Project Portfolio (ski)

Garrett Harmsen Project Portfolio

Skinning to the Fowler-Hillard Hut, White River National Forest, CO

About Me

I’m Garrett Harmsen, currently a senior studying mechanical engineering, economics, and environmental science at Duke University.

For as long as I can remember, I’ve been obsessed with creating - transforming ideas and notebook sketches into products that make life easier and more fun.

I believe that good design comes from experience, motivation, and even true obsession. My upbringing in Colorado instilled in me a passion for climbing, skiing, photography, and solving environmental issues that is reflected in many of the projects displayed below.

This portfolio is intended to show my thought process in pursuing a new idea as well as demonstrate my design, engineering, and manufacturing skills. Unless otherwise indicated, all the projects were completely self-motivated individual pursuits. I hope you enjoy and feel free to contact me with any questions or comments.

Additionally, all the photos are of me or taken by me, and are meant to show my backcountry skiing experience.

Summit of Torrey’s Peak (14,275) Summit County, CO

Quick Gear Holder Climbing Harness Racking System July 2013 - Present

Motivation - The

current carabiner

-

gear loop system on climbing harnesses is

inherently inefficient for trad climbing

- Placing

gear, especially nuts, is a difficult two-handed process

that is very strenuous on steep routes or during crux sections

-A

better, one-handed gear racking and placing system would

make trad climbing more efficient and safer

-

allowing a climber to

spend less energy on protection and more actually climbing

Ideation

and

Design

- I begin all my brainstorming with a list of problems to fix and key design criteria

- From

there,

I

Initial Ideation Sketches

make quick sketches of various ideas, trying not to get

fixated on anything.

- The best ideas are taken further into detailed sketches - In this case, the final idea involves a “clothespin” attachment

system

Celebrating on the summit of Blimit, Arthur’s Pass Nat. Park, New Zealand

Engineering

-No matter how pretty an idea is, if it doesn’t work, it’s pointless - By utilizing my knowledge of physics, solid mechanics, and materials

science,

I

was able to calculate the ideal dimensions for my racking system

- Picking

the correct width, height, and thickness of each

“clothespin”

holder

was critical to ensure that each would be stiff enough to hold gear in while climbing, yet flexible enough to allow easy user access without failing

FEA Modeling

- To finalize the prototype design, I created an accurate model Solidworks - Finite Element Analysis tools were then used to confirm my

in

prior calculations and find any problem areas with higher than expected stress and deflections, which were fixed by making minor modifications

- Because

of uncertainty in real world factors and not know-

ing exactly how much stress would be applied to the part during a climb,

I

designed the first prototype with a variety of

pin” sizes to test in the field

Modeling Typical Loading on Prototype #1

A Sunset hike to “The Professor”, Loveland Pass, CO

“clothes-

Kicker Session on a windy evening, Loveland Pass, CO

Prototyping

and

Testing

- In order to quickly make prototypes, I utilized a FDM 3D printer - I tested the first prototype in Joshua Tree National Park and at local crags in North Carolina - Feedback from the first phase of testing led me to design and create a second prototype - Prototype #2 is designed to be more flexible, integrate smoothly with the harness, and handle cams as

Next Steps

- I’m Currently in the process of creating about 10 copies of Prototype #2 to give out to friends for testing - Taking into account their feedback, I’ll develop Prototype #3 - a fully integrated harness/racking system with more durable wiregate “clothespins”

well as nuts

Prototype #1

Prototype #2

Looking out into the Rakaia Valley, Little Alaska, New Zealand

Skinning in search of pillows, Vail Pass, CO

Duke Electric Vehicles Ultra - Efficient Transport August 2011 - Present

About

- The Shell Eco-Marathon

is an international competition aimed at

fostering the development of automobile energy efficiency technologies

- Our 10

The 2014 Car design

student team designs, constructs, and tests a new electric

vehicle each year

- As

vice president of the organization, my primary role is developing and

coordinating all testing and component manufacturing

Testing - As

testing team leader

I

coordinate and lead sessions to design test

fixtures and methods to test various components and systems of the car.

- Testing

results provide insight on where design should be focused (ex:

showing that the majority of energy losses go to friction and not drag)

-

by isolating variables, testing can show the effect of factors such as

wheel size, bearing choice, driving strategy and tire pressure on efficiency

The Design Process - Beginning

with group ideation sessions, we collaboratively

narrow down potential designs until we agree on the best

- A small group finalizes the details and draws the part up in Solidworks, running finite element analysis software to make sure the part will perform as expected

- We

are currently in the process of designing a carbon fiber

monocoque body for the

Scoping the descent from the summit, Torrey’s Peak, CO

2015

car

Model and Assembly for the steering system I worked on for the 2014 car

Manufacturing - Constructing

the

Eco-Car

from materials with high strength to weight ratios such as aluminum and

carbon fiber is key to an efficient design

- Using

these materials involves employing manufacturing techniques ranging from

lathing to wet-layup vacuum-bagging.

-I

CNC

led the manufacturing group for many frame and steering components including the brakes,

cross-members, carbon fiber support rods, footrest, rack and pinion, and motor mounts.

- Additionally, I

played a key role in constructing the carbon fiber body, axle mounts, and reinforced

carbon fiber seat.

