IFB Industries Limited, Goa (May 2023 - December 2023)

Role: Intern(Air Conditioners Division)

Department: R&D Department - Refrigeration and Heat Transfer Team

Tools: Fusion 360, Creo, ANSYS,

Concepts: Heat transfer and Refrigeration, Thermodynamics, Mechanics of Solids, Finite element analysis, Material Sciences, Fluid Mechanics, Applied thermodynamics, Heat Cycles, Gas Dynamics.

Manufacturing Experience: Welding, Soldering, Machining

Project Statement:

I was entrusted with the task of creating a device/product that could improve the heat exchange rate of an Air Conditioner by installing this device within the tubes of the condenser pipes of an outdoor unit. To accomplish this task I had to perform multiple tasks as explained below.

Key Responsibilities:

  • I designed a filter mechanism with a specific porosity with ball bearings obstructing the flow and compressing the fluid between the gaps present in the condenser tubes'.

  • Then I calculated all the theoretical parameters required to make sure the volumetric flow rate, temperature, moisture content etc. do not damage the filter being assembled.

  • After performing a detailed analysis using various literary resources and with the help of my managers I decided on the material to be used for the project.

  • Different variations of the same model had to be made to test the reliability of the design and hence a large amount of time was spent in designing various CAD models which would suit the conditions and dimensions of the Air conditioners that were at that time being used.

  • After getting approval for the CAD designs, the attaching mechanism had to be designed and visualized in order to attach this device inside the condenser tubes.

Key Responsibilities:

  • Then the location for the device in the condenser arrangement had to be fixed to optimize results

  • The kind of adhesive and raw materials required for the manufacturing also had to be decided upon. All these decisions were taken on the basis of exhaustive analyses and comparisons between various options present in the industry.

  • Other analyses were also performed to test the reactivity of the device with other materials which could possibly be present in the fluid.

  • Then, prototype development was performed to try to manufacture the device at a lower cost, in order to avoid unnecessary manufacturing costs.

  • Simulations were performed to depict the compression of fluid and how the compression of fluid along with the design and materials used can improve the surface area to enhance heat transfer and faster cooling. The main concept used in the project was known as Throttling.

  • The final project presentation was presented to the R&D team and the project was carried on by another intern to complete the manufacturing.

  • Below attached is the Consolidated report for the same.

Bharat Heavy Electrical Limited (April 2023 - June 2023)

Role: Student Trainee

Department: Turbine Manufacturing Department

Tools: Machining, Welding, CNC Milling, Boring, Threading

Concepts: Thermal Manufacturing, Heat Management, Cooling effects of fins, Energy Conversion.

Manufacturing Experience: Machining, Welding, CNC Milling, Boring, Threading

Project Statement:

I was required to observe and learn the various Manufacturing techniques used to design and manufacture a steam turbines fin. An enriching experience where I understood the significance of various manufacturing techniques.

Key Responsibilities:

  • I was required to understand all the processes carried out in the workshop to understand my requirements.

  • Based on my observations I had to sketch a roadmap required to manufacture the fin of a turbine.

  • After procuring the raw materials required, I went on to understand every process and helped the manager in charge of each machine or operation to finish each operation while practicing all safety protocols.

  • I had give appropriate lubrication and take necessary precautions to make sure none of the processes affect the accuracy of my piece.

  • After performing all the operations a report was drafted to outline all the operations performed and the thought behind each action and step taken.

Pacify Medical Technologies (May 2022 - August 2022)

Role: Intern(Air Conditioners Division)

Department: Mechatronics & Design Team

Tools: Fusion 360, Creo, ANSYS, Solidworks

Concepts: 3D Modelling, Stress & Strain Analysis, Thermal effects of Force, Material Sciences, Mechanics of solids.

Manufacturing Experience: NA

Project Statement:

In this project I was required to refurbish a skin spray gun which was a product this startup was working on used to treat burnt skin in cases of an emergency. There was some feedback obtained from doctors in the industry and customers in the market leading to scope for improvement which had to be fixed, analysed and tested by aspiring engineers in our team.

Key Responsibilities:

  • Firstly, given the feedback from customers and doctors, the areas of interest and failure had to be identified and depending on the location and problem, an appropriate solution had to be devised.

  • After a few brainstorming sessions with the CEO and managers, our team was divided, with each member allotted a problem to deal with. Each of us had to use our CAD expertise and improve the performance and efficiency of a particular aspect of the skin spray gun.

  • In my case, there was a piece of solid material which was being bent to failure when the user tried to exert force and spray skin cells. This part had to be re-designed in such a way that it was able to resist a higher force coefficient and was durable.

  • This required me to understand techniques used in trusses to improve strength which could be modified and used in the case of my problem statement as well.

  • In addition, we were tasked with designing various fitting techniques and devices to attach different shooting mechanisms, tailored to specific requirements and applications.

Key Responsibilities:

  • The designs were made and designed after elaborate discussions and brainstorming sessions, various other industry experts were also consulted to validate for the feasibility of our ideas.

  • Multiple simulations were also performed to evaluate the strength of all of the designs we proposed.

  • Comparison to competitors was also done to get a better idea of the perspective to keep in mind while designing solutions.

  • Based on the simulations performed other changes were made to existing designs and a cost analysis was also performed.

  • The availability of parts and vendors capable of producing parts with sufficient strength and quality were also approached and a list of best vendors for the designs suggested was created.

  • A report was drafted including all this research given below.