Sahib Virdee

Welcome to the personal, professional, and projects portfolio of Sahib Virdee. Sahib is a mechanical engineering graduate from York University in Toronto, born and raised in Nairobi, Kenya. Explore a curated showcase of engineering designs, 3D models, hackathons, and professional experience.

Portfolio Sections & Projects

Home

Section: Home

still working on this
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Save Game

Section: Personal / Art / Save Game

Explore the details, media, and 3D models for the portfolio project: Save Game.
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Sketches

Section: Personal / Art / Sketches

Explore the details, media, and 3D models for the portfolio project: Sketches.
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Quardin's Trophy

Section: Personal / Gifts / Quardin's Trophy

Explore the details, media, and 3D models for the portfolio project: Quardin's Trophy.
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Music

Section: Personal / Music

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Honda of Canada

Section: Professional / Internships / Honda of Canada

Explore the details, media, and 3D models for the portfolio project: Honda of Canada.
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Digibus

Section: Professional / Internships / Master / Digibus

Engineering experience at Master Fabricators a bus manufacturer in East Africa , focusing on transport mechanisms and structure layouts.
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Office Bus

Section: Professional / Internships / Master / Office Bus

Explore the details, media, and 3D models for the portfolio project: Office Bus.
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CubeSat

Section: Professional / Research / CubeSat

Explore the details, media, and 3D models for the portfolio project: CubeSat.
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Resume

Section: Professional / Resume

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This Website

Section: Professional / This Website

# Markdown Test Page This page is for testing how my portfolio renderer handles normal markdown, media lines, buttons, tables, lists, inline formatting, and mixed content blocks. It should feel like a real project page, not just lorem ipsum. ## 1. Basic Text This is a normal paragraph. It should wrap naturally and keep readable spacing between blocks. This paragraph includes bold text , italic text , strikethrough text , inline code , and a . Here is a sentence with a longer line of text to test how the page handles wrapping, rhythm, and spacing when the content becomes more explanatory and less like a short caption. ## 2. Project Summary Block Role: Mechanical design, CAD, prototyping, testing Timeline: May–July 2025 Context: Portfolio renderer test page Tools: Markdown, Google Sheets, JavaScript, media tags Status: Testing The summary block above should be easy to skim. This is the kind of section I would use near the top of a real project page. ## 3. Headings # H1 Heading ## H2 Heading ### H3 Heading A paragraph after headings should not feel cramped. The spacing should make the hierarchy obvious without needing extra styling. ## 4. Lists Unordered list: - First item - Second item with bold emphasis - Third item with a - Fourth item with nested items: - Nested item A - Nested item B - Nested item C Ordered list: 1. Understand the problem. 2. Collect the evidence. 3. Build the first version. 4. Test it physically. 5. Document what changed. ## 5. Table | Version | Change | Result | |---|---|---| | v1 | Basic layout | Proved the idea | | v2 | Added media support | Better visual archive | | v3 | Added clearer writing | More useful for interviews | | v4 | Reduced unnecessary UI | Closer to the intended feeling | Tables should remain readable on mobile and not destroy the page width. ## 6. Quote / Reflection A good portfolio page should not just show the finished object. It should show the situation, the constraints, the decisions, and the proof that I actually worked through the problem. This blockquote should visually separate itself from the normal paragraph flow. ## 7. Code Block js function describeProject project { return { problem: project.problem, role: project.role, evidence: project.media, outcome: project.result }; }
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Autonomous Rover

Section: Professional / YorkU / Coursework / Autonomous Rover

.8 Design of an Autonomous Skateboard Chassis for Parking & Police Enforcement Vehicles Objective: Design a modular, durable, and weather-resistant IP67 autonomous chassis for patrol and automated license plate recognition ALPR . It features a 2:1 chain & sprocket drivetrain, a 12V LiFePO4 battery, a Raspberry Pi edge node for low-level controls, and base station processing over a local Wi-Fi hotspot.
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Mini Rover

Section: Professional / YorkU / Coursework / Mini Rover

Explore the details, media, and 3D models for the portfolio project: Mini Rover.
View Project Detail - Mini Rover
River Cleaning Robot

Section: Professional / YorkU / Coursework / River Cleaning Robot

.8 An autonomous river-cleaning robotic platform designed to collect debris and floating waste from water channels.
View Project Detail - River Cleaning Robot
Rubber Band Car

Section: Professional / YorkU / Coursework / Rubber Band Car

.9 One of my first CAD designs ever. The objective was to design a rubber band-powered car to travel as far as possible by driving both axles with rubber bands and using large wheels to maximize tension and distance traveled per revolution.
View Project Detail - Rubber Band Car
Sun Tracker

Section: Professional / YorkU / Coursework / Sun Tracker

.8 .7 A floating, sun-tracking solar panel system designed to optimize energy capture on water bodies using active tracking. testing
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Wing Flap Mechanism

