Spring 2012
Phillip Daniel
Overview
I designed, modeled, and built a surface grinding machine that achieved 15.5 μm peak-peak flatness and 1.5 μm roughness over the tested portion of its workspace. The total workspace of the machine is 75mm X 87mm X 12.6mm. Here I present design and testing records for the machine.
​
Accomplishments
In this project I demonstrate my ability to design a precision system to a specified error tolerance, design and conduct sub-assembly tests to verify the hardware’s performance during fabrication, and fabricate a full system to the desired tolerance.
Fall 2019
Overview
I worked on a small team with an electrical engineer and bio-mechanics specialist to model and simulate biped robot locomotion. We predicted the impact of distal weight on the biped's legs on the power consumption of its gait. We then built a planar biped to validate the results of the simulation.
​
Responsibility
I developed the micro-controller (FRDM-K64F) level logic to track the gait that we designed, as well as the experimental platform's software infrastructure to design the gait in Matlab, transmit it to the microcontroller, record the system's state during the experiment, and transmit it back to Matlab for analysis. I also integrated the hardware and electronics built by my team member with the control and analysis environment that I built.
​
Outcome
The trend of our simulation results matched well with our experimental results.
Spring 2015
Overview
I designed, built and controlled a self-balancing inverted pendulum using loop shaping design methods with contactless position sensor feedback. The device uses the torque from a reaction wheel for control effort. The system was linearized about its marginally stable equilibrium point, and a lead controller was implemented. Efforts are now being made to configure a reliable power supply/electrical system that is capable of absorbing the energy from regenerative braking.
Responsibility
I modeled the system analytically, simulated the system and controller to observe the effect of nonlinearities such as motor saturation, and designed and built the project’s hardware and software architecture.
Fall 2013
Overview
I designed and built a setup to find the resonant frequency of an arbitrary spring-mass system by measuring it’s frequency response. This system was powered from the wall through a step down transformer, and it was controlled with a PSOC 4. I designed the power electronics and wrote the logic for the setup.
​
Outcome
The system consisted of a buck converter, two full wave rectifiers and a digital H-bridge controlled by a PSOC microcontroller. The final version was able to successfully locate the resonant frequency of the test spring-mass system.
​
Skills Learned
I learned how to design, build and troubleshoot a buck converter, boost converter, buck-boost converter, fly-back converter, full wave rectifier, digital H-bridge, and analog low-pass filter. I also learned how to measure and process signals, and command actuators projects with a PSOC. Finally, I learned how to drive induction, brushed and brushless motors using discrete components and chip level logic.
Overview
I worked on a small team to design a three part yo-yo toy for mass production. We produced 100 of the toys. The injection molded parts were within a tolerance tight enough to facilitate a press fit.
Outcome
I designed the mold and injection process parameters based on a model of the thermal distortion of the parts. The process parameters were also optimized to yield a fast production run. I produced toleranced drawings for the mold, and manufactured a set of the product's mold myself.
Fall 2012
Overview
I measured the speed of a Taekwondo kick in comparison with the speed of a block. After analyzing the data, I was able to conclude that a Taekwondo kick by a practitioner is faster than a block by both the general population and another Taekwondo practitioner.
​
Skills Learned
I learned how to design an experiment, coordinate experimental subjects, use a data acquisition system (NI MyDaq) to measure and analyze results, use MathCad for analysis, and present my result at a poster session.
Spring 2012
Overview
I designed and built a coil winding machine to expedite the process of wrapping simple geometries of coils for my research lab. This project was also an introduction to Labview, as this was the software used to create the user interface and control the machine.
​
Skills Learned
I learned to write Labview code to interface a CopactRIO with a stepper motor driver and to implement position control on a brushed DC motor with encoder feedback. I also gained experience designing rigid structures, identifying critical modules, and rapid prototyping. I used rapid prototyping to discover unforeseen complications early in my design process.
