Portafolio - daniel serrano

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BRAKE
GEARBOX
DAMPER
αβus
KINEMATICS
ELECTRIC
WRITING
STRATEGY
Daniel Serrano | [email protected]
daniel serrano
work in progress
about this
document
about
me
This document is not an
exhaustive revision of all
my work. Confidentiality
agreements impeded me
to retain copies of most of
my engineering job. Of
course, the experience
acquired lives within me.
I am a cultural kaleidoscope. Half Spaniard, half French,
I have always lived in the verge of different cultures. I
have lived in 3 different countries, visited 17, and been
in 9 different states in the US —and yet this represents
only 8% of the World. I understand there are many
different ways to interact with people and with the
environment. The world is a universe of cultural
frameworks and heuristic biases.
I spent a good amount of
my time leading an
enthusiastic and
passionate group of
mechanics from which I
learnt many useful tricks
to better deal with work
and with life. I could not
find a way to capture all
the invaluable experience
I got from my colleagues
in this portfolio.
I am an avid learner. I try to self-teach myself in different
disciplines. That spirit was what pushed me to move to
the US and keep learning immersed in a different
culture. I believe that the best way to learn is practicing
and making mistakes, provided that you learn from
these. Meanwhile, I try to learn photography, which I
found useful to spend more time observing things.
Having an ESFP Myers-Briggs type profile, which is not
very common among engineers, I am passionate about
my enterprises and I like to make work fun — I would
not have survived 12 years in the Racing world
otherwise.
menu
BRAKING SYSTEM
Project 206 XS Desafio
Daniel Serrano
Printed 26/10/2008, 15:35:15
hydraulic conception
2D48A-02
012 BAV-TAV
7
2D48A-04
018 RDAV
2D48A-07
018 RGAV
5
9
9
3
A BOMBA FRENO
Pinza de freno
delantera derecha
10
11
11
2D48A-06
014 pDAV
10
2D48A-08
014 PGAV
Pinza de freno
delantera izquierda
8
Depósito líquido
1
1
8
Salvo indicación, tolerancias generales según ISO 2768 -mK
Este dibujo es de nuestra propiedad.
No puede ser reproducido o
distribuido sin consentimiento escrito
Dibujado:
Limitador
Titulo:
D.S.H
Papel:
Material:
A PINZA DERECHA
A PINZA IZQUIERDA
Peugeot Sport España
B.M.Racing
Circuito de frenos 206 XS
A3
Nº Plano:
2D48A-00
Escala:
Tratamiento:
Rev:
A
Hoja:
1/2
Printed 26/10/2008, 7:12:43
A PINZA IZQUIERDA
6
2D48A-13
025 LIM-BFM
8
6
1
2D47A-03
2
Bomba de Pie
4
9
8
CP2326-90
Pinza de freno
trasera derecha
Pinza de freno
trasera izquierda
2D47A-01
5
3
7
Bomba de Mano
9
9
A BOMBA FRENO
Salvo indicación, tolerancias generales según ISO 2768 -mK
Este dibujo es de nuestra propiedad.
No puede ser reproducido o
distribuido sin consentimiento escrito
Esquema de implantación del sistema de frenos
1
Elementos y enrutamiento de las canalizaciones
8
Dibujado:
Material:
A PINZA DERECHA
menu
Tratamiento:
D.S.H
Peugeot Sport España
B.M.Racing
Titulo:
Papel:
Escala:
Circuito de frenos 206 XS
Nº Plano:
2D48A-00
Rev:
Hoja:
A
2/2
Project 206 XS Desafio
Daniel Serrano
Figura 4.3. Posición de la T pasamuros de la instalación delantera desde el vano motor
hydraulic prototyping
Figura 4.3. Posición de la T pasamuros de la instalación delantera desde el vano motor
Figura 4.1. Vista del montaje del kit de freno de mano hidráulico y el limitador
Figura 4.3. Posición de la T pasamuros de la instalación delantera desde el vano motor
Figura 4.4. Salidas desde bomba y paso de los tubos al habitáculo
Figura 4.4. Salidas desde bomba y paso de los tubos al habitáculo
Figura 4.2. Posición de la T pasamuros de la instalación delantera desde el habitáculo
Figura 4.4. Salidas desde bomba y paso de los tubos al habitáculo
Figura 4.5: Vista desde atrás de la instalación montada.