CNC Milling the 2014 Frame

Results

- The 2014 car placed 2nd of 36 in the battery electric category last April in Houston, Texas - We achieved a fuel economy of 310 miles/ kilowatt hour - Efficient enough to Drive around the World on $8.50 of electricity - Had the lightest Frame at the competition, weighing less than 9 lbs

Hunting for lines in the backcountry of Mount Olympus, NZ

milling and

The 2013 Car in Competition

Approaching through the rainforest Cragieburn Range, New Zealand

Amazing terrain on Mt. Phipps Temple Basin, New Zealand

The “Whipper” Calculator Fall-Force Calcuating iPhone App

The Problem - Climbers

are often unaware of how much force is applied

to their gear during a fall

July -December 2013

- This

knowledge can lead to better risk assessment and

smarter decisions in the future

The Idea - Utilize

the iPhone’s accelerometer to

measure fall forces, time, and height

The Design

- Simple and able to run with little - Keep the focus on the climbing

user input

and off the phone

- Incorporate

a clean interface with detail

views displaying more information and history

General App Layout Bouncing down some pillows near the Fowler - Hilliard Hut, CO

The Process - Collect

and analyze accelerometer data from real-world climbing

- Develop

an algorithm using this data that determines when

falls from a variety of routes, climbers, and belay types.

the climber is falling and being caught by the rope.

- Use Objective-C

and

IOS SDK

tools to turn this

algorithm into a user friendly application.

Force profile from a typical fall

The Product

- Easy to use application that accurately calculates fall forces - Displays common gear and compares their force ratings

and height

to the forces generated in the fall

- Saves

Screenshots from the App - showing intro screeen and gear forces

all previous data and displays it in an intuitive format

Bootpacking up the “back ridge�, Mt. Olympus, NZ

Finding some air on Berthoud Pass, CO

Spinning in the “Backcountry Park”, Vail Pass, CO

Eddy Current Disc Brakes Mountain Bike Braking System September 2013

Motivation

- Disc brakes are the current standard in mountain bike brakes - While effective, brake pads wear out quickly, generating waste

and

causing the brakes to quickly become ineffective and dangerous

-A

no-contact braking system would allow for a much longer lifespan

Concept - Magnets

can be used to induce eddy currents in the discs, slowing

their rotation

- Using

physics principals

I

showed that a biking eddy current brake

could generate sufficient braking force to be useful

-A

supplemental pad brake is necessary to brake at low speeds, but low

speed braking generates little pad wear, so the system would still be effective

- Different

diameter holes for hydraulic fluid allow for one brake lever

to activate magnetic braking first, then, if necessary, the traditional pad

Sketched designs and ideas

brakes

View into the Mingha and Mt. Temple, Temple Basin, New Zealand

CAD Models

- By

using

Solidworks

and

Future Steps

to create detailed models of the eddy brake current

concept, it is easier to see how the concept would function in reality

- While

the brake would be larger and heavier than modern lightweight

disc brakes, it would have much greater braking power, particularly at high speeds, making it ideal for downhill freeride biking.

-A

prototype brake is currently being planned, and

end of the semester.

- Future versions could potentially multi-material custom discs.

I

hope to test it by the

include lighter materials and

Solidworks Renderings of a Possible Design

Midnight session near Fowler- Hilliard Hut, White River Nat. Forest CO

Watching some classic MSP films and dreaming of powder in the parking lot, Mt. Olympus, New Zealand

Reaping the rewards from a cold night with first tracks down “the Sphinx�, Mt. Olympus, New Zealand

Current School Projects 2014-15 Academic Projects

Bartender Robot - Lead Mechanical Engineer

on a team of

8

retrofitting a

pharmaceutical robot to become a bartending robot

- My major tasks include designing pumps, liquid level sensors, refrigeration system, and user interface - Will experience working with software and hardware engineers to meet a strict schedule of deadlines

The Claw - Arm Assembly The Original Pharmaceutical Robot

The Type of Jet Engine we are Designing for

Jet Engine Acoustic Liner - Working

with a team of

5

to develop an improved acoustic

liner for commercial airline jet engines

- An

ideal solution will provided significantly reduced noise for

passengers while not necessitating major engine redesign

The Eiseman Hut under the stars, White River Nat. Forest, CO

- By

the end of the year, we will have a functional proof of

concept and industry partners

Skinning into the alpine near Butler Gulch, CO

Cruising away after a June descent of Dead Dog Couloir on Torrey’s Peak, CO

EasyMix Composter Gardening Tool December 2013

The Completed Composter

About - The

idea originated as a

Christmas

present for

my dad, who has always loved to garden but

struggled with his current composter’s size, production rate, and ease of use.

- The EasyMix

is intended to allow faster aerobic

digestion through a simple rotational mixing system and interior ventilation piping.

- I

designed and constructed the composter

over a period of two weeks while on break from school

Initial Sketch and Design of Composter

Evaluating the snowpack before dropping into a powder filled couloir, Cragieburn Range, New Zealand

The interior ventilation system

Powder day on Little Phipps - Temple Basin, New Zealand

Ideas, Sketches, and Past Projects

Automatic Teamaker - Uses

an

Arduino

and servo set

to a timer to prepare tea automatically before

I

wake up

Climbing Phone Case - iPhone case designed to secure the phone to a harness, preventing dropping the phone when taking photos while climbing yet still maintaining a light and slim structure

Farming the Back Ridge at Mt. Olympus, New Zealand

Â

Compressed Air Energy Storage Prototype -

stores energy

produced by small scale renewable energy systems

Ski

touring binding to incorporate both a

Dynafit

pin style

toe piece for lightweight uphill travel and a traditional toe for downhill stability.

Would

bindings for skiing and more efficient than bindings for touring.

Dynafit Marker Duke style

be more stable than

One Handed Camming Device -

allows for a single mo-

tion to move cam lobes and disengage carabiner from harness

-

allowing for easier placement

Shredding some “NZ Pow�, Temple Basin, New Zealand

Leaving the Fowler-Hillard Hut and the amazing surrounding terrain - White River Nat. Forest, CO

Thank You

for taking time to review my portfolio.

I

hope you now have a better vision of

my skills, creativity, and motivation.