The Design Portfolio - of - Justin Ketterer

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The Design Portfolio - of -Justin Ketterer

• He that invents a machine augments the power of
  a man and the well-being of mankind."
• -
  Henry Ward Beecher, 1887

http//justinketterer.com
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The Juicenami

• Assignment design and build a machine which
  accomplishes a task of your choice. It must
  incorporate a four-bar linkage, a gear, and a
  cam.
• My design solution The Juicenami
• I led the design and construction of a device
  which opened a canned beverage, poured it into a
  cup, and deposited a reasonable amount of ice in
  the cup. The device
• Secured a cup and the canned beverage.
• Employed two perpendicular shafts.
• One shaft served as one linkage in an offset
  slider-crank. The slider-crank drove a metal
  punch on rails which punctured the can. The
  opposite end of this shaft also served as the
  hand-crank for actuation of the system.
• The other shaft, perpendicular to the first and
  driven by a gear, served as a camshaft which
  drove a two-stage door system which measured out
  portions of ice, dropped into the cup through a
  metal chute.

Ice Reservoir
Two-Stage Door System
Cams
Canned Beverage
Hand Crank
Gears
Metal Punch
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The Juicenami, cont.

• The following projects will show concept sketches
  and iterative development of the device sketches
  for this project were submitted to the Professor
  and could not be retrieved for inclusion here.
• Results
• Continuously served beverages with the device for
  several hours at the Design Day competition.
• First Place for Mechanical Design award.
  Third Place, Kids Choice Award.

Design details permitted rapid adjustment of cam
and gear timing (details marked).
Aluminum Ice Chute gravity drives transfer of
ice from reservoir to cup.
A two-stage cam-driven door measured a reasonable
amount of ice into the cup.
Ice Reservoir
Ice Reservoir
Ice Chute
Door One
Intermediate Ice Chamber
Rubber bands for door retraction
Door Two
Cup
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Human-Powered Water Purifier

• Assignment build a human-powered water
  distillation machine which could convert
  polluted (food colored) water to fresh water.
• My design solution a pedal-powered,
  friction-based device.
• Major design constraint a human generates a
  surprisingly small amount of energy, relative to
  energy required to boil an appreciable amount of
  water ? The design must minimize energy losses!
• Electrical generators and heating elements have
  significant energy efficiency issues. Friction
  directly converts mechanical energy to heat
  without intermediate steps and their associated
  inefficiencies Bicycle drive-train can have
  losses of less than 2 of input energy An
  outline for an efficient concept emerges.
• I developed a concept which used two wooden disks
  spinning against either side of a small aluminum
  drum to heat the water inside. Evaporated water
  exited and condensed outside the drum via copper
  tubing.

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Water Purifier Major Systems
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Selected Sketches from Water Purifier Project
Development
CONCEPTUAL
DETAIL
EMBODIMENT
Heating Device
Pedals
Pedals
Heating Device
Intermediate Shaft
DRIVE TRAIN
Heating Drum
Threaded rod / bolts press friction pads onto
sides of drum.
Intermediate Drive Shaft
H20 HEATER
SHAFT DESIGN
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Frictional Force Concepts Project Results
Early concepts involved applying force through
the drive shaft or via a conically shaped
rotating element. These were mechanically
infeasible and would have been difficult to
fabricate and adjust.
The frictional force mechanism needed to apply a
variable normal force at the drum, subject a
minimum number of components to stress, and be
easy to fabricate. This concept was the first to
get close to satisfying those requirementsbut
would still have been difficult to fabricate
Iterative revelation C-Clamp Lazy Susan
Bearing!
This is the form which the final frictional
mechanism took Spanning bolts and thrust
bearings give a linear, balanced force system.
This eliminated the problems of bending forces,
which the concept in the image above may have
suffered from.