Section: Professional / YorkU / Coursework / Wing Flap Mechanism

.8 Inboard Trailing Edge Wing Flap Linkage Mechanism Focuses on trailing edge wing flaps on modern aircraft to generate lift and prevent stalls. This scaled-down, Grashof type-1 linkage mechanism has 1 degree of freedom 1-DOF and is actuated using an Arduino Nano and a microservo. ### Actuation Demonstration: ### Ultrasonic Height-Dependent Control:
View Project Detail - Wing Flap Mechanism
SARIT

Section: Professional / YorkU / Research / SARIT

.9
View Project Detail - SARIT
Camera

Section: Professional / YorkU / Research / SARIT / Camera

### May 2025 A series of 3D-printed camera mounts for the SARIT pedestrian detection system, built around OAK-D and OAK-D Pro stereo cameras. assets/ sarit-oakd-camera-mount-installed .jpg : OAK-D camera mounted inside the SARIT frame; the mount had to stay rigid without drilling new structural holes. ## Quick Read - Took over the camera mount project at version 3. - Checked fit, form, and function against the physical camera and SARIT frame. - Finalized v3 documentation in SolidWorks. - Designed an adjustable v4 mount for camera calibration. - Later returned to a simpler static v5 mount for the OAK-D Pro. - Learned a lot about designing 3D-printed parts for clamping, overhangs, and vibration. ## Need The technology team needed a rigid mount for the OAK-D stereo camera used in the pedestrian detection system. The mount had to attach to the SARIT frame without drilling into structural members and without shifting during field use. ## v3 - Finalizing Existing Work The first two versions had been designed in Fusion 360 before I joined. My work started at v3. I checked the existing prototype against the physical camera and the SARIT mounting point, then cleaned up the SolidWorks model. The changes were small but practical: - Removed unnecessary fillets. - Tightened fit tolerances. - Checked assembly clearances. - Created drawings and assembly documentation. - Archived the finished version. ## v4 - Adjustable Mount During development, the detection team needed to physically adjust the camera angle. v4 added tilt and swivel adjustment using mechanical fasteners and friction joints. The goal was a mount that could be loosened with a hex key, adjusted by hand, and tightened again. The hard part was the joint. Too little clamping force and the camera would drift. Too much clamping force and the printed plastic would deform or seize. assets/ sarit-camera-mount-v4 .jpg : Adjustable camera mount prototype; the joint geometry was mostly about balancing adjustment range against clamp stiffness. ## v5 - Static OAK-D Pro Mount Once the camera calibration was stable, the adjustable mechanism was no longer needed. v5 returned to a simpler static mount designed around the OAK-D Pro body. - Clean-sheet SolidWorks model. - Fewer overhangs. - Reduced unnecessary fillets. - Standard 1/4-20 hardware. - VESA M4 holes retained as backup mounting points. - Print orientation chosen to reduce supports. ## What I Would Improve Now I would test joint stiffness more formally instead of relying mostly on hand feel. For a camera mount, small movement matters. A simple vibration or repeatability test would have made it easier to compare versions.
View Project Detail - Camera
Climate

Section: Professional / YorkU / Research / SARIT / Climate

### 2025 An exploratory 12V cabin heater prototype for the orange SARIT, using a compact ceramic heater and a 3D-printed hood intake duct. assets/ sarit-climate-caddy-installed .jpg : Climate Caddy prototype installed in the orange SARIT; the system worked, but the low mounting position limited its usefulness. ## Quick Read - Explored whether a compact 12V heater could act like a small SARIT climate system. - Built CAD around an off-the-shelf ceramic heater from product photos and dimensions. - Added a 3D-printed hood scoop to route outside air to the heater. - Installed and ran the prototype in the orange SARIT / SARIT 8. - Worked in limited cold-weather use. - Not recommended for production. ## Need The heated accessories research looked at seat and handlebar heating. Climate Caddy asked a different question: could a compact heater and intake duct become something closer to cabin climate control? The answer was technically yes, but practically limited. ## Heater The heater was a compact 12V ceramic unit about the size of a large travel mug. It had adjustable louvers and was intended to mount around a cup-holder-style location. No manufacturer CAD was available, so the model was built from Amazon photos and listed dimensions. The mount placed the heater low on the dashboard near knee level. That was the available space, but it meant the heat mostly pointed toward the driver's legs instead of the upper body. ## Hood Scoop The hood scoop was a 3D-printed intake duct that clipped onto the front hood panel and connected to a hose running to the heater intake. The geometry came from a scaled screenshot of the SARIT hood panel. That was not ideal, but it was accurate enough for the prototype. assets/ sarit-hood-scoop-prototype .jpg : Printed hood scoop used to feed outside air to the heater intake; the part proved the idea could be installed without permanent body modification. ## Performance The heater worked, but only within limits. On a cold morning, the cabin felt warmer after a few minutes. At around -5°C it was a real improvement. At around -15°C it was still a winter-jacket situation. In summer, it was just a fan blowing warm air, so it was left unplugged. ## Outcome The prototype showed that a 12V cabin heater and printed intake duct could be installed on SARIT without permanent modification. It also showed the limits: - Low mounting position. - Low airflow volume. - Weak value in warm weather. - Worse cost-to-benefit than heated seats or handlebar grips. The Climate Caddy was not recommended for production. ## What I Would Improve Now I would not start with cabin air heating. For the SARIT cabin size and power level, heating the occupant directly through the seat and grips is probably a better first step than trying to warm the air.
View Project Detail - Climate
Electrical

