Dmitry Yudovsky

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Dmitry Yudovsky

• Project Portfolio,
• Fall 2002 through Fall 2006

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Project Portfolio

• Lawrence Livermore National Laboratories, Summer
  2006
• KDP Crystal Mitigation Machine for the National
  Ignition Facility
• UCSD, MAE156B, Winter 2006
• Z-Microsystems Server Cooling. Corporate
  Sponsored Project
• Lawrence Livermore National Laboratories, Summer
  2005
• Numerical Optimization of High Pressure
  Containers
• Applied Materials, Inc Electro Copper Plating
  Group, Summer 2004
• Bubble removal from Liquid Delivery System
• Applied Materials, Inc Chemical Mechanical
  Planarization Group, Summer 2003
• Metrology Unit Validation
• Improvement to Factory Automation Software
  Development Process
• San Diego Supercomputer Center, Spatial
  Information Systems Laboratory
• GIS HTML Viewer

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Lawrence Livermore National Laboratories.Manufact
uring and Materials Engineering Division

KDP Crystal Mitigation Machine for the National
Ignition Facility (NIF) Architecture and HMI
Development Summer, 2006
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Lawrence Livermore, 2005. Page 1
Problem Statement

• Background
• NIF (the National Ignition Facility) optics are
  made up of optically interesting KDP crystals.
  Unfortunately, after every shot, these crystals
  develop surface damage. This damage propagates
  and ruins the optic during subsequent laser
  shorts.
• Purpose
• Crack mitigation on KDP crystals.
• Extend life of 30k crystal 10-fold by removing
  surface cracks caused by laser damage

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Lawrence Livermore, 2005. Page 2
Methods - Hardware
Method Build a high precision diamond ball
end-mill to remove the specified volume.
camera
flexure
KDP
End-mill
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Lawrence Livermore, 2005. Page 3
Methods Software architecture
interface
Pressure switches
MDI G Code
2 Stepper motor Servo motor 2 linear drives
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Lawrence Livermore, 2005. Page 4
Methods Software architecture
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Lawrence Livermore, 2005. Page 4
Results
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UCSD, Mechanical and Aerospace Engineering Course
156B

Z-Microsystems Server Cooling Improvement Corporat
e Sponsored Project Winter 2006
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UCSD MAE 156B Project. Page 1

• SPONSOR
• Z Microsystems
• Leading The Evolution In Field-Ready
  Computing.
• Design Manufacturing of Rugged Computer
  Hardware.
• PURPOSE
• Sealed Computer Module (SCM) is overheating.
  Develop a cooling system that is passive and
  rugged. It must keep the internal temperature at
  25ºC above ambient

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UCSD MAE 156B Project. Page 2
HARDWARE CONFIGURATION
Proposed Design

• IMPROVEMENTS
• Eliminates About 50 of The Thermal Resistance
  Interfaces.
• Doubles The Effective Surface Area Of The Top
  Panel And Localizes It Above The CPU.
• Modifies Top Panel To Increase Airflow
• ADVANTAGES
• Passive Cooling
• Does Not Require Refrigerants or Liquids.
• Has Zero Degrees Of Freedom

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UCSD MAE 156B Project. Page 3

• SIMULATION RESULTS
• Heat Sink Optimization for fin spacing (A) and
  thickness (T) . Coded in Matlab.

Sweet Spot
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UCSD MAE 156B Project. Page 4

• TEST RESULTS
• At 100 system load and 23ºC ambient
  temperature
• SCM internal temperature rises by 23ºC from
  ambient
• CPU core temperature rises 34ºC
• Spec requirement met

PROTOTYPE
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Lawrence Livermore National Laboratories.New
Technologies Division

Numerical Optimization of High Pressure
Containers Summer, 2005
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Lawrence Livermore, 2005. Page 1
Problem Statement

• Purpose
• Optimize cylindrical, multilayered high pressure
  vessels for ultra-high speed wind tunnel
• Background
• Various techniques exist for raising the overall
  strength of vessels (such as cannons, or
  canisters). This includes increasing the strength
  (and cost) of materials, shrink fitting
  concentric shells, and over straining
  (autofrettaging) shells. An optimal assembly with
  shrink fitting and autofrettaging can be found.
• Challenges
• Multivariable optimization problem with many
  non-linear constraints. Numerically, negative
  radii might be great, but the solution must be
  kept realistic.
• Method Choose
• Gradient projection method. Find steepest
  descent and project it on the set of active
  constraints.

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Geometrical configuration of problem
Lawrence Livermore, 2005. Page 2
more shells
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Numerical Optimization Using Gradient Projection
Method
Lawrence Livermore, 2005. Page 3

• Definitions
• Active set the set of currently enforced
  constraints
• Inactive set set of constraints that, when
  violated, become active
• Process
• Find cost function gradient
• Select active constraints
• Project gradient onto active set
• Go down projection

gn(x)lt0
gn(x)0
Breach step
Inequality constraint
Projected gradient
gn(x)gt0
Iterative downhill search
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Graphical User Interface
Lawrence Livermore, 2005. Page 4
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Calculation Results
Lawrence Livermore, 2005. Page 5
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Applied Materials, Electro Copper Plating Group
Bubble removal from Liquid Delivery
System Summer 2004
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Problem Statement
Applied Materials, 2004. Page 1

• Purpose Bubbles form in a high pressure
  chem-delivery line. These are detrimental to the
  subsequent process.
• Background Degassers are commercially available
  however these bubbles are caused by a chemical
  reaction, not dissolved gas. So a bubble trap is
  required.
• Challenges Waste, startup time, and installation
  and maintenance costs must be minimized. This
  would be an upgrade to existing systems.
• Method Utilize the disparity between liquid to
  surface interaction.