• Results
• Water reached a boil in less than one minute of
  pedaling.
• Design flaw restrictive distillation tubing
  caused polluted water to boil out of the heating
  chamber, polluting the distilled fresh water.
• Lessons learned uncertainties about design
  features must be counteracted by flexible or
  conservative designs.

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M1A3 Sparty Tank

• Assignment design and build a robot that can
  roll around and interact and talk with Michigan
  State University sports fans during sporting
  events.
• My design solution
• The initial concept suggestion by the project
  sponsor was infeasible given the four-month
  project window and the technical difficulties
  inherent to creating a humanoid robot. For any
  design scenariobut particularly in a case like
  thisit is important to work with the customer to
  define the fundamental need which he wishes to
  satisfy. I identified that crowd entertainment
  was the crux of this task.
• Based on this key goal, I proposed a remote
  controlled battle tank which could roll around
  during games and shoot t-shirts to the crowd with
  a pneumatic air gun. The sponsor loved the idea.
• More than any other design project I have done,
  this required attention to planning, conceptual
  iteration, sourcing of material, and fabrication
  work with machine tools. More than any other
  project I have done, I had fun!
• Google M1A3 Sparty Tank for more information.

Iterative C.A.D. Development
Final Product!
Initial Concept Sketch
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M1A3 Sparty Initial Concept Embodiment
Drawings
Systems Integration Chassis Design
Barrel Designs
Hub Designs
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M1A3 Sparty Tank, cont.

• In this project, I learned the importance of the
  designer focusing efforts at the level of detail
  which the complexity of the project permits him
  to accomplish
• For a very complex system, time constraints
  require the design team to shift much of the
  detail design work to suppliers, thus saving time
  for the team to design those components which
  permit the integration of the suppliers
  components.
• This project would not have been finished if I
  had irrationally devoted myself to designing and
  building every single one of its components.
• Thus, this project demanded that I become more of
  a systems engineerI had to focus more time on
  the integration of components which were sourced
  and purchased by team members.
• Below, I show several of the purchased components
  from the pneumatic system which I had to reverse
  engineer into hand drawings (calipers were my
  constant companion in this project), and then
  model in our C.A.D. assembly to preempt
  interference issues.

Pneumatic Solenoid Valves
The Paintball Air Tank Reservoir
Hose Fittings
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M1A3 Sparty Tank Production Documents
Custom designed parts required dozens of
dimensioned drawings to clearly convey to the
team what had to be made.
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C.A.D. Production Documents Tank Project Results

• When it was easier to do so, production documents
  were produced by printing out C.A.D. images with
  specifications written or printed directly on
  them.

Template created from CAD model for motor hole
location and drilling.
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Solar Powered Hot Dog Cooker

• Assignment design a solar-powered hot dog cooker
  for the Heat Transfer Lab competition. Maximize
  hot dog temperature minimize weight of device.
• Led the design of a large parabolic hot dog
  cooker. A truss frame was fabricated using
  housing insulation foam sheeting Mylar was used
  as the mirror surface. Major features shown
  below
• A sighting tube to align the cooker with the
  sun.
• A Mylar lined cover at the focal point minimized
  convective heat losses and caught errant
  reflected sunrays.
• A durable pivot point which allowed ease of
  alignment with sun and minimized structural
  flexure from uneven ground.
• Results placed well in the class, but team
  placement would probably have improved with more
  testing other team members interest in doing
  further testing was lacking.
• Lesson learned project success directly relates
  to the team members interest in itgood
  leadership entails sparking this interest.

