Noah Varley Engineering Portfolio

Noah Varley
Mechanical Engineering
Portfolio
BEng Mechanical
Engineering

About Me
Highly motivated and capable Mechanical Engineering graduate with experience in CAD, Mechanical
Design, Mechatronics and Energy Systems. Self driven and organized individual who takes initiative
and has the ability to quickly adapt and manage several complex tasks.
Objectives:
Short term: Apply my mechanical engineering design skills to a challenging and engaging full time
position as a Mechanical Engineer in Training (EIT). Continue to expand upon and develop new skills
in a fast-paced, innovative environment.
Long term: Pursue a career which positively impacts the worlds growing population and addresses
many of the problems facing humans today such as climate change, food security, or healthcare.
Noah Varley Mechanical Engineering Portfolio
noahcvarley@gmail.com
2

Mica Robot (1st Place Winner of 2017 IEEE Design Challenge)
Description:
• Mica’s purpose is to assist people
with limited motor skills who have
difficulty controlling a camera
• Mica enables users to control the
height and orientation of a camera
while following them
autonomously
• Developed in a 6 person team of
mechanical and computer
engineering students over 3
months
3

Mica Robot (1st Place Winner of
2017 IEEE Design Challenge)
Contribution:
• Designed and machined 3-axis camera rotation system
• Wrote MATLAB scripts to simulate the system kinematics and
dynamics
• Determined motor torques using Iterative Newton-Euler
method
• Analyzed machined components and critical fasteners using
Solidworks FEA
• Created clear, easy to read shop drawings for parts
manufactured using a CNC mill and manual lathe
• Created final renders and animations using Solidworks and
Photoview360
• Sourced telescoping linear actuator for the vertical lifting
system
4

Mica Robot (1st Place Winner of 2017 IEEE Design Challenge)
Further information can be found on the
website created to showcase the project
https://aspectrobotics.wixsite.com/home
5

Automated Conveyor Belt Sorting System
Description:
• The system’s purpose is to sort 48 assorted
pieces of aluminum, steel, black and white
plastic in under 60 seconds
• It features a conveyor belt, powered by a DC
motor, and a sorting tray attached to a
stepper motor
• It uses several different sensors to read the
material, classify it and sort it into the
available trays
6

Automated Conveyor Belt
Sorting System
Contribution:
• Programming of Atmel AT90USB1287 MCU using C
• Developed program algorithm and code skeleton flowchart
making use of interrupts and a linked list structure
• Tested and optimized stepper motor acceleration profile
• Developed ADC calibration code to calibrate system
• Created circuit diagram
Noah Varley Mechanical Engineering Portfolio noahcvarley@gmail.com 7

Hearing Aid Battery Changing Device
Description:
• The purpose of the device is to help elderly
hearing aid users who have poor vision,
dexterity and memory have difficulty changing
hearing aid batteries
• A semi-automated, portable device that assists
elderly hearing aid users in replacing hearing
aid batteries
• Demonstration of working prototype:
https://www.youtube.com/watch?v=TCzoYdoJi
20
8

Hearing Aid Battery
Changing Device
Contribution:
• Team leader who managed team resources,
organized meetings, and developed project
timeline
• Developed mechanisms for open/closing the
battery door, removing the old battery and
inserting the new battery
• 3D scanned the hearing aid to create a 3D
printed mold to secure the hearing aid
9

Mid-drive Electric Bike Gearbox Design
Description:
• The gearbox is designed to be a retrofit system for
bicycle owners to upgrade their existing bikes to e-
bikes
• The mid-drive system allows the rider to make use of
the bicycle's rear cassette for changing gears
• Because of this feature, the mid-drive system can
operate in a more efficient range, and the rider has an
easier time accelerating and also traveling around
sloping terrain.
• Detailed design for gears utilized the AGMA methods
for analysis of bending and surface fatigue
• Detailed part and assembly design drawings using
Solidworks
• MS Excel tool used to quickly iterate through design
changes
10

Mid-drive Electric Bike
Gearbox Design
Contribution:
• Duty cycle determination and gear ratio optimization
• Analysis of all critical failure locations on shafts for
static and fatigue failure using the stress-life method in
conjunction with Miner’s rule
• Bearing selection, arrangement, and lifetime analysis
using the SKF online tool
11

Hybrid-Electric General Aviation Aircraft Design
Description:
• Conceptual design of a hybrid aircraft based on an
Undergraduate Team Aircraft Design - Hybrid-Electric
General Aviation Aircraft (HEGAA) request for
proposal
• Based on these design requirements the following
areas were developed in detail: MTOW, Take off and
landing, Wing Design, Fuselage Design, Static
Stability, Hybrid Design, Engine Specifications,
Propeller Design
• Iteratively designed using MS Excel in a team of 6
Mechanical Engineering students
12

Hybrid-Electric
General Aviation Aircraft Design
Contribution:
• Assessment of static stability of the aircraft
• Assistance in all calculations and iterative design changes
to reach a design which met all the requirements primarily
focusing of areas of static stability, weight refinement and
propeller selection
• Technical documentation of design process and detailed
design
13

UV15 FSAE Brake Rotor Design
Description:
• Research and design of brake rotors for the UV15
FSAE car
Contribution:
• Analyzed different steels, cast irons and coatings to
select ideal material and post-processing
• Researched manufacturing techniques to achieve
desired tolerances and surface finish
• Determined heat flux from braking based on energy
balance and braking cycle data collected by on-
board DAQ
• Simulated thermal cycling to ensure heat
dissipation was sufficient for the selected material
using Excel and Solidworks
• Optimized lightening holes to reduce weight based
on static FEA simulations in Solidworks
14

Building Energy Simulation and Design Project
Description:
• Proposed a plan to reduce energy consumption in a target building through integration of high
efficiency heating systems, conservation measures, and on-site generation
• Design process revealed the solutions that have the greatest impact on energy reduction, as well
as the most cost-effective solutions
• Report produced documenting the the proposed system integrations and their impact on the
baseline electricity and gas consumption
15

Building Energy Simulation and Design Project
Contribution:
• Modelling of building energy consumption
using CAN-QUEST software
• Investigation and analysis of different high
efficiency heating methods, on-site generation
methods, windows, lighting systems and
insulation
16

Custom Mendel 90 3D Printer Build
Description:
• Personal project to obtain a cost effective 3D
printer by making use of recycled or affordable
parts and materials
• Sourcing, fabrication and assembly of a
custom RepRap 3D Printer based on the
Mendel 90 design by Chris Palmer
17

Custom Mendel 90 3D Printer Build
Contribution:
• Generated custom design using open source Python code
• Redesigned spool holder and cable management using
Solidworks to accommodate different sized spools and
connectors
• Designed custom extruder using Solidworks
• Cut birch plywood frame using Trotec Laser Cutter
• 3D printed parts for the printer using Ultimaker 2
• Modified ATX power supply and old hard drive to create 12V
power supply
18

Academic Achievements
• Canadian Society of Mechanical Engineering
Gold Medal (awarded to the top student in
faculty)
• UVic Excellence Scholarship (renewed each year
of degree)
• Faculty of Engineering: Dean’s Entrance
Scholarship
19

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