Section: Professional / YorkU / Research / SARIT / Electrical

### May 2025 to Fall 2025 Accessory electrical architecture work for SARIT research vehicles, including reverse detection, power rails, and diagnostic limits around the ASI BAC2000 motor controller. assets/ sarit-electrical-panel .jpg : Added SARIT electronics around a stock 48V vehicle architecture that was not originally built for research accessories. ## Quick Read - Worked on accessory power questions while supporting camera, hitch, and power-delivery projects. - Documented the 48V, 12V, and 5V power rail structure. - Helped reason through reverse detection for buzzer and camera switching. - Investigated limitations around ASI BAC2000 controller access. - The main constraint was adding research electronics to a vehicle that did not originally provide clean accessory infrastructure. ## System Need Every added SARIT technology needed power. That included cameras, displays, telemetry, pedestrian detection hardware, reverse buzzer behavior, and future sensors. The stock vehicle electrical system was built around the drivetrain, not research accessories. ## Power Rails The working architecture used three main rails. - 48V traction rail: battery, main solenoid, ASI BAC2000 motor controller. - 12V accessory rail: headlights, horn, relay coils, user-facing accessories. - 5V logic rail: ESP32 telemetry, hall sensors, GPS, and signal electronics. One important issue was that an earlier 12V converter configuration stayed live even with the key off because it was wired before the solenoid. That made it a possible contributor to parasitic drain. ## Reverse Detection The SARIT did not have a clean built-in reverse signal output. The team needed reverse detection for two things: - Triggering a reverse buzzer. - Switching the display to the rear camera view. The solution was to tap the signal path between the handlebar forward/reverse switch and the ASI motor controller. The voltage change was too small to drive a relay directly, so a custom amplifier circuit boosted it enough to switch a relay. That relay could then trigger the buzzer and camera display behavior. ## ASI BAC2000 The SARIT drivetrain uses an ASI BAC2000 motor controller. It is capable hardware, but the normal BACDoor configuration software requires OEM or authorized dealer access. That limited what the research team could inspect or change. Without full controller access, some diagnostics became harder: - Internal controller state. - Regenerative braking parameters. - Whether startup current behavior was normal or a fault. - Low-level drivetrain settings. A read-only ASI monitoring app provided some diagnostic visibility without full OEM credentials. ## What I Would Improve Now I would document the accessory electrical architecture as a formal interface earlier. Mechanical projects kept crossing into electrical constraints. A shared interface document would have made camera, buzzer, telemetry, and power work easier to coordinate.
View Project Detail - Electrical
Heating

Section: Professional / YorkU / Research / SARIT / Heating

### 2025 A research specification for heated SARIT accessories, focused on low-risk 12V seat and handlebar heating instead of full cabin climate control. assets/ sarit-heated-accessories-research .jpg : Heated accessory research for SARIT winter use; the recommendation stayed in the documentation stage rather than becoming an installed system. ## Quick Read - SARIT is enclosed but not insulated. - Winter use still leaves the driver sitting in a cold aluminum cabin. - Evaluated heated seat pads and handlebar grip heaters. - Compared 5V, 12V, and 48V accessory options. - Recommended 12V accessories with safety certification. - No procurement or field installation happened. ## Need The SARIT cabin blocks rain and wind, but it does not act like a heated car cabin. For winter users such as maintenance staff, security, or zoo workers, the vehicle can still be uncomfortable for longer outdoor use. The goal was to find a simple heating option that did not require redesigning the vehicle. ## Options The research focused on two accessory types. Seat heating: - USB 5V/2A heated cushions. - Seat-only pads. - Back-and-seat pads. - Low-profile pads under the existing cushion. The sliding seat backrest was the main constraint. Anything attached to the backrest had to move without binding or pulling wires. Handlebar heating: - 12V motorcycle-style grip heaters. - Compatible with the SARIT handlebar layout with minor adapter considerations. - Typical price range was $13 to $64 CAD. ## Voltage Choice | Voltage | Assessment | |---|---| | 5V DC | Safe and easy through USB, but low heat output | | 12V DC | Best product ecosystem and vehicle-accessory fit | | 48V DC | Efficient at high power, but few suitable off-the-shelf products | 12V was the recommendation. ## Regulatory Notes The recommendation was to use CSA/UL certified accessories with built-in safety features such as overheat shutoff and adjustable heat levels. The goal was to avoid modifications that would change the vehicle's regulatory classification. ## Outcome The project stayed in the documentation phase. No parts were ordered and no field test was completed. The recommendation was still useful: if the priority returns, the team has a low-risk path based on removable, certified 12V accessories. ## What I Would Improve Now I would test one seat pad and one grip heater on a cold day before spending more time on product comparison. A short field test would answer the comfort question faster than more documentation.
View Project Detail - Heating
Hitch