01
Documentación técnica 206 XS – Desafío Peugeot
Total
01/04/08
Frenos 206 XS
4
D206XS - 04
Edición
01
Fecha
01/04/08
Frenos 206 XS
D206XS - 04
5
Figura 4.5: Vista desde atrás de la instalación montada.
Edición
01
Fecha
01/04/08
Frenos 206 XS
D206XS - 04
5
Figura 4.5: Vista desde atrás de la instalación montada.
Edición
01
Fecha
01/04/08
Frenos 206 XS
D206XS - 04
5
Figura 4.1. Vista del montaje del kit de freno de mano hidráulico y el limitador
menu
Project 206 XS Desafio
Daniel Serrano
system design
The design of the braking system started with the definition of a
design process. At this stage of the design most of the data had to be
estimated. I developed a software application under the Matlab
environment to facilitate the iterative design of the componentʼs
dimensions.
The tool allowed to converge to the solution reducing the uncertainty
of the first design stages.
!
menu
Project 206 XS Desafio
Daniel Serrano
front disc design
With the results of the design of the
brake system I selected a brake disk.
The design of the disc bell had to be
tailored to the disc specs, the hub specs,
and the geometry of the suspension
system.
The designed disc bell was validated
using Catiaʼs V5 Finite Element Analysis
Module (FEA)
menu
Project 206 XS Desafio
Daniel Serrano
bell FEA validation
!
menu
Project 206 XS Desafio
Daniel Serrano
mfg. blueprint
menu
Project 206 XS Desafio
Daniel Serrano
caliper selection
N:\SolidWorks\Customer\cp7606-20cd.slddrw
Last Saved: jheritage on 22 November 2005 13:32:33
7
8
9
FIRST ANGLE
PROJECTION
11
10
P
W5 MAX
W4 MAX
W3 MAX
W2 MAX
W1 MAX
N
114.00
112.50
1.50" BORE
(LEADING)
W1 MAX
1.50" BORE
(TRAILING)
© AP Racing Ltd. 2005
10.30
10.10
PA
TH R15
WA 0.0
YR 0
AD
IUS
1
Alterations
Particulars
Date & No.
P
Tel: +44 024 7663 9595
Fax: +44 024 7663 9559
e-mail: [email protected]
Web site: HTTP://www.apracing.com
FIRST ISSUE
B3965
05/01/2005
22/11/05
B4434
2
#
CDA
#
JH
N
CP7606-18/19S0 ADDED
M
L
KEY TO DIMENSIONS:
‘PL’: TOP OF PAD MATERIAL TO MOUNTING BOSS FACE WITH
PAD SITTING DOWN ON LEDGE.
‘U’: WHEEL CENTRE LINE TO CALIPER MOUNTING BOSS FACE (DISC
Ø/2)-DIMENSION ‘PL’.
'U' DIMN
DISC ROTATION
20
19
AP Racing
Wheler Road
Coventry
CV3 4LB
INSTALLATION INFORMATION
DISC & CALIPER MOUNTING TOLERANCES TO BE SUCH THAT THE DISC
IS CENTRAL TO THE CALIPER TO WITHIN ±0.5mm.
CALIPER TO BE MOUNTED WITHIN ±15° FROM VERTICAL.
DISC DIAMETRAL CLEARANCE SHOULD BE 2.5mm NOM. FROM DISC O.D.
TO PATHWAY.
BLEED SCREW MAX. TIGHTENING TORQUE 17Nm
'PL' DIMN
53.00
41.90
R5 MAX
R4 MAX
R3 MAX
R2 MAX
R1 MAX
R10 MAX
R9 MAX
R8 MIN
R7 MIN
R6 MIN
K
18
17
TECHNICAL INFORMATION:
TOTAL PISTON AREA: 22.8cm2
PISTON MATERIAL: ALUMINIUM ALLOY
BODY MATERIAL: ALUMINIUM ALLOY
ASSEMBLY WEIGHT: 1.70KG (LESS PADS)
MAX WORKING PRESSURE: 70 bar
M
W7 MAX
16
APPLICATION:
LIGHT FORMULA CARS
R11 TYP.
