Problem:

• Company was currently purchasing water coolers to use in induction heaters at a high price

Role:

• Iterate upon existing design

• Create detailed CAD model, engineering drawings, BOM, and source parts

• Prototype and test function

  • Assemble tank, radiator, fan, motor, filters, and piping

  • Braze together copper tubing and joints

  • Wire pump motor

  • Record water cooling capabilities

Constraints:

• Fits within existing induction heater cavity

• Made out of a non-corrosive material

• Cycles water sufficiently to cool induction heater cables under normal operating conditions

Outcome:

• Functionality metrics were obtained

• Final cost 33% less than purchased model

Manufacturing Considerations:

• Consolidated sheet metal components using DFM methodologies, reducing the number of welds required during fabrication

• Included simply removable pipe joints for ease of filter replacement or inspection

Controls/Electronics:

• Wired flow switch to the alarm system in the induction heater to ensure that the system does not run while cooling system is compromised, thus preventing overheating

This was the first project that I got to see from CAD model to prototyping to implementation. That taught me the importance of DFM, iteration, and how fun it can be to build your designs with your own two hands.