Source: www.itrobotics.com

MFL Sensor housing- The requirements were to increase the accuracy of the tool. I doubled the number of magnetic flux leakage sensors and decreased their distance to where the coiled tubing passes through. Materials were selected, drawings were made, machine shops selected, and SOPS were written for assembly. In fact, I saw through all improvements listed below from brainstorming to installation in the field. This work required working closely with the electrical engineer, physicist, and the sofware engineer, and highlights my ability to communicate designs with an inter-disciplinary team.

Chassis- The re-designed MFL sensor housing meant the chassis on which they sit on (pre-loaded with springs) had to be re-designed, balancing tool weight and ruggedness. FEA in Solidworks was used to optimize this trade-off. Tight mechanical tolerances were called out to respect the length constraints based on statistically expected kinks in the tubing. Different tools were designed for use in steel mills and in oil environments.

Probe housing- The mechanical assembly, inlcuding plastic protection caps and springs, was designed with the supervision of a lead engineer.

Sheet metal protection-The sheet metal protection was redesigned and fabricated, highlighting my skills in designing sheet metal parts in Solidworks.

ATEX Cables- I coordinated with OEMs, my supervising engineer, and an in-house electrical engineer to have custom cables manufactured and rated for explosive environments in Europe .

CE and ATEX ratings- I worked closely with a CE and ATEX consultant to devise and see through to completion a host of tests (+12) dictated by standards to certify the tool for CE marking and explosive environments. I carried out different electrical tests, grounding tests, impact tests, temperature resistance, EM radiation tests, etc. and redesigned the tool to pass where it did not before.