L
15
GENERAL DESCRIPTION:
4 PISTON CALIPERTO SUITIRON DISC Ø295.0x20 MAX
W6 MAX
W5 MAX
W4 MAX
W3 MAX
14
13
12
THIS DRAWING IS CONFIDENTIAL AND IS SUPPLIED ON THE EXPRESS CONDITION THAT
IT SHALL NOT BE LOANED OR COPIED OR DISCLOSED TO ANY OTHER PERSON OR USED
FOR ANY OTHER PURPOSE WITHOUT THE WRITTEN CONSENT OF AP RACING LTD.
Zone
6
5
IF THIS DOCUMENT IS PRINTED IN HARDCOPY,
IT IS FOR INFORMATION USE ONLY AND THEREFORE
IS NOT SUBJECT TO UPDATING CONTROLS. ALWAYS
REFER TO SOLIDWORKS VIEWER FOR LATEST ISSUE
Initials
B1
4
3
2
INSTALLATION
DRAWING
Issue
No.
1
K
CALIPER PART NUMBERS
CP7606-12S0 – RIGHT HAND TRAILING (BEHIND AXLE)
CP7606-13S0 – LEFT HAND TRAILING (BEHIND AXLE)
CP7606-14S0 – RIGHT HAND LEADING (IN FRONT OF AXLE)
CP7606-15S0 – LEFT HAND LEADING (IN FRONT OF AXLE)
DISC CL
DISC & WHEEL CL
J
J
CP7606-18S0 – RIGHT HAND TRAILING (BEHIND AXLE)
CP7606-19S0 – LEFT HAND TRAILING (IN FRONT OF AXLE)
REPLACEMENT SEAL KIT
SEAL KIT (HIGH TEMP) CP4518-JJ
H
THIS CALIPER IS LIMITED TO 70 BAR
WORKING PRESSURE APPLICATIONS.
130.00
MOUNTING HOLE CTR'S
16.00
2.50 MIN
FRICTION MATL
20.00
INLET PORT
M10x1.00
BLEED SCREW MAX.
TIGHTENING TORQUE
17Nm
G
OFFSET
G
F
H
113.48
F
46.10
E
6.75
9.00
E
FRICTION RETAINING PINS
CP7600 PAD FAMILY
D
D
PAD AREA (MAX) 44.90cm²
C
C
SHEET 1 OF 1
SCALE 1:1
DRAWN
RADIAL PROFILE DATA
B
DISC
EFF
PART NO.
DISC Ø WIDTH OFFSET RAD
R1
R2
R3
R4
R5
R6
R7
R8
R9
R10 R11
W1
W2
W3
W4
W5
W6
W7
CP7606-12/13/14/15S0
267
18
37.25 111.85 156.00 147.00 138.40 124.20 117.40 82.45 85.45 100.50 126.70 138.40 4.50 34.00 48.25 54.90 59.40 59.90 62.40 39.50
CP7606-12/13/14/15S0
295
18
37.25 125.40 170.00 161.00 152.40 138.20 131.40 96.45 99.45 114.50 140.70 152.40 4.50 34.00 48.25 54.90 59.40 59.90 62.40 39.50
CP7606-18/19S0
295
20
38.25 125.40 170.00 161.00 152.40 138.20 131.40 96.45 99.45 114.50 140.70 152.40 4.50 35.00 49.25 55.90 60.40 60.90 63.40 40.50
DERIVED FROM
TITLE
INSTALLATION DRAWING
DRG NO.
2
3
4
5
6
7
8
9
10
menu
11
12
13
14
B
CALIPER
A
1
CHRIS ARROWSMITH
APPROVED
15
16
17
18
A
CP7606
19
20
Project 206 XS Desafio
Daniel Serrano
attachment design
I designed the attachment of the brake
caliper to the front wheel hub.
The material used was a high grade AL
7075 with a hard anodizing coating.
Using the forces obtained in the
simulation, I conducted a FEA analysis to
validate the design.
Although the analysis shows regions
were the part could have been further
machined to reduce its weight, cost
constrains forced to retain the stark
physical design
!
!
!
!
!
menu
!
Project 206 XS Desafio
Daniel Serrano
GEARBOX
Project 206 XS Desafio
Daniel Serrano
mechanical setup
The definition of a gearbox for
rally usage has a particular set
of requirements:
• Bigger tire diameter
• Increased tire adherence
• Higher torque at wheels
• Lower top speed
In addition the whole gearbox
had to be changed due to the
inability of the carʼs original
gearbox to cope with the new
requirements.
