Engineering Design Portfolio
Rick Rui Zhang
Contents
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Professional statement ………………………....... 3
O ve r v i ew … … … . . … … … … … . … … … … … … … 4
Definition of Engineering Design ………………
Personal Engineering Design Process …………. 6
Artifacts …………………………………………….. 10
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5
Conceptual Design Report ..………………… 11
Detailed Design Report …………………………12
Senior Reach RFP ………………………. 13
CIV102 bridge ………………………… 15
Rube Goldberg machine ………………………… 17
Areas of Improvement ..………………………... 19
Professional Statement

My name is Rick Rui Zhang, and I am a first year Engineering Science student at the University of
Toronto. In the past 8 months, I have learned, defined and practiced engineering design in
courses such as Praxis, CIV102 and beyond. These experiences has helped me to develop my
personal perspectives and philosophies of the engineering design process, accompanied with
some basic design/modeling skills.

I have participated in several design projects like conceptual and detailed design reports in
Praxis I – where as a team solved problems that dealt with sleep deprivation during lectures and
reusable writing mechanisms. Request of Proposal in Praxis II – where we tried to sustainably
improve the quality of life of seniors in Toronto, by increasing the distance of convenient reach in
the home environment. The bridge designs projects in CIV102, where truss and beam bridges
were designed, followed by a series of calculations and then prototyped. Along with these
courses related projects, I was also the construct/design executive of the U of T National
Engineering Month club where a Rube Goldberg machine was designed, modeled and
constructed from scratch. The design skills and the processes in which I have developed and
practiced through these activities are reflected through the solutions I have proposed.

In this early stage as an engineering designer, my strength lies within my strong research skills
as well as my ability to produce simple, effective, satisfactory designs, models and prototypes.
And are demonstrated through the solutions to the Senior Reach RFP and CIV102 bridges.

An area I would like to improve on is my communication skills as I often find difficulty
communicating ideas without the aid of drawing utensils. On top of that, I find it troublesome
connecting and summarizing series of ideas together in the form of reports. Which were
demonstrated in the conceptual and design reports, critique and, showcase. Limiting my
development as an engineering designer. I intend to practice and participate in activities that
will improve my presentation and writing skills in the future.
Personal
Engineering
Design
Process
 My Personal
Engineering
Design Process
consists of two
main phases:
Setup and
Design.
Identify
Problem
Setup Phase
Understand
Brainstorm
Research
Improve/
Redesign
Select
Mock-ups
Iteration/
Testing
Analysis
Prototype
Design Phase
Solution


It is worth noting that my current
personal design process was not
significantly modified from my original
design process which were developed
before university. The steps and the
direction they are taken are relatively
the same. However, my original steps
did not include loops and the process
did not consider focusing on the details
of the solution such as meeting the
metrics, criteria and constraints.
My current engineering design
process was modified so that the
solutions produced from the process is
optimal. And that decision makings are
based on solid researches and
background information and thorough
understanding of the problem.
Solutions are presented in detailed
sketches/models to present and
communicate ideas.
Identify Problem
Research
Design + Sketch
Analyze
Prototype
Original Design
Process
Identify
Problem
Setup Phase
Understand
Brainstorm
Research

Identify Problem:

My understanding of: goals are defined as the long term, general
achievements. Where objectives are defined as the achievements that are
more specific and are accomplished in a shorter period of time.

Understand:

This process is often accomplished by creating checklists and scope
diagrams (much similar to the ones distributed in Praxis Studios), as it
clearly outlines both the important and missing features.

Research:
The engineering design process begins with
identifying the problem. This step is essential because it sets both the goals
and objectives of the entire process.
In order to proceed further with the problem, one
has to fully understand the problem. Either trying to come up with a
problem or trying to solve a problem.
Based on the current understanding of the problem, I am
set to gain further insights and background of the problem; by gathering
information, defining stakeholders and community, finding possible
reference designs and current solutions. Which will aid me in defining and
understanding the problem further. Setting up possible, metrics, criteria
and constraints; reframing the problem if necessary.

Brainstorm:

Understand->Research->Brainstorm

As I loop over these processes again and again, I will eventually build strong foundations and understanding of the problem.
And through frequent brainstorming, I will have come up with multiple designs or ideas. I will then filter the ideas, and select
the idea that best fit the metrics, criteria and constrains I have setup through research for more detailed designing.

We now proceed to the design phase.
Brainstorm enables me to solve the design problem through rapid and unrestricted exploration of ideas.
One aspect of an idea often stimulates new ones. Working in groups enables each member to exploring more concepts which
increases the chance of producing effective solutions. The sketches created during this process enables the communication
between ideas quickly and effectively, and can later be used as the foundation to more detailed designs (ex. Solid-works).
forms a loop (as I call the setup phase). As my understanding of
the problem enriches, my perspective may shift in different directions, and my approach might be set on a different path. As a
result, I can define new need and set new objectives.

