UMD Loop

In September 2017, I joined the University of Maryland hyperloop team for their 3rd SpaceX Hyperloop Pod Design Competition. We work to design, build, and test a working hyperloop pod prototype. As a member of this team I have worked with many other students in a structured environment with clearly defined roles and subteams. I have gotten the chance to apply concepts that I have learned in my classes as well as learn from others and gather hands-on experience and knowledge that just isn't available in a classroom setting. In my two years of being on the team, I have progressed from a new member to the Structures and Integration Team Leader for Competition 4.

Competition 3

My specific role on the Competition 3 team centered around the design of the pod's rigid, lightweight frame to which all other components are mounted. I worked on a team of five to design this frame consisting of aluminum sheet metal outer panels and rigid internal aluminum bulkheads. In addition to the frame I designed lifting points that are to be mounted to the frame to transport the pod onto the track during the competition. 

Along with design I also performed hand calculations to determine loads and stresses experienced by the pod in various scenarios. These calculations were used to confirm simulation results in cases such as acceleration, braking, lifting, and crashing.

I worked with my team to compile a technical document detailing the frame's design and expected performance under various conditions. In addition to documenting the frame's overall analysis I detailed the design for the lifting points as well as a method for mounting a carbon fiber aeroshell (shown above). The technical documentation for the frame was integrated into a larger final design package for the entire pod which was submitted to SpaceX for review.

Working on the structural components of the pod required me to constantly view the project from a systems level. I was responsible for confirming that all components of the design could function nominally without causing damage to the frame or interfering with other components mounted to the frame. 

Competition 4

After joining the team for Competition 3, my role expanded to the Structures and Integration Team Leader for Competition 4. This position required me to be responsible for overseeing the design and analysis work done on the pod’s structural components as well as facilitate full pod integration and assembly. I also helped lead a major design shift from an aluminum torsion box frame with magnetic levitation and propulsion to an aluminum panel and rib design with an electric motor and drive wheel.

Building off of what I learned from my first year on the team, I designed the approximately 6’ x 10” x 5” chassis shown below. The structure is made out of 3/8” aluminum panels with cutouts and aluminum “c” ribs. All interfaces consist of bolts and threaded inserts to allow for a more modular design that is easier to assemble. The pod’s propulsion, braking, avionics and electronics systems all interface directly with this primary structure. It was my responsibility to coordinate and communicate with each subsystem regarding mounting and load paths in relation to the structure. I also completed hand calculations, bolted joint analysis, and finite element analysis to write safety margins for critical areas of the chassis.

Similar to Competition 3, the work was documented and submitted to SpaceX for a design review. Our team was selected to build and bring our pod to compete in Hawthorne, CA at the Competition Weekend at SpaceX headquarters. After a successful build and test phase, our pod was examined by SpaceX engineers at the competition. All of the structural systems on the pod were approved and qualified for a run on the SpaceX track.