I developed a software
application to facilitate the
design of the gearbox stages
and maximize torque and
power availability.
The visualization of the results
was overly improved over
other software tools
menu
Project 206 XS Desafio
Daniel Serrano
interface constrains
engine interface
command
interface
chassis interface
driveshafts
interface
menu
Gearbox drawing courtesy of Peugeot Automobiles
Project 206 XS Desafio
Daniel Serrano
command interface
installation drawing courtesy of
Peugeot Automobiles
menu
Project 206 XS Desafio
Daniel Serrano
DAMPERS | SHOCKABSORBERS
Project 206 XS Desafio
Daniel Serrano
process mapping
Obtain Car Sprung
Weights
No
Obtain Car
Unprung Weights
Calculate Critical
Damping
+
Calculate
Theoretical
Damping Law
Test on Dynamic
Simulator
+
Obtain Suspension
Kinematic Ratios
No
Yes
Define Shim Stack
+
Test Damper on
Dyno
Compare Results
with Theoretical
+
Test on Car
+
+
Validate Damping
Law
+
No
Theoretical Calculations and Analysis
Physical Test and Analysis on Lab
menu
Project 306 Maxi
Daniel Serrano
software simulations
To validate a damper setting,
the usual methodology is to
test on-board a variety of
damping settings. This is an
expensive process needing
about 10 iterations and relying
on driver and test conditions.
I developed a model simulator
on Simulink that allowed to
pretest damping settings and
adapt them to the unique
characteristics of the car.
As a result of the pretests, we
only need to go through one
iteration on the front damper
and none on the rear damper.
menu
Project 206 S1600
Daniel Serrano
assembly design
I designed the physical
components of the
damper as the different
simulation were done.
The whole process
was faster and less
tentative due to the
data obtained during
the simulations.
menu
Project 206 XS Desafio
Daniel Serrano
detail design
menu
Project 206 XS Desafio
Daniel Serrano
design analysis
Commercial damper
dynos test dampers at
predefined frequencies.
The outputs are the force,
speed and position at the
the damper rod. The
obtained data needs to be
post-processed to obtain
any useful information.
I conceived a software
application
and
conceptualized the GUI in
Matlab in order to analyze
the damper response on
the car wheels.
The tool allowed to
compare different settings
for the same end an
compare front and rear
responses to better
understand the coupling
effects.
menu
Project 206 S1600
Daniel Serrano
rear damper
menu
Project 206 XS Desafio
Daniel Serrano
menu
Project 206 XS Desafio
Daniel Serrano
menu
Project 206 XS Desafio
Daniel Serrano
menu
Project 206 XS Desafio
Daniel Serrano
KINEMATICS
Project 206 XS Desafio
Daniel Serrano
mcpherson strut
•
•
I developed a software to analyze the kinematics of
the suspension components. The goals were:
•
menu
to understand the effects on the set-up
to understand the relationships between the
different components
to design an optimized solution
Project 206 S1600
Daniel Serrano
semi-trailing arms
visualization
plot variations
menu
Project 206 S1600
Daniel Serrano
ELECTRICAL HARNESSES
Project 206 XS Desafio
Daniel Serrano
power harness design
Printed 30/01/2001, 15:34:07
BM34: Cajetín
Potencia Motor
Long.
2D56A-06 (CC – BM34)
OJIVA B
OJIVA A
2D56A-04 (BAT - CC)
REFERENCIA
LONG.
OJIVA A
OJIVA B
CABLE
2D56A-03
325
6-10
6-10
Radaflex 0.6Kv 16mm
2D56A-04
1850
6-10
6-10
2D56A-06
975
6-10
6-10
Radaflex 0.6Kv 16mm
2
Radaflex 0.6Kv 16mm
2
2
2D56A-03 (MASA – BAT)
-
+
Salvo indicación, tolerancias generales según ISO 2768 -mK
Este dibujo es de nuestra propiedad.
