Micromobility IoT Module
2018 - 2019
Photo by Brett Sayles from Pexels
Challenge:
Design an enclosure for an IoT-enabled subsystem for integration into a shared micromobility vehicle. This challenge brought with it harsh lifetime requirements (including IP66, vibration resistance, vandalism resistance, and a multi-year life cycle) compounded by a tight schedule formulated to meet a critical launch date.
Approach:
Led mechanical design team of 2 from architecture development through first overseas build in 3 months
Mechanical Design Architecture
Pulled mechanical, electrical, and RF teams together to quickly establish volumetrics in response to tight space constraints, user UX interface locations, and required antenna performance
Produced mechanical architecture and derived critical keep-ins/outs to unblock electrical design
Detailed Design
Managed a contractor resource:
Established division of labor and critical design interfaces
Conducted design reviews periodically to ensure adherence to best practices and established requirements
Assisted as-needed on facets of sealed housing design, including completing tolerance analyses and interference checks between subsystem components
Designed and integrated a multi-purpose injection molded part providing ingress protection via USW weld, impact protection, and light piping for a user interface
Prototyped full-up assemblies in-house to anticipate/prevent DFA-related issues (RP plastics/PCBA, cabling, etc.)
Lobbied and established a schedule update required complete due diligence of mechanical design and evaluate key mechanical risks
Released full tooling CAD package and mechanical BOM to CM, including full 2D documentation
Overseas Build 1
Provided on-site ME support for manufacturing bring-up of IoT-enabled subsystem as well as a separate subsystem meant for integration in to the end-product
Responsible for on-site bringup of 6 single shot IM parts and 2 double-shot IM parts
Reviewed FAI data and initiated tool updates to be completed between builds
Fit-checked and tested first sets of mechanical parts (first assemblies surpassed ingress test requirements)
Conducted DOE on material, tint, and dispersant for molded light pipe
Overseas Build 2
Conducted DOE on ultrasonic weld parameters in order to improve impact resistance and establish process control
Reviewed IM part inspection reports, investigating and correcting deviations as needed prior to approval
Updated 2D documentation as needed to incorporate DFM changes and tolerancing changes
Conducted FA on units undergoing HALT HASS testing
Advised on ME-related capital equipment purchasing
Facilitated transition of subsystem ownership back to client
Skills:
ME Team Leadership
Injection Molded Plastics Design
Overseas Build Support
Overmolding
Ultrasonic Welding
Lightpiping