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Drawing to Supplement Technical Writing

• Ive found that the best way to clearly convey
  technical concepts and processes is through
  digital or hand sketches. Here are some images
  from my undergraduate reports, done in MS Paint

A report on how printing presses function the
newspapers path and order of inking.
A camera system to illuminate and photograph a
micro pillar array submerged under water. Glass
mounted obliquely in the tube illuminated the
pillars indirectly.
A rheometer-a spinning conical disk submerged
in fluid which yields a laminar linear velocity
profile, and a uniform shear field. A camera
measured the pillar tip deflection through the
clear plastic of the rheometer.
Force-displacement relationships could then be
determined.
Particle image velocimetry was used to monitor
fluid flow in a water channel. The three areas in
which images were taken are emphasized.
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Abstract Design Concepts Through Images

• Below is what I consider the key concretization
  of ideas which I put forth in a paper which I
  wrote for my graduate design class (Human Design
  Context Identity, Values, and Ethics, J.
  Ketterer, 2008). In that paper, I relate mans
  nature to the purpose of design because some
  actions can harm life while other actions promote
  it, the purpose of design must then be creating
  products for customers which improve their
  lives. To do otherwise would risk harming human
  life. Values which objectively promote life
  instead of harming itwhat Ive called Objective
  Valuesexist, and are independent of what the
  customer and designer choose to personally value.
• These facts set up the three broad domains of
  values illustrated below in the Venn Diagram of
  Values. A Designers Values are his personal
  values as it relates to the design process
  (payment for work done, job satisfaction, etc.)
  and the Customers Values are his or her
  personal values with respect to the product being
  designed (does the customer believe that the
  product provides a useful service, is the service
  worth the cost, etc..). But, independent of
  these two individuals sets of values, are
  Objective Values, the third domain shown below.
• The key point for a given customer and
  designer, any given product will lie within one
  of these seven domains of values.

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Abstractions Images, Cont.

• This tool acknowledges that customers and
  designers can engage in trade which objectively
  harms life. For example, cigarettes and heavy
  smoking would fall into region six because it
  does not promote life. However, it is obvious
  that the cigarette manufacturer and the
  individual who smokes still consider cigarettes
  to be a value worth trading, or they would not
  choose to trade.
• This tool also acknowledges that there are
  boundaries of uncertainty over what region a
  certain product belongs in There are debates
  over whether a certain product is really life
  promoting, for example, and this is illustrated
  by the black shaded boundary. The blue and green
  shaded regions illustrate the regions of value
  where a customers or designers personal
  valuesand consequent ideas of opportunity
  costmake it hard for them to decide whether the
  product under consideration is a value to them or
  not.
• The key messages which a designer should take
  away from this tool are the following
• It is important to identify where a certain
  product or product concept currently would reside
  within these seven domains of value.
• If currently outside of domain 7, a designer
  should devote his creative skills towards
  identifying and resolving the product issues
  which are preventing it from being a life
  promoting value to both the customer and the
  designer himself.
• If already in domain 7, creative energies should
  be devoted towards optimizationthinking of ways
  to improve the product by rendering it more
  effective at providing the nine Objective Life
  Promoting Values listed in the table within
  domain 1 titled Values which promote LIFE.

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Abstractions Images, Cont.

• Here is a second visual tool which I created and
  proposed in the Identity, Values, Ethics paper.
  
• The Productivity Pyramid illustrates how an
  employees productivity is directly related to
  the stimulation of his personal values.
• For a given employee, a project will lie
  somewhere within the spectrum of productivity
  represented by this pyramid.
• The pyramids base rests on the initial
  requirements which must be met by the employee,
  if he is to engage in the job at all the
  Talents / Training required to do the job (or
  the motivation to learn the skills for the job!).
• Following consideration of Talents / Training,
  the initial point at which a project will then
  compel an employee to participate, through
  stimulation of his personal interests, is then
  represented by the base of the pyramid the
  employee must agree with the Ethicality of the
  project. When a customers demand and an
  employees ethics agree, this serves as the first
  point at which an employee will be motivated to
  do the work. As a contrast, imagine asking
  Gandhi to work on the design of a weapon of mass
  destruction. No matter what payment you offered
  him, he would be recalcitrant in working on the
  weapons design. His attitude in this case is a
  direct result of the fact that he does not
  fundamentally consider that this project is
  ethical.
• The next level in the pyramid which represents
  another form of motivation which can compel an
  employee to participate in a project is of course
  Salary. As long as ethical agreement is
  achieved, providing payment will only further
  motivate an employee to contribute to the
  project. The Zone of Opportunity Cost also
  shows that, generally, when ethics are sacrificed
  for income, motivation will decrease, and vice
  versa.

