Designing and manufacturing a steel piston-cylinder pump that won the "Golden Bolt" for its top-of-the-class performance
Overview
Designed, manufactured, and tested a reciprocating positive displacement cylinder-piston pump to maximize water mass pumped in a five-minute competition. This comprehensive project involved the complete design and manufacturing process for all four critical components: piston, cylinder, connecting rod, and crankshaft.
Key Contributions
- Complete System Design: Designed all four major components (piston, cylinder, connecting rod, crankshaft) as an integrated system
- Manufacturing Process: Handled the full manufacturing process from raw materials to finished assembly
- Quality Control: Implemented inspection procedures to ensure component quality and fit
- Performance Testing: Conducted endurance testing and optimization for maximum efficiency
- Competition Success: Achieved first place and set class record in performance competition
Technical Design
The reciprocating positive displacement pump was designed with the following key features:
- Piston Design: Optimized for maximum displacement and minimal friction
- Cylinder Assembly: Precision-machined for optimal piston fit and sealing
- Connecting Rod: Engineered for strength and efficient power transmission
- Crankshaft: Balanced design for smooth operation and maximum power output
Manufacturing Process
The project involved hands-on manufacturing of all components:
- Material Selection: Chose appropriate materials for each component based on performance requirements
- Precision Machining: Used various machining techniques to achieve required tolerances
- Assembly Process: Carefully assembled components with proper fit and alignment
- Testing and Optimization: Iteratively tested and refined the design for maximum performance
Competition Results
In an endurance competition against three other teams, our pump achieved:
- First Place Finish: Outperformed all competing designs
- Class Record: Set new benchmark for water mass pumped in five minutes
- Performance: Successfully pumped 18 gallons in the five-minute competition period
Technical Challenges
The project presented several engineering challenges:
- System Integration: Ensuring all four components worked together optimally
- Manufacturing Tolerances: Achieving precise fits between moving components
- Performance Optimization: Balancing power output with reliability and efficiency
- Competition Constraints: Working within time and material limitations
Impact and Learning
This project provided comprehensive experience in:
- Full Product Lifecycle: From concept to manufacturing to testing
- Mechanical Design: Applying engineering principles to real-world problems
- Manufacturing Processes: Understanding the relationship between design and production
- Performance Optimization: Iterative testing and refinement for maximum efficiency
Reflection
This project demonstrated the importance of systems thinking in mechanical design. Creating a successful pump required understanding how each component affected the overall system performance, not just individual component optimization. The hands-on manufacturing experience provided valuable insights into the practical challenges of turning design concepts into working products.
The competition aspect added real-world pressure and constraints that mirrored professional engineering challenges, requiring both technical skill and practical problem-solving under time constraints.