Mock-ups:

I define this step as the extra-low fidelity step. Where I will try to create a
mock-up based on the selected design (sketch) from the set-up phase, using
the whatever materials I have around me.

Once an idea has been established and chosen. A mock-up
of the solution often takes place first.
Analysis:
Examine the problems that may occur based on the mock-ups
and the design. Use various sample tests and pre-calculations to search for
possible weaknesses and areas of improvement. The metrics, criteria and
constrains may be adjusted, and detailed decisions such as dimensions,
materials will be made using the info from research.
Mock-ups
Iteration/
Testing
Analysis
Prototype

Engineering drawings or 3D modeling will be made based on the complexity
of the design.

Prototyping:

However, the prototypes may be optional as the resources and materials used
are often limited.

Iteration/Testing:

This design phase also forms a loop, because errors, doubts and new ideas may often be generated during the
design phase, which means adjustments will have to be made. So the steps often has to be repeated.

However, when doubts and questions start to come up frequently, we often have to go back to more research
and more idea generating (setup phase).

But if the solutions satisfy all the proposed metrics, criteria and constraints. The solution to the problem is
produced.
Design
Phase
I will make the prototype according to the sketches
(detailed drawings) and the detailed decisions. However, based on the
complexity of the design and the amount of resources (which are often
limited), low/medium/high prototypes will be made accordingly.
Solution
The designs are rarely perfect, and may often
contain flaws. These flaws may happen in any of the previous steps: the
prototyping process or from the initial designs. So in this process, I will have
to again analyze the existing design, rework and fix the problem.
I would like to note that used to
illustrate my engineering
design process are mainly
group projects. However, I will
identify my contribution to the
artifact along with its relevance
with the design process.
Conceptual
Design
Report
The infrared massage patch was designed to
help users reducing stress and the wristband is
a activity monitoring device that improves the
user’s time management skills.

The setup phase is demonstrated by the Conceptual
Design Assignment from Praxis I. My team was given
the “Increasing Lecture Effectiveness” brief which
was to improve the student’s learning experience by
preventing them from falling asleep during lectures.
It was a good topic, because I experienced such
problems myself, and developing such bad habits
really affects one’s understanding of the lecture
contents. I contributed to the assignment by
researching topics such as all the possible causes of
sleep deprivation, specifically in class; for different
age groups, gender and race. The current existing
methods preventing sleep or stress and the
architectural designs of lecture rooms in U of T and
how the layout of the room improve lecture, etc. From
there, my team combined all our researches,
followed by discussions on the current
solutions/reference designs. Through series of
diagrams, Pugh charts, rough sketches (ex. Layout of
lecture rooms) and more research. My team decided
that developing better time management skills,
reducing stress and improving hearing abilities are
some of the possible and realistic solutions to
improving lecture effectiveness. In addition, we
reframed and adjusted some of the criteria and
constraints. Thus, the setup phase was followed in the
conceptual design report.



The Detailed Design Report in Praxis I
demonstrates my development and progress in
the design phase.
The report focused on finding solutions to
renewable writing utensils. The conceptual design
report given to us already had 3 solutions, and we
chose the solution that was the most favourable UV erasable pen, without knowing whether the
solution legitimate or solidly researched. So
minimal research and detailed decision making
were made and my team went straight to
prototyping, avoiding some of the obvious flaws
such as safety issues related to UV lights and the
overheating of the UV power source built into the
pen. And so, my team was penalized in the
evaluation.
From there, I always made sure that
research and analysis were implanted
in the design process. This
modification to my design process is
later shown in my solutions to Senior
Reach RFP in Praxis II.
Detailed
Design
Report

Senior
Reach RFP
My personal engineering design
process (both setup and design
phase) is illustrated through solving
the Senior Reach RFP this semester.
The senior reach RFP addresses the
need to “Improving the reaching
ability in seniors using ambulatory
aids in order to prevent injury and
ensure quality of life”. After a series
of research on falling related
injuries, design sketches and team
discussions, we decided to integrate
both already existing reachers and
walkers to prevent senior related
(ex. falling) injuries while reaching
for objects in a home environment.


We also reframed the community in
need as “seniors that have enough
strength to pick up a pickle jar and
are able to stand up straight and
walk (within the home) without
nurturing assistances”.
On the left is a 3D model of a house
I made to demonstrates the use of
the reacher and walker by seniors
in the home environment such as
the: kitchen, living room, bedroom
and washroom.

