rapidly cools biological samples (10,000°C/sec) resulting in vitrification

•Use of a linear motor and laser curtain prevent mechanical deformation

Jamison Micah Pezdek

mirror module •Major component of touch freezing device

•Houses four copper mirrors, held under liquid nitrogen

•Inclusion of T-type thermocouples allow for monitoring of mirror temperature

•T-6061 Aluminum Alloy: Ideal for low thermal expansion

Jamison Micah Pezdek

final assembly •Most machined parts were done in house.

•The Mirror Module was sent out to an outside machinist.

•Construction and Assembly took about three to four weeks

Jamison Micah Pezdek

results •Preliminary results were very favorable

• Device effectively vitrified the leading edge of the samples, ensuring quality images

•Tests prove design as a working prototype.

•Device is currently in use at Northeastern University

•Water Droplet Test

Jamison Micah Pezdek

contact

Cell: (518) 810-7736

E-mail: jamisonpezdek@gmail.com

Address: 15 Wensley Street Boston, MA 02120

Jamison Micah Pezdek