Section: Professional / YorkU / Research / SARIT / Hitch

.5 .5 .5 ### May 2025 to July 2025 A fabricated trailer hitch system for SARIT electric three-wheelers, designed so the research fleet could tow cargo trailers without major frame modification. assets/ sarit-hitch-final-with-wike-trailer .jpg : Final Wike trailer hitch installed on the orange SARIT; the design had to clear the frame while allowing the trailer to articulate through turns. ## Quick Read - Designed a new hitch after an earlier design had tilt and documentation issues. - Built a SolidWorks model of the Wike trailer from physical measurements. - Compared pintle, lunette, and ball-mount hitch options. - Used DFM feedback from the machine shop to revise the geometry. - Created BOMs, FEA checks, fabrication drawings, and supplier references. - Machined square tube parts, waterjet bracket plates, printed drill jigs, and installed the final assembly. ## Need The SARIT fleet was being explored as a last-mile delivery platform. To test that properly, the vehicle needed a trailer hitch that could tow lightweight cargo trailers without permanently redesigning the SARIT frame. A previous hitch existed, but it had a nose-down tilt issue and was not documented well enough to reproduce easily. ## Wike Hitch The first trailer was a Wike cargo trailer rated for about 150 lb / 70 kg. No manufacturer CAD was available, so I measured the physical trailer and built a SolidWorks model to use as the design reference. The hitch went through four main versions: - v1 compared hitch types and established the ball-mount direction. - v2 added DFM changes and early FEA. - v3 developed the full BOM with part numbers, materials, masses, and supplier references. - v4 changed the SARIT-side bracket to 6061 aluminum to reduce weight and avoid galvanic corrosion against the SARIT frame. ## Fabrication The fabrication week was July 14 to 18, 2025. I machined the square tube components on the mill at the Bergeron machine shop and cut steel bracket plates on the water jet. Drilling into the SARIT frame needed a 3D-printed drill jig. I also printed nut carriers because some fasteners had to be held inside hollow aluminum frame sections where a wrench could not reach. assets/ sarit-hitch-drill-jig .jpg : Printed drill jig used to locate mounting holes on the SARIT frame; this was needed because the frame geometry was not easy to mark accurately by hand. assets/ sarit-hitch-nut-carriers .jpg : Nut carriers for holding fasteners inside the hollow frame, solving an access problem that only showed up during physical test fitting. ## Impact Hitch After the Wike hitch, the team acquired a MotoAlliance Impact trailer rated for about 1,500 lb. The second hitch was faster because the workflow was already established: measure, model, simulate, review, build. The scale changed the design: - Thicker tube walls. - Larger fasteners, moving from 1/4 in to 3/8 in. - 2 in tow ball / receiver hardware. - Heavier trailer geometry and higher load assumptions. ## Outcome Both hitches were completed and deployed. By early 2026, the orange SARIT had a functional hitch and five assembled Wike trailers were staged in the Bergeron courtyard. ## What I Would Improve Now I would document the physical installation steps more thoroughly, especially the fastener access problems inside the frame. The nut carriers were a useful fix, but they were discovered late. I would now treat wrench access and installation sequence as part of the CAD review, not something to solve after fabrication.
View Project Detail - Hitch
LiDAR