The above photos of the low and
high fidelity walker I made using
ABS pipes as the frame, wood,
sponges and duck for the seat,
cardboard for the wheels.
We further refined the solutions by
making detailed decisions. For
example, the walker consists of 5
wheels to increase stability, triangular
and aluminum framed structure for
better maneuverability, balance bar
and folded chair to increase support.
As for the reacher, arm support and
easier grip to reduced strain on the
wrist and forearm. Carbon fibre frame
for reduce self-weight and silicon to
prevent the object from slipping off the
reacher. I was in charge of researching
for the walker, designing both the
walker and reacher (I did the rough
sketch, another group member made
the 3D model), purchasing the
necessary materials and producing
both prototypes. However, I spent most
time constructing the walker by myself
(both low and medium fidelity), testing
for possible failure every step of the
way; while the rest of the team helped
me construct the reacher. Thus, the
design process was met from
understanding the problem,
researching for solutions, idea
generating through sketches and 3D
modeling. Analyzing, prototyping and
testing.

CIV102
Bridge

The design process (both setup and
design phase) is demonstrated from the
CIV102 Bridge Designing Projects in the
fall term. Designing truss bridge on
St.George street connecting Bahen
Centre and Galbraith building
(calculation and engineering drawing
only), and Mat board beam bridge
design (functional prototype + report).
Because the problem for both bridge
projects given were well defined, with
the required knowledge taught in
lectures and tutorials, minimal research
were required. However, my group
members and I made dozens of bridge
sketches with special themes (as the
best theme will be given 0.5-1% bonus).
Various types of calculations (ex. Shear,
wind bracing) were made and later
putted into spread sheet. However, the
only testing and prototyping possible for
the St.George bridge design was
calculations and appropriate designs.
When choosing the final design of the
bridge, the one that was most favourable
was chosen with no comparison and
filtering with the given criteria and
constraints. Flaws were found later which
complicated the design (ex. Stress
calculations).

On the left, is a engineering
drawing I produced for the
St.George bridge report. Both side
of the small truss spells ENG
(stands for ENGINEERING).

As for the beam bridge design, minimal
research was required. But sketches were
made and compared to similar existing
bridges. Various calculations were made
and tested with different scenarios using a
program called “beam-boy”. Low fidelity
prototype was made using the provided
Mat-board and tested throughout the
process, series of mini tests was consulted
after its completion. However, the
prototyping step was troublesome and
problematic, as it was difficult to cut the T
shaped diaphrams without damaging the
sides.
Bridge
Design
(cont.)
Rube
Goldberg
Machine

I took the role as the Construction/design executive
for National Engineering Month this school year
(2011-2012). Me and dozen other engineering
students built a Rube Goldberg Machine in the
Standford Fleming Atrium. This activity also
demonstrates my designing process – although it was
not done as professionally as the previous artifacts,
the designing processes still applies.

The problem (goal) was to create a Rube Gold Berg
Machine, the research was done by studying the
existing machines on YouTube. Couples dozens of
sketches were made, analyzed, critiqued and
sometimes integrated by others (setup phase). Six
Designs were chosen, and rough 3D modeling were
made through Google sketch-up, solid-works and
Open-Scad. However, most of the 3D designing were
produced by upper year engineering students.
Followed by designing, I was in charge of buying
materials (ex. Metal balls, springs, motor, strings
etc.) at a store called Active Surplus. Small samples
and rough sketches were made before every
construction session, and work were divided into
pairs, to working on different parts of the machine. As
the executive, I was involved in building each part of
the machine and assembling them all together.
Series of trials, tests and adjustment (minor and
major) were made throughout (design phase).

The photos shows the folding seat I
made using thin wood, sponges and
camouflage duck tape. 9 out of 10
people actually thought I took it off
another walker/chair.
My strengths in the engineering design process are
strong research skills, designing+ prototyping. The
former applies to the setup phase, while the latter
applies to both phases of my design process. As
described through my artifacts, I am able to
research for valuable and relevant information,
articles and studies in detail. Even though hard to
prove, most of the detailed decisions were made
based on my solid research. On the other hand, I am
very creative and productive with engineering
drawings, sketches and prototypes. I am always able
to complete these tasks with my groups members
satisfied and confident. Taking the 3D home model
from the Senior Reach RFP for instance, I was able to
demonstrate every aspect on how and where the
walker and reacher individually and as a
combination in the home environment; by creating a
3 min animation displaying the various details and
perspectives.
Even though I was able to follow through my
engineering design process, I still need to further
develop my engineering communication skills such
as trying to delivering my ideas and thoughts
through speaking, rather than sketches and rough
drawings. For example, in Praxis I and II, I found it
difficult to communicate the exact idea and thoughts I
have with the Teaching Team during Critiques and
Team Liaison– support from group members were
often needed to help me complete my point and
argument during the Q&A periods.
As for the writing components, even though I had
solid research and background information, I had
difficulty and was lacking the ability to tie everything
together – in the form of paragraphs and reports. My
group members often assisted me in these areas.
And as for the Showcase, even though series of
practices were taken place before the showcase, I still
found it difficult to communicate my ideas as I may
have lacked the confidence, engineering arguments
techniques and terms.
Therefore, I should on improving my engineering
communication skills – writing and speaking, as they
will be crucial in my future development as an
engineering designer.
Areas of
Improvement
(cont.)