No puede ser reproducido o
distribuido sin consentimiento escrito
Bateria
Dibujado:
Material:
Tratamiento:
menu
D.S.H
Peugeot Sport España
B.M.Racing
Titulo:
Papel:
Escala:
Instalación de Potencia 206 XS
Nº Plano:
2D56A-00
Rev:
A
Hoja:
1/1
Project 206 XS Desafio
Daniel Serrano
control harness design
Printed 27/03/2001, 15:33:03
7
6
17
6V Negro
Inyección
4V Negro
Patm
2V Gris
8
2V Negro
11
12
3V Azul
Tª Agua
PAP
18
13
2V Negro
Régimen
Manocontacto DA
2V azul
19
16
3
14
32 V Gris
15
4V Verde
Lambda
380
Derivación
2
16V Rojo
BM34
4V gris
Bobinas
2V Gris
2 V Negro
Centralita Bosch
Origen
20
2V Azul
1
Tronco 4
Tronco 3
Tronco 2
330
32V Negro
21
Tronco 1
Masa
210
2
Derivación
0
Derivación
3
Masa
Velocidad
3V blanco
2 V Blanco
Derivación
1
620
10
4V Azul
Lambda
9
23
3V Amarillo
22
130
4
200
2 V Negro
5
24
55V
Centralita Marelli 1AS
25
4V Negro
Diálogo PC
Versión
Multiplexado
Salvo indicación, tolerancias generales según ISO 2768 -mK
Este dibujo es de nuestra propiedad.
No puede ser reproducido o
distribuido sin consentimiento escrito
Dibujado:
Material:
Tratamiento:
D.S.H
Peugeot Sport España
B.M.Racing
Titulo:
Papel:
Escala:
Instalación motor modificada 206 XS
Nº Plano:
2D60D-01
Rev:
A
Hoja:
1/2
!
menu
Project 206 XS Desafio
Daniel Serrano
TECHNICAL DOCUMENTS
Project 206 XS Desafio
Daniel Serrano
technical documents
Documentació
4. SISTEMA
D
n técnica 206
XS – Desafío ocumen
Peugeot tació
Total
n té
cnica
206
Tota XS – Des
l
afío
NUM
DE FRENO S
Peug
e
ot
MAT
El KIT se co
ERIA
mpone de lo
s siguientes
L
INSTelementos:
x KIT DE CA
ALAC
NALIZACIONE
TIPO
IÓN
1 S
MAR
AR
Adap
CAJE
x KIT DE FR
t
ENO DE MAN
a
d
o
2 O HIDRÁ
r
E
LON
tique
Cana ULICO
x KIT DE FE
G
tado
NOS DELAN
M12
3TEROS lización
x
m
1
A
m
RAC
00 a
x LIMITAD
dpat
OR
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OR DE FREN4
ador
ENT
Flex.
ADA TRASER
RAD
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x SERVOFR
A
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t
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Project 206 XS Desafio
Daniel Serrano
technical website
I produced a website to facilitate
customersʼ access to technical
documentation upgrades and eliminate
distribution costs of the paper version.
The rally version was developed
and published in 2007
http://www.peugeotsport-es.com/desafio/index.htm
The homologous circuit version
was developed in 2009
http://www.peugeotsport-es.com/circuito/index.htm
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Project 206 XS Desafio
Daniel Serrano
αβus
the customizable touch screen interface
Daniel Serrano
αβus
the customizable touch screen interface
Project developed for a course on New Product Development during Fall 2009
I was part of the team of five students that
developed a concept for a new computer
interface. The new tool attempted to
answer three questions:
• Why can’t I see what I am about to
type?
• Why can’t I set up the keyboard of a
computer as I please?
• Why can’t we integrate all the computer
peripherals in one single interface?
You need an internet connection to download the keynote
10.5 Mb
Germ of the idea
During Summer of 2009 I attended the
Summer Institute of International Scholars
at Tufts University, where I shared
experiences with twelve students form
eight different countries. I could observe
how painful was the experience of writing
in an American typed keyboard for every
one. To write a short email in the laptop of
one of my Japanese friends took me a lot
of time. It was a frustrating experience.
The idea started as a new keyboard,
evolving as we deep-dived.
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Daniel Serrano
STRATEGY
Daniel Serrano
strategy
Company
R
Document
Link
How to...
Experience Design
26.8 Mb
Business Strategy
3.5 Mb
South Africa
International Strategy
1.7 Mb
Agent Based Simulation
Paper Model
2.5 Mb
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Daniel Serrano