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SOLAR PLastic melting plant
Pakistan generates nearly 4.5 million tons of plastic waste a year! It also is a country blessed with an average solar irradiance of 5-7 kWh/m^2 per day. With these impressive statistics we undertook a the project of using a regular satellite dish, and converted it into a solar concentrator capable of melting plastic and creating tiles around 4-5mm thick. This project required a combination of mechanical design coupled with electrical control as the dish could automatically track the sun.
Control box featured manual precise control over the direction of the dish as well as an auto mode (orange 3D printed part is the Sun sensor)
Solar Hotspot initially gave us a temperature upwards of 700°C measured using an IR gun however we moved the hotbox 1-1.5" closer in order to reduce the focal point as the metal sheet started to warp due to the extreme temperatures!
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Ezbike
ezbike is the first electric scooter sharing company in Pakistan! I started working here as lead engineer and managed a few departments like R&D, Fleet Maintenance and Assembly.
Assembly Prep
The Tool Wall
While designing the assembly process I also noted the number of tools required and arranged them according to frequency of usage and ease of access.
The torque wrench was added especially to reach some form of uniformity and standardization in the manufacturing of the bikes. Although there was no documentation I managed to find out the correct tightening torque using the bolt size and thread pitch.
Assembly Stand
The place dedicated for assembly was quite small so a conventional assembly line didn't seem possible. The room allotted to us was no bigger than 300 sq-ft, that meant that assembly had to be done on a singular station and not on a moving platform.
In order to achieve this I made the assembly stand; based off a scissor lift mechanism. An electric linear actuator replaced the hydraulic/pneumatic lift jack.
Assembly Stand.mp4Ezbike factory space
Eventually we did move out of the tiny facility after building 150+ bikes in that space 😆
A new challenge presented itself "Conversion of an empty building into a proper factory space"
pre-Assembly racks
This was the first time I had undertaken an endeavor of this size. Among some of the accomplishments pictured to the left was the commissioning and maintenance of a 7.5kW screw compressor coupled to a 800L air tank, and my favorite machine: "The frame number puncher" which was basically a marking machine used to etch the frame numbers into metal.
My team and I designed and built all the stands pictured to the left. We handled the production in-house, thereby significantly reducing capital expenditure and shortening completion time.
Headlight Modification
Most of the bikes at the company were deployed in the city and thus faced the harshest conditions possible. In our reports on the most damaged parts, we found that the headlights needed replacement the most frequently. These replacements were costly, and due to import restrictions at the time, we were unable to bring them into the country.
To address this issue, I made a modification to the handlebars and had a few hundred small plates laser-cut. These plates needed to be bent to a specific angle and then welded precisely where the old headlights were mounted.
I also designed and fabricated bending jigs and a welding jig to hold the bent plates in place for accurate welding onto the handlebars.
vic quadcopter
The Vertical Inspection Cube (although technically a cuboid 😂) was an innovative concept developed by FPV Karachi*. The VIC was designed to navigate and operate within the confined spaces of industrial cooling towers, the environments of which are characterized by high temperatures and hazardous conditions, making human inspections both dangerous and time-consuming.
Over the course of its development, the VIC underwent four iterations to perfect its design and functionality. I modelled each version, CNC cut carbon fiber and 3D printed the battery compartments and bumpers, ensuring precision and quality at every stage.
Return of the JEEP
After sitting on the jeep for a very long time I finally could afford to swap the engine out on it, as well as get some of the body work done. This marked a new beginning for it as I managed to do quite a few "resto-mods" for it
Since I made so many stainless steel exhausts at my time in HPR I decided to do one for myself on the Jeep. Got the metal joints laser cut in 1/2" thick mild steel making for some good chunky metal to weld to.
During the bodywork phase of the jeep rebuild the entire original wiring was lost. Which was probably for the best as it allowed me to rebuild the 40 year old wiring.
Powered windows.mp4Me super excited about the working power windows when the denter (body repairman) explicitly told me that a modification like this wasn't possible.
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