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Abstractions Images, Cont.

• The peak of the pyramid represents the point of
  optimal agreement between an employee and his
  work. This is where an employee will be
  compelled, through the works direct stimulation
  of his own values and interests, to achieve his
  personal peak of productivity. This occurs when
  the employee enjoys the nature of the work
  itself. When an employee finds the work enjoyable
  and gives him a sense of accomplishment, his or
  her productivity will surge.
• A second Zone of Opportunity Cost between the
  Salary and Values level illustrates that,
  generally, sacrificing job satisfaction for
  income will lead to decreased productivity, and
  vice versa.
• The key messages which this tool helps to
  emphasize are the following
• Managers and employees should actively engage in
  introspection and evaluation of what they value
  to determine the work which they fundamentally
  enjoy doing.
• Companies which actively seek out and hire
  employees who love their work will not only
  maximize the value which the employees contribute
  to the company, but they will also have extremely
  happy employeesa true win-win situation!
• Especially in the long run, it is best to invest
  in employees who enjoy the work they do. While
  more experienced employees may initially be more
  productive than those with less experience, I
  firmly believe that an employees excitement
  about a project will trump experience in the
  majority of job positions. An excited employee
  will, of his own accord, put in the effort
  required to come up to speed in a job and
  overtake the productivity of an experiencedbut
  less motivatedemployee.

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Photography Art

• Aesthetics may have not been emphasized in my
  formal engineering education, but I feel that I
  have a strong sense of what fits the definition
  ofand the ability to createthe visually
  appealing.
• The following slides display this through my art,
  photography, interests, and activities. First,
  several projects from high school art and drawing
  classes Attention to detail is not lacking!

Symmetrical Art Assignments with a Pattern of our
Choosing
Curves, Edges, and Points Oil Paint Art I,
2000 12 x 12
Street Corner Pencil Drawing I, 2001 12 x 12
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Photography Art, Cont.
Two More Art Projects
The Ablest Navigator Monochromatic Marker
Assignment Art I, 2000 11.5 x 17.5
Deep Sea Stevenson H.S. Two Point Perspective
Assignment in Pencil Fanciful Rendering of
Hallway Corner in High School Drawing I,
2001 17.5 x 12.0
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Photography Artand New Technology!

• Prior slides which explained my design projects
  displayed my ability to convey ideas through
  images created in MS Painta software which is
  limited by a relatively small toolset. To more
  easily compose digital sketches, I purchased a
  drawing tablet which came with a copy of Adobe
  Photoshop Elements. The increased flexibility
  provided by this new hardware and the powerful
  tools of this software will enable me to
  accomplish quite a bit more in digital rendering.

A typical Facebook profile (my sisters, in
fact).
My profile, touched up with the tablet and
Photoshops trimming tools.
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Photography Art, Cont.

• Natural landscapes, industrial architecture, and
  dynamic statuary are fascinating and appealing to
  me. I would classify my aesthetic interests as
  that of Romantic Realist.
• Industrial Architecture

Völklingen Ironworks, Saarland, Germany
Warehouse canal, Hamburg, Germany
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Photography Art, Cont.
Kinetic art art which conveys dynamism
Monumento Nazionale a Vittorio Emanuele II Rome,
Italy
A techno themed party which I hostedilluminated
by glow sticks black lights. (Photo credit
Danielle Pisano.)
The sculptures of Jean Tinguely. Basel,
Switzerland.
One frame from a time lapse video I made
(youtube /watch?vhz0a29kzLEs)
lighting and lines which do the same.
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Photography Art, Cont.

• Landscapes, vistas, mans position within it

Paros, Greece
Interlaken and Lauterbrunnen, Switzerland