Kinetic Traction Systems
Company Name: Kinetic Traction Systems Inc.
Website: www.kinetictraction.com
Job Title: Consultant Design Engineer
Dates: September 2014 - August 2016
Location: Bristol, UK; Deeside, Flintshire, UK & Chatsworth, CA, USA
"Founded in 2010, Kinetic Traction Systems, Inc. (KTSi) designs, develops and manufactures clean technology products for energy storage, power regeneration, waste heat recovery and turbo aeration applications. Product development is based on proprietary know-how and expertise in high-speed permanent magnet motors, magnetic bearings, power electronics and controls combined with advanced analytical capabilities. Kinetic Traction Systems’ products are designed to improve performance and efficiency, reduce energy consumption and lower carbon emissions, while providing innovative solutions to a variety of applications and industries in global markets. KTSi headquarters, research and development, and manufacturing are located in Chatsworth, California, USA with a design and application center in North Wales, UK."
Source: http://kinetictraction.com/
I first started working with KTSi after being approached for a position to work with a small project team of highly skilled external contractors from the likes of Williams F1 & Micheal Butler Creative.
Over the years I've worked on a number of projects and most recently on the design and development of a 4000 SCFM high speed centrifugal fan, with applications in the waste water and processing industries. For details of my involvement in each project please see below.
300 kW Waste Heat Recovery Generator (Organic Rankine Cycle)
I joined the WHRG project team in the later stages of the development process. Much of the design direction had already been defined and a manufacturing of the key components underway. My role was to assist the engineering team in the translation of the design and assembly intent into manufacturable components and subsequent technical documentation.
Due to the large forces involved and temperature differential between components - such as the generator stator and ductile cast iron housing - a number of critical limits and fits required defining. Using a combination of mathematical and computer aided numerical techniques I worked to define robust connections, taking into account machining capabilities for each of the critical interfaces. Examples of challenges I was responsible for solving include;
Detailed analysis of interference fits in a R-245fa pressurised environment using standard mathematical models and finite element analysis.
Assembly tooling design, development, testing & producing manufacturing packs.
GD&T utilising Solidworks DimXpert & TolStack for tolerance stack analysis.
Cost down activities such as replacing high cost per part metal components with polymer parts incorporating structural bonding.
Bolted joint analysis for key structural connections.
I began working on the development of the Turbo Aerator early in the product design cycle. Working with KTSi's engineering teams both in the USA & UK, as well as with specialist external suppliers we worked from first principles to design from the ground up a high speed centrifugal fan offering higher efficiency at increased turn-down ratios predominately for use in the waste water processing industry.
My focus were mainly on the mechanical, thermal and fluid flow aspects of the system's design but worked in conjunction with the external suppliers for key components such as the impeller and the 5 axis active magnetic bearing (AMB) system, both bespoke . Due to the high speed nature of the machine (27 krpm), structural dynamics played a key factor in the development of the rotating components as well as the bearing system, auxiliary bearing system and aluminium sand cast housing. Utilising computer aided engineering tools I ran multiple design schemes for shaft design and component configuration, minimising the effect of the overhung mass and ensuring shaft critical outside the operating range of the machine.
My involvement in the design and development of the machine incorporated all aspects from concept to assembly including;
Shaft design for structural integrity and dynamic performance.
Translating volute scroll geometry into sand casting minimising hydraulic losses.
Design of split housing sand casting incorporating conductive and convective thermal pathways for motor cooling.
Design for manufacturing - high speed rotating components, shrink & interference fits, castings, fabrications, pipework & electromechanical systems.
Design for assembly - non contact sensors, AMB system integration, cable routing, sealing, environmental packaging.