Section: Professional / YorkU / Research / SARIT / LiDAR

### July 2025 to Oct 2025 A rotating LiDAR mount concept for a Garmin LIDAR-Lite v3 sensor, focused on vibration control, bearing preload, and slip-ring-ready wiring. assets/ sarit-lidar-mount-v1 .jpg : First printed LiDAR mount prototype; the physical print exposed fit and rigidity questions that were not obvious in CAD. ## Quick Read - Started after the trailer hitch project wrapped. - Designed around a Garmin LIDAR-Lite v3 sensor. - Main issues were vibration, repeatable rotation, and wire routing through a rotating joint. - Identified slip ring need for continuous rotation. - Built v1 physical prototype. - Iterated v2 around bearing preload and rigidity. - Project stopped when team priorities shifted to power delivery. ## Need The technology team was integrating a Garmin LIDAR-Lite v3 sensor for object detection and distance measurement. The mounting problem was different from the camera mount. LiDAR data quality depends on the sensor staying rigid and repeatable. If the mount rotates, small wobble becomes angular error. ## Research The first phase was BOM and mechanism research. Key findings: - Vibration can be reduced with TPU pads, rubber grommets, or mechanical isolation. - Continuous rotation needs a slip ring for power and signal. - The sensor had six wires, which made slip-ring routing manageable. ## v1 Prototype The first CAD version was completed in early August 2025 and printed as a PLA prototype. The print was not intended as final material. It was a fast physical check before committing to PETG, nylon, or another stronger material. Having the prototype in hand made the rigidity and assembly issues easier to see. ## v2 - Bearing Preload v2 focused on bearing preload. Without preload, even a good bearing can have small play. In a rotating LiDAR mount, that play becomes measurement error. The challenge was designing preload into a printed assembly: - Small forces. - Tight tolerances. - Plastic creep under sustained load. - Assembly sequence had to stay reasonable. I spent about three weeks refining the geometry, improving rigidity, and simplifying the assembly. At one point the CAD assembly became hard to edit because of suppressed features and interdependent sketches, so I rebuilt it from scratch. ## Outcome The project was discontinued in early October 2025 because the Power Delivery System became more urgent. The v1 prototype and v2 CAD were archived. The work was still useful: the bearing preload problem had a design direction, the slip ring need was identified, and the next person would not be starting from zero. ## What I Would Improve Now I would build a simple wobble test fixture earlier. For a rotating sensor mount, the useful measurement is not just whether the part fits. It is how much angular movement exists under load.
View Project Detail - LiDAR
Mirrors

Section: Professional / YorkU / Research / SARIT / Mirrors

### 2025 A side mirror mount project for SARIT vehicles, designed to raise and extend magnetic mirrors for better rear visibility without permanent body modification. assets/ sarit-side-mirror-v5-installed .jpg : Final side mirror mount on the orange SARIT; the design raised the mirror while avoiding permanent changes to the door panel. ## Quick Read - Stock SARIT mirrors sat low on the door and had poor sight lines. - Designed a raised/extended mount for magnetic tractor mirrors. - Iterated through five versions. - Main constraints were thin aluminum door panels, folding/stowage, and print durability. - A printed detent failure led to a metal insert revision. - v5 became the version recommended for wider use. ## Need The stock SARIT mirrors were small, fixed, and mounted low on the door panels. They were useful for seeing the ground behind the vehicle, but less useful for seeing cyclists, pedestrians, or traffic approaching from behind. The problem was worse for taller drivers and during reverse operation. ## Mirror Choice The mirror was a KEMIMOTO magnetic tractor mirror. It was not a custom part, which was the point. - Rubber-coated magnetic base. - 114 lb holding force. - Originally for tractors and forklifts. - Available cheaply on Amazon. - Same-day replacement possible. That mattered because mirrors could be stolen or damaged. A mirror that can be replaced immediately is easier to support than a custom part with a long lead time. ## Design Constraint The SARIT door frame is thin-walled aluminum. Any clamp-on mount had to spread load over a wide area so tightening the mount did not deform the door panel. ## Versions - v1: basic extended arm, PLA proof of concept. - v2: folding hinge added, but hinge slop made the deployed position feel unstable. - v3: ball-and-socket detent for deployed and stowed positions. - v4: metal insert added after the printed socket wore/seized. - v5: reduced material, cleaner clamp geometry, support-free print orientation. assets/ sarit-mirror-detent-failure .jpg : Earlier detent version after field use; the printed socket wore and seized, which pushed the design toward a metal insert. ## Outcome The v5 mount was used on the orange SARIT and recommended to Elvy as a possible production accessory. ## What I Would Improve Now I would test the detent through repeated temperature cycles before field use. The failure was not obvious in a static fit check. It showed up after real use, which is exactly the kind of thing a small durability test could catch earlier.
View Project Detail - Mirrors
Power

