Embedded Files
Winch Spool
Optimized the UAV's winch-basket spool to resolve a critical single-point failure identified during operational testing: dynamic rotation caused the internal collar clamp set screw to back out. Because the tether cable wrapped directly over the hardware interface, servicing or tightening the loose fastener in the field was impossible without fully dismantling the system. I redesigned the component to enable direct hardware accessibility and improve drivetrain reliability.
Transparent Winch Spool Design
Process
Process
Design for Serviceability (DFS): Engineered a strategic internal pocket window through the spool wall, creating direct clearance for tool access to the collar clamp without requiring cable unwinding.
Stress Management: Utilized generous radii and structural fillets around the cutout to maximize tool clearance while mitigating stress concentrations under tension.
Drivetrain Integration: Mated the core hub profile directly to a positive-engagement hexagonal motor shaft to eliminate rotational slippage under dynamic torque loads.
Opaque Winch Spool Design
Manufacturing
Manufacturing
Additive Manufacturing: 3D printed functional components in PETG for high impact resistance and mechanical durability, and PLA for rapid form-factor validation.
Procurement: Specified and integrated precision shaft clamps, fasteners, and drive shafts sourced from McMaster-Carr.
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