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This project involved designing two test fixtures to hold a projector securely, a SOM carrier board, and two data acquisition devices (DAQs). These fixtures were specifically intended for Highly Accelerated Life Testing (HALT), where the components are subjected to extreme temperature variations ranging from 80 degrees Celsius to -60 degrees Celsius and vibrations.

 

The HALT table was used to simulate vibrations similar to a bumpy car ride ranging from 2 to 10 gRMS, which was achieved using pneumatically tuned hammers. These test conditions allowed for the rigorous evaluation of the resilience and reliability of the fixtures under harsh environmental stresses. The tests were used to first evaluate the securement of the optical prism and then to assess the performance of the projectors.

 

I then performed Finite Element Analysis (FEA) to determine the resonance and natural frequencies of the fixture that holds the projector module to verify the rigidity of the fixture. Finally, I drafted detailed drawings for these parts to be manufactured.

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Different phases of the project can be found in the pictures below!​

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