Section: Professional / YorkU / Research / SARIT / Power

### Fall 2025 to Jan 2026 An investigation into SARIT parasitic battery drain, leading to a proposed charger-isolation contactor and a current-monitoring "digital fuse box" architecture. assets/ sarit-battery-compartment .jpg : SARIT battery and electrical compartment; the drain problem came from parked vehicles losing charge without being driven. ## Quick Read - Investigated why SARIT vehicles lost charge while parked. - Compared immediate post-charge range against range after 72 hours parked. - Found a drop from about 15 km to about 6 km after sitting with the charger connected but unplugged. - Estimated continuous parasitic draw around 100-200 mA. - Ruled out BAC2000 inrush current as the drain source. - Proposed charger isolation with an AEV250-G contactor. - Proposed an I2C current-monitoring system across the 48V, 12V, and 5V rails. ## Problem The SARIT fleet had a range problem that was not caused by driving. A vehicle charged for one hour could drive about 15 km immediately. But after sitting for 72 hours with the charger physically connected to the battery and unplugged from the wall, the same charge cycle produced only about 6 km of range. | Condition | Charge time | Idle time | Resulting range | |---|---:|---:|---:| | Baseline | 1 hour | 0 hours | 15 km | | Drain test | 1 hour | 72 hours | 6 km | That suggested a parked parasitic drain. ## Investigation A clamp meter was the first tool tried, but it was not useful at the current levels involved. The readings fluctuated between about -0.1A and 0.2A, which was too noisy for milliamp-level leakage. Large 10-30A spikes appeared when reconnecting the battery, but those were a red herring. They matched the ASI BAC2000 motor controller input capacitance charging up, not a continuous drain. The useful test was disconnecting the onboard charger from the battery terminals. After that, the measured drain dropped to zero. The working hypothesis became charger back-feed: the battery was slowly discharging through the charger's internal circuitry when the charger was connected to the battery but unplugged from the wall. ## Proposed Fix The immediate fix was to isolate the charger from the battery when the vehicle was parked. The proposed part was an AEV250-G contactor: - SPST normally open. - 48-72VDC coil. - 500A rating for capacitive inrush. - Coil economizer draw around 0.03A at 48V. ## Digital Fuse Box The longer-term proposal was a current and voltage monitoring system across each rail. | Component | Part | Purpose | |---|---|---| | I2C power monitor x4 | Adafruit 5832 / INA228 | Monitor battery, 12V, 5V, and 48V rails | | Traction current sensor | Allegro ACS758-200B | Isolated current sensing on the motor rail | | DC shunt | FL-2-100A / 75mV | Main battery negative measurement | | STEMMA QT cables x4 | Adafruit 4401 | I2C daisy-chain wiring | Estimated BOM cost was $124.02 CAD. Assigned I2C addresses: - 0x40 main battery. - 0x41 12V rail. - 0x44 5V rail. - 0x45 48V rail. ## Handoff In January 2026, the project was handed off for KiCad formalization. The intended schematic structure was: - Traction 48V. - Accessories 12V. - Logic 5V. - Current sensors and shunt footprints. ## What I Would Improve Now I would repeat the drain test with a proper inline current measurement setup earlier. The clamp meter was useful for proving what did not work, but the actual problem needed lower-current instrumentation from the start.
View Project Detail - Power
De-Icing Robot

Section: Projects / Hackathons / De-Icing Robot

.7
View Project Detail - De-Icing Robot
Gaming Chair

Section: Projects / Hackathons / Gaming Chair

.8
View Project Detail - Gaming Chair
Ontario Engineering Competition

Section: Projects / Hackathons / Ontario Engineering Competition

Explore the details, media, and 3D models for the portfolio project: Ontario Engineering Competition.
View Project Detail - Ontario Engineering Competition
Thermoelectric Cooler

Section: Projects / Hackathons / Thermoelectric Cooler

Explore the details, media, and 3D models for the portfolio project: Thermoelectric Cooler.
View Project Detail - Thermoelectric Cooler
Goose 4

Section: Projects / Rocketry / Goose 4

Explore the details, media, and 3D models for the portfolio project: Goose 4.
View Project Detail - Goose 4
Rover

Section: Projects / YURS / Rover

.9
View Project Detail - Rover
CIRC 2023

Section: Projects / YURS / Rover / CIRC 2023

Explore the details, media, and 3D models for the portfolio project: CIRC 2023.
View Project Detail - CIRC 2023
CIRC 2024

Section: Projects / YURS / Rover / CIRC 2024

Explore the details, media, and 3D models for the portfolio project: CIRC 2024.
View Project Detail - CIRC 2024
eStop Mount

Section: Projects / YURS / Rover / eStop Mount

Explore the details, media, and 3D models for the portfolio project: eStop Mount.
View Project Detail - eStop Mount
Gripper

