3DOF Measurement Arm

This project was inspired by a problem I regularly faced at work, trying to take three dimensional measurements around engines using tools designed for one dimension. To solve this, I designed a three degree of freedom (3DOF) measuring arm that could capture length, width, and depth in a single measurement.

To test the concept, I thought up an initial design using potentiometers at each joint for angle sensing and designed the structure in CAD around these components. The system was assembled with an ESP32 microcontroller and some forward kinematics code to calculate position, I used custom jig to calibrate each potentiometer to counter their lack of linearity. I also developed a simple web interface to take and display measurements.

The finished prototype can measure within a 40 cm workspace with  +-2mm accuracy. I noted that the initial design had several limitations, including poor linearity in the potentiometer measurements, a lack of structural rigidity, and the need to be connected to a laptop to operate, which made the system bulky and inconvenient to use. I have since begun developing a second version using AS5600 magnetic encoders, a more solid design and a built in touchscreen interface, targeting an accuracy of 0.1 mm.


Converted Alternator to BLDC Motor

One day at work I noticed a pile of old alternators that had been thrown out because they were no longer generating electricity. I remembered from my first year at university that generators and brushless motors share very similar internal structures, so I started wondering if one of the alternators could be repurposed as a motor instead of being scrapped.

After disassembling one of the units, I removed the internal voltage regulator so the windings could be driven directly. I found that the stator windings could remain largely unchanged, but the rotor needed to be supplied with current so it could act like a permanent magnet. Using a 48V battery, I created two parallel circuits. One used a step down transformer to supply 12V to the rotor, while the other sent 48V through an electronic speed controller to produce a three phase signal for the stator windings. With a throttle connected to the speed controller, I was able to control the speed of the system.

After some testing I found that the converted motor could reach a no load speed of around 3600 rpm, giving it a KV rating of roughly 75 rpm per volt. Under load the speed dropped due to losses and torque demand, but the project proved that a discarded alternator could be successfully converted into a functioning motor and it set the foundation for my next project.

Converted Alternator E-bike

Integrating the alternator motor into the bicycle required designing a completely new mounting system and drivetrain. I started by measuring the mounting holes on the alternator and designing a custom bracket in CAD that would correctly position and orient the motor relative to the frame. The bracket was 3D printed and used to space the alternator properly from the frame. Once everything was aligned, I drilled mounting holes into the bike frame and secured the motor in place.

Instead of using a traditional chain and sprocket system, I designed a pulley and belt driven drivetrain. This allowed me to experiment with different pulley ratios to tune the balance between torque and top speed, while also making the system smoother and quieter. Switching away from the chain system introduced a few challenges. One of the first was removing the existing sprockets while still keeping the one way bearing that allows the bike to glide without pedalling. To solve this, I designed a setup where a pulley could be bolted directly to the existing sprocket body, placing the bolts between the teeth to create a strong connection that transferred the rotational motion to the pulley.

Another challenge was selecting the correct belt and ensuring it had enough tension to prevent slipping. I chose a belt slightly larger than required and incorporated an idler tensioner to properly tighten it around the pulleys and maintain consistent contact during operation.

After fixing the brakes, mounting the throttle, and 3D printing a custom phone holder, I was finally able to test ride the bike. It reached a top speed of around 30 km/h, which closely matched the performance I had predicted from my pulley ratio and motor speed calculations. This project while functional is still a work in progress, in the future I would like to implement some better cable management and a removable battery mounting system to allow for easier recharging.


Recycled Vape Battery Pack

During my previous e-bike project I realised that the single most expensive component of the entire system was the 48 V battery pack. That got me thinking about alternative ways to source batteries more cheaply, especially from devices that are commonly thrown away.

Although I do not personally use vapes, I have friends and family who do. Out of curiosity one day I decided to open one of their used disposable vapes to see what components were inside. While taking it apart I discovered that these single use devices almost always contain a small 2500mAh, 3.7 V lithium polymer battery. What surprised me most was that these batteries are fully rechargeable cells, despite being packaged in products designed to be discarded after a short lifespan.

Seeing this was pretty eye opening. Disposable vapes are thrown away in huge numbers, yet each one contains a perfectly usable lithium battery. Realising how much energy storage was effectively being wasted sparked the idea of recovering these cells and repurposing them for engineering projects.

Since then I have used a few of these single cells to power some of my smaller esp32 projects and I have started a collection in hopes of replacing the battery used for my e-bike. I have calculated that for the specs I want to achieve, I will need 78 cells, 6 parallel rows of 13 cells in series. I will also need to buy some nickel plating to join them together, buy a battery management system, and 3D print a case to house and insulate them.

Bop-It Game

This project was completed as part of a university class where we were tasked with designing and building an Arduino powered version of a “Bop It” style reaction game. The project involved creating the full circuit schematic in KiCad and writing the firmware to control the gameplay.

The game worked by moving a sequence of lights from left to right across a row of LEDs. The player had to press a button at the right moment while the light was in the green zone to advance to the next level. If the button was pressed too early while the light was in the red zone, the player would drop back a level. Pressing the button in the yellow zone would keep the player on the same level.

To make the game progressively more challenging, the speed of the moving lights increased each time the player advanced a level, requiring faster reactions and better timing.

The project helped in my introduction to circuit design, microcontroller programming, and game logic to create a simple but engaging interactive system.


Folding Bridge

This project was completed as part of a university class and involved working within a multidisciplinary team. Our task was to design and manufacture a model bridge capable of accommodating both car and boat traffic. We were given a set of design constraints and encouraged to develop a creative solution rather than relying on a conventional vertical lift bridge.

I worked closely with our structural engineers to develop a folding bridge concept inspired by the Hörn Bridge. Using my CAD skills, I helped model and simulate the bridge’s folding motion and led the development of the pulley system that enabled the mechanism to operate smoothly.

On the systems side, I wrote the majority of the integration code responsible for coordinating the traffic lights and ultrasonic sensor systems. I also played a key role in developing the web interface alongside our software engineers, ensuring that the bridge controls and system feedback were accessible and functional.

This project helped me develop strong teamwork and communication skills while working in a collaborative engineering environment. It also gave me the opportunity to take on leadership responsibilities, particularly in guiding the development of the electrical system and helping coordinate integration between the mechanical, electrical, and software components.