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Bubble Trap Concept
Applied Materials, 2004. Page 2
waste
Ideal bleed hole case
delivery
bubbles float up
surface tension
pressure force
Find r to balance the two
clean liquid
s 0 for gas
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Bubble Trap Implementation
Applied Materials, 2004. Page 3
Exit to atmospheric pressure
Ended up using long, very thin inner diameter
tube. Friction (and some surface tension) effects
counteracted the pressure force and allowed
liquid to bleed at a prescribed rate, but gas to
escape very quickly.
Hagen-Poiseuille
µ very small for gasses
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Applied Materials, Chemical Mechanical
Planarization Group

Metrology Unit Validation Summer 2003
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Problem Statement
Applied Materials, CMP, 2004. Page 1

• Purpose Applied Materials CMP leads the world in
  wafer planarization. However, it only makes a
  crude, in process metrology unit to test the
  quality of the polishing. External metrology must
  be performed this is done by third part units.
  CMP System Integration was validating two
  competitors. My function was to test to
  stability, functionality, and compatibility of
  the this unit with our CMP hardware and software.
• Challenges
• Two teams from different corporate cultures
• Third party unit still in beta phase
• Time constraints
• Accomplishments
• Prepared and implemented test scenarios
• Found and helped fix many bugs

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CMP Process
Applied Materials, 2004. Page 2
front end
back end
crude in-process metrology occurs during polishing
wafers container
back-end processes
polishing process 1
polishing process 1
passed
polishing process 1
polishing process 1
cleaning process
failed
metrology validation
Unit of interest
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Applied Materials, CMP Group
Improvement to Factory Automation Software
Development Process Summer 2003

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• Purpose Optimize the software development (SW)
  process dealing with factory automation (FA).
• Background FA for a complex machine requires
  keeping track of 1000s of events, status
  variables, errors, logging variables, and
  controllable variables in the operating system of
  the machine. Naming and numbering of these data
  variables requires careful planning no two
  events can have the same logical address. At
  Applied Materials CMP SW, a software package
  simplifies the actual C coding by generating
  most of the header files and event handling
  functions. The input to this preprocessor is a
  syntax based language, GCD, where each datum is
  defined. The file was, in turn, generated from
  other files written by different members of the
  SW team in Excel, Perl, VB, or just text. This
  decentralized process was very cumbersome and
  slow.
• Solution Create a one-source database (DB) that
  the entire SW team could share. The DB would be
  locked to one user at a time to prevent
  collisions, control number ranges, and allow for
  easy import from and export to any standard or
  user defined format.

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San Diego Supercomputer Center, Spatial
Information Systems Laboratory

GIS HTML Viewer Development Spring 2002
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SDSC, 2002, Page 1
Problem Statement

• Purpose Develop a web-based graphical user
  interface for a Geographical Information System
  (GIS) database.
• Background GIS is a useful tool for decision
  making. It facilitates the graphical
  representation, superposition, and spatial
  querying of data.
• Method Use XML, JavaScript, and DHTML to
  accomplish the said goal.

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SDSC, 2002, Page 2
GIS Overview
GIS Geographic Information System
GIS database
Map generator
SQL
XML
Browser, JavaScrpit, DHTML
Images, data
Vector data
User interacts with GIS database through an HTML
viewer. This viewer must be portable over many
platforms. And it must be pretty.
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SDSC, 2002, Page 3
Old Style Viewer
layer list is unstructured
static toolbar with limited featurs
query results in pop-up window
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SDSC, 2002, Page 4
New Style Viewer
dynamics and hierarchal layer list
minimize/move features added to windows
dynamic legend
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UCSD Structural Engineering Department, Professor
Ahmed Elgamal
Satellite Based Structural Healthmonitoring of
the Vincent Thomas Bridge Ongoing

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UCSD Structural Engineering, Page 1
Project Overview Vincent Thomas Bridge

• Purpose Build a a remote structural health
  monitoring system. Prove that off- the-shelf
  components can be used to do remote data
  gathering.
• Schematic

On bridge
In lab
Data flow schematic
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UCSD Structural Engineering, Page 2
Project Overview

• Sensors
• Temperature, surface, and air
• Camera
• Accelerometer
• (red dot indicates approximate location)
• Extensive Collaboration
• UCSD Structural Engineering
• CalTrans
• Hughes Network Systems
• San Diego Super Computer Center
• Potential
• New, more complex testbeds
• Temperature to frequency response correlation

http//healthmonitoring.ucsd.edu/
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UCSD Structural Engineering, Page 3
Results Thermal Data

• Data for May 2005 through February 2006

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UCSD Structural Engineering, Page 5
Results Camera Data
Sunrise
Single Frame
http//healthmonitoring.ucsd.edu/vtb/remote/vtb_re
mote_imaging.jsp
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UCSD Structural Engineering Department, Professor
Ahmed Elgamal
Remote Structural Healthmonitoring of Voigt
Bridge Ongoing

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UCSD Structural Engineering Voigt Bridge
UCSD Structural Engineering, Page 1

• Purpose Monitor Voigt Bridge with accelerometers
  and a camera
• Methods A camera is used to determine the
  location of a vehicle on a bridge. A network of
  accelerometers monitors the excitation cause by
  this vehicle along the bridge. Thus we know the
  location of the load and the excitation.

http//healthmonitoring.ucsd.edu/voigt.jsp
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UCSD Structural Engineering, Page 2
Vehicle Tracking over Voigt Bridge