Section: Projects / YURS / Rover / Gripper

.9 : Version 7. Served two years and three international competitions with YURS, at the 2023 Fall, 2024 Winter, and 2024 Fall . ### May 2023 to Aug 2023 A low-cost modular rover gripper built around reused lead screws, scavenged old rover hardware, machined aluminum parts, and 3D-printed task-specific pads. This was my first contribution to the mechanical subteam at the rover team. ## Quick Read - Built a low-cost rover end effector for CIRC-style manipulation tasks. - Reused old rover lead screws, motor hardware, aluminum stock, and printed parts instead of buying a new mechanism. - Iterated through seven versions, from a CAD 400 McMaster concept to a final machined/printed assembly. - Designed around swappable task pads, printed gears, wire routing, camera/laser mounting, and competition repair constraints. - Bench-tested grip behavior and estimated lead-screw clamp force, but did not measure actual grip force with a load cell. - Mounted on the rover, though the full rover arm/control stack was not stable enough for a clean competition task demo. ## Team Need The rover needed an end effector for , not just a generic open-close claw. The end effector had to handle several different task objects without becoming expensive, heavy, or hard to rebuild between events. ## Requirements - Grab and lift 4 inch PVC pipe. - Press buttons. - Hook or latch onto loops. - Turn a ball valve. - Switch on a water pump. - Handle unknown “uranium rod module” geometry. - Leave room for possible tool or soil-collection attachments. : The “uranium rod modules” at competition. The geometry was not something I could design around exactly, so the gripper needed some tolerance for unknown shapes. : The astronaut plushy rescue task was one reason the gripper had to close around soft, awkward objects instead of only rigid parts. ## Constraints - Keep the cost low, ideally under CAD 70. - Reuse old rover hardware where possible. - Avoid relying too much on 3D-printed load-bearing parts. - Machine only a small number of aluminum parts. - Make the task pads swappable instead of redesigning the whole gripper for every task. - Keep printed parts small enough to use the university Sandbox print service when possible. The first few versions were mostly about finding a mechanism that could do the job without becoming expensive or hard to machine. ## Iterations : v1 was the expensive McMaster version. It helped define the mechanism, but it was not realistic for the team budget. ### v1 - McMaster Version - Left-handed lead screw. - Double-shaft worm gearbox 12V DC motor. - Mostly McMaster-Carr parts. - Around CAD 400 before tax and shipping. - Dropped because the cost and left-handed hardware sourcing made no sense. ### Found Parts v1 was too expensive, so the project changed direction during the annual hangar cleanup. : Parts found during the annual hangar cleanup in the Bergeron Centre. This changed the project from a McMaster-Carr shopping list into a reuse-what-we-have gripper. The hangar was the garage/workspace we used in the Bergeron Centre at YorkU. While cleaning it out, we found old rover hardware that could be reused for the gripper. That changed the design completely. Instead of buying a left-handed lead screw, worm gearbox, and new hardware, I started designing around what was already in the room. - Motor from the 2022 gripper. - Lead screw from the 2022 wrist. - Existing aluminum stock. - Existing linear bearings / guide hardware. - Printed parts only where they made sense. : v2 was the first serious low-cost version, built around reused rover parts and two right-handed lead screws. ### v2 - SolidBugs - Two right-handed lead screws, made by cutting the reused lead screw into two pieces. - Printed gears inverted one side so the two sides could move together. - Motor from the 2022 gripper. - Interchangeable printed task pads. - Almost CAD 0 except bearings and bolts. - Dropped because the SolidWorks assembly became unreliable. : v3 simplified the gear and shaft-coupler interface instead of treating the printed gears as separate parts. ### v3 - Coupler Gear Version - Printed gears built around available shaft couplers. - Orange PLA parts for gears and pads. - Still needed bearings. - Kept the two-lead-screw layout. - Main goal was to reduce part count and make assembly easier. : v4 to v6 were mostly buildability iterations: bearing fits, shaft retention, CAD rebuilds, drawings, printed gears, and the first moving assembly. ### v4-v6 - Making It Buildable After v3, the main mechanism did not change as much as the CAD and fabrication details did. I kept restarting the assembly because each rebuild made the layout cleaner. At the time, every version felt like the cleanest one I could make, then I would start over and find a simpler way to constrain the parts or package the mechanism. - Kept the two right-handed lead screw layout. - Reworked the printed gear and shaft coupler interface. - Worked through linear bearing fits and shaft retention. - Updated the CAD around the actual scavenged parts. - Prepared drawings and STLs. - Moved from CAD to six machined aluminum parts. - Reached the first moving proof of concept. The first moving version used the 2022 wrist lead screw cut into two pieces, about 14 cm and 16 cm long. Those were mounted to opposite-rotation gears so both moving jaw bodies travelled together. ## v7 - Final Version : v7 was the final integrated version. It kept the reused lead screw mechanism, but cleaned up the packaging, covers, mounting points, and printed task geometry. v7 was the version that actually got built and stayed with the rover. At this point the mechanism was mostly settled: two lead screws, printed gears, machined structure, and swappable task pads. The main change was making the assembly easier to build, mount, wire, and maintain. I originally made the moving jaw bodies from aluminum. After machining them, I realized that was not a useful place to spend weight. The printed gears, budget, and packaging mattered more than making every visible part metal. : Earlier moving jaw bodies were machined from aluminum. After making them, I realized they were heavier than they needed to be and were not the part most likely to fail first. : First full assembly. The main structure was