Fall 2013
Overview
A recurring TA for the MIT course, Momentum. This course offers students an interdisciplinary perspective on solving challenges. Each year, students worked in small teams and had the opportunity to apply deterministic design principles to build devices that accomplished various tasks. The tasks varied from designing a cable management system for Ford (2012), to modifying Flying Robots to have Increased Range, Endurance and Sensors (2014), to robot control based on EMG sensor feedback and Inverse Kinematics (2015).
​
Skills Learned
I gained practiced managing teams and improved my communication skills, through lecturing and hosting office hours.
Spring 12,14,15
Overview
I worked with Dr. Alexander Mitsos to design a low-cost heliostat kit for schools to use to expose their students to engineering. Each heliostat costs $120 in parts, if purchased online, and there is a one-time cost of $80 to purchase tools. The parts cost decreases if the components are purchased in bulk. Projects such as these, which introduce young students to engineering, are key to increasing the diversity of students in engineering programs
Outcome
An assembly document was written to explain the motivation for the project, the steps to assemble the kit, and where to buy all of the components. This project log was featured on the website’s homepage and was runner up in a site-wide contest.
Spring 2011
Overview
I designed a low cost Heliostat as part of an earlier project, and then found myself on a team of students planning to cycle across the country and teach engineering along the way. I raised funds through a Kickstarter campaign and taught classes across the country based on the Heliostat.
Outcome
I recruited a team member to help me build the Kickstarter campaign. Together we raised $3000 to fund the classes. The publicity and success of the campaign resulted in a later donation of $1000 from the Maine School of Science and Math and $500 from Draper Laboratories. These additional funds made it possible for me to teach a pilot class to middle school students at MIT, where I polished my curriculum.
Spring 2011
Overview
Me and 7 of my peers rode bicycles from San Francisco, California to Washington, DC. During the bike tour, I taught four classes in Colorado, Kansas, and Kentucky to ~20 students using the curriculum developed for the Heliostat project mentioned above.
Summer 2013
Overview
Pneumonia is one of the leading causes of infant mortality world-wide, but it is easy to detect with current Pulse Oximetry technology. Unfortunately, the technology is designed for developed countries and not appropriate in a third world context, in places such as Vietnam. To help reduce the prevalence of preventable deaths in babies world-wide, I worked with a team of MBA students and designers, in partnership with Design that Matters, to design a Pulse Oximeter for the third world. I used serial communication with a hobby microcontroller to prototype a working blood oxygen sensor based on Nonin’s OEM Pulse Oximeter circuit board.
​
Skills Learned
Through working with the team, I learned and implemented an effective product development process that is generalizable to any product/product opportunity. I also learned how to work in an interdisciplinary team, which includes skills such as efficient time management and meeting planning and how to productively deliver criticism.
Spring 2012
Overview
The small business began as a birthday gift for a friend. I asked her to tell me about some of the places she has been to in the world and decided that I would make, as a gift, a map of her undergraduate institution. Following this first map, I created maps of Japan, Norfolk State University, Virginia Tech University, NC State University, MIT, Harvard and Cambridge.
​
Outcome
I recruited two team members and we built an online store. We refined a medium volume manufacturing process and piloted the sale of art online to gauge its commercial feasibility. The maps are high quality, easily personalized, and comfortably manufactured in volumes of ten 12”x12” frames per week.
Spring 2015
Summer 2014
Overview
Living in Cambridge near the iconic Charles River, I wanted interact with the natural structure on my own terms without being limited by rental equipment. I wanted to build a boat, but I didn't know the best way to get started. Soon thereafter, I received an email from somebody who wanted to get rid of a derelict, wooden kayak frame that they no longer had time to repair. After inspecting the frame, I decided to repair it.
​
Outcome
After removing the cracked skin, repairing the broken and rotted lengths of the frame, and stitching and sealing a canvas skin on the boat I was left with a beautiful sea worthy vessel that glided over the salty waters of the Charles River with ease. I also wrote a project log that I posted to Instructables.com. This project log was later featured on the website’s homepage