machined aluminum, while the orange printed parts handled gears, task pads, covers, and adaptable geometry. The final design was less about making every part stronger and more about putting strength where it mattered. - Two reused lead screws. - 3D-printed gear set. - Swappable printed task pads. - Machined aluminum structure. - Printed moving jaw bodies instead of aluminum ones. - Central cover around the exposed gear area. - Zip-tie holes for wire routing and competition fixes. - Mounting points for camera, laser, and tool ideas. - Motor encoder available, though it was not used in the final control setup. The center cover was partly there to close the open gap around the gears. It also became a useful place to mount or route small things. I added holes because competition hardware always ends up needing last-minute wire routing, strain relief, or temporary fixes. Zip ties were the realistic answer. The task pads also had large openings so a valve handle could fit through them. The idea was to close around the handle and use the wrist rotation to turn the valve. ## Grip Testing : Crude grip test. I was watching motor current as a rough signal for when the gripper had contacted the object and was clamping hard enough; this was not a calibrated force test. ### Grip Force Estimate I did a rough lead-screw force estimate before the first full assembly. The assumptions I wrote down at the time were: - 29 kgf-cm motor stall torque. - T8-style 8 mm lead screw. - 2 mm lead used in the original estimate. - 0.1 assumed friction coefficient. Using those assumptions, I estimated about 362.5 kgf of clamping force at the moving jaw body. Later, after more assembly work, I described the design as roughly 300 kgf of grip force. I would treat both numbers as rough theoretical estimates, not measured results. The basic idea was that motor torque gets converted into axial force by the lead screw. $ F = \frac{2 \pi T}{l} $ A more realistic power-screw estimate includes thread friction: $ T = F \frac{d m}{2} \left \frac{l + \pi \mu d m}{\pi d m - \mu l} \right $ Where: - T is motor torque. - F is axial force from the lead screw. - d m is mean screw diameter. - l is lead per revolution. - μ is the friction coefficient. I used the nominal 8 mm screw diameter in the original estimate. A more careful calculation would use the thread mean diameter and would check the actual screw efficiency, so I would not present the 362.5 kgf number as a measured or verified result. I also need to verify whether that screw was single-start or multi-start. The equation uses lead per revolution, not just thread pitch, so this assumption matters a lot. The important part is that I checked the order of magnitude and realized the mechanism could generate much more grip force than the printed parts or task objects probably needed. What I should have done next was test it with a load cell between the pads and record actual grip force against motor current. The motor had an encoder, so position feedback was physically available. It was not used in the final rover setup because the interface did not match what the electrical/software side was using at the time. : Unfinished but useful test. The part that failed was not the gear train; the printed jaw body walked off the brass lead screw nut because I had not screwed it in yet. I'm recording this video. The printed gears were still something I worried about. I had to use printed gears because proper gears did not fit the budget, and I printed spares in case they failed at competition. By the final version, they held up better than I expected. ## Integration The gripper was mounted to the rover and tested separately for opening and closing. It was physically ready enough to reach the rover, but using it in a task depended on the rest of the arm and rover stack being ready too. : Gripper mounted during a 2023 CIRC indoor panel task. This is not a clean gripper demo; it shows the rover trying to approach the task panel while the full arm, wrist, drive, and control stack was still being debugged. I never got a clean competition run where the gripper completed a task. That was disappointing, but it is also a normal systems problem. The gripper depended on the drive base, arm, wrist, wiring, power, motor controllers, and software all working at the same time. The electrical and software teams were working through custom Vroom motor controllers, CAN communication, drive reliability, circuit protection, power issues, and later Spark MAX controllers for the arm. For this page, the honest outcome is that the gripper reached the rover, but the full rover was not stable enough to show it properly in a competition task. ## What Changed The biggest change was going from a bought-parts design to a found-parts design. The second biggest change was realizing that metal was not automatically better. Some parts needed to be machined aluminum. Other parts were better as printed geometry because they were lighter, faster to replace, and easier to adapt for tasks. The final gripper was not the design I would make with more time and money. It was the design I could actually build with the team’s budget, tools, and timeline. ## What I Would Improve Now I would measure the actual gripping force instead of relying on a theoretical lead-screw calculation. I would use a load cell between the task pads and record force against motor current, so the current limit could be based on real data instead of a rough bench test. I would also spend more time on integration earlier. The gripper had an encoder available, but it was not used. If I were doing it again, I would define the electrical and software interface earlier instead of treating the gripper mostly as a mechanical object. I would still keep the swappable task pads. That part of the design made sense. The rover tasks were too varied for one fixed jaw shape, and changing printed pads was much cheaper than redesigning the whole gripper.
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Resin Wheels

Section: Projects / YURS / Rover / Resin Wheels

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URDF

Section: Projects / YURS / Rover / URDF

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SumoBot

Section: Projects / YURS / SumoBot

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