Andrew Burks

Tag: Solidworks

Experimental Brake Pedal

by on Aug.08, 2010, under Formula SAE, Pedals


This summer I have had access to the waterjet at NREC where I had my internship.  The current pedal design calls for a series of 2-dimensional parts that I knew I could cut on the waterjet very easily (it can cut through stuff faster than 10 inches/minute, so it’s preferable to a CNC for this application).  Unfortunately I put off cutting these parts until the last week of my internship.  At 10PM on the last Tuesday night of the summer, I realized that I needed to prepare the .dxf files (files that define the shapes of a 2-dimensional part) I would need to cut some parts out after work.

When I went to make the .dxf files, I realized that I could make the entire pedal assembly out of welded steel plates cut from the waterjet.  That night I started making a new version of the pedals (version 9) and had the rough outlines of all of the key parts by the time I went to bed at 3AM.  I also never made the .dxf files I wanted for the next day.

Wednesday night I made the .dxf files I needed for the old pedal design, then spent the rest of the night optimizing the brake pedal assembly for weight.  Here are some renders of the design, as well as some FEA results:

Render - ISO Render - Front Render - Side
Stress Plot
FEA - Stress
Factor of Safety Plot

An Exploded View Animation of the Assembly Process


On Thursday night I stayed after work to cut my parts on the waterjet off-hours.  It took about 5 hours to cut three sets of parts for the old design and two sets of the experimental pedal.  Though the brake pedal hasn’t been welded yet, the tabs were easy to press together to get a good sense of what it will look like in real life.  I was really impressed that I could go from concept to completion in only 48 hours, thanks to SolidWorks, NREC, and the waterjet.  Mike was kind enough to take some glamour shots of the final product:


PIC - Front PIC - Right
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Workstation Build Completed

by on Jun.14, 2010, under Personal Projects, Workstation

My new workstation is now humming along perfectly.  To review, the specs are:

  • Intel i7 920 Quad-core @2.66GHz (currently not overclocked)
  • ASRock X58 Motherboard
  • Nvidia FX Quadro 580 workstation graphics card
  • 6GB RAM
  • 1TB Samsung HDD
  • 650 Watt Corsair Power Supply
  • CoolerMaster Hyper 212 CPU cooler
  • CoolerMaster 335 Case

Build Observations

Putting together a computer was quick and easy.  Everything went super smoothly and was very straightforward.  I never really had to read the directions (although Mike Ornstein was guiding me heavily).  The hardest part was making sure all of my components were designed to work together.  I spent more time researching individual parts than I did assembling the whole system.

Overclocking seems unnecessary right now.  I have Solidworks running in RealView, and I can spin large models with no lag.  The biggest improvement is my rendering ability.  1920×1080 renders of complex geometries in Photoview used to take more than an hour, or just crash my laptop.  On the new computer, it takes only four and a half minutes.  This makes sense, considering that my Windows 7 Experience index raised from a 3.1 (Limited by graphics score) to a 6.9 (Limited by HDD score; Graphics and processor are highest – tie at 7.9).  I successfully played an HD movie over the weekend, and am very pleased with the results.


With one computer that i use in my room (or remote into) and another I take around with me, it is important to make sure they play nice.

I found a file synchronization tool, FreeFileSync, that I really like.  I have a “SYNC” folder on each computer, with everything I want to have available to me on any computer (School/Project/Personal files, Music, etc).  FreeFileSync matches this folder from each computer against a backup I set on my external hard drive.  So I have three sets of identical data in three separate places.

I was having trouble syncing my iTunes playlists.  The way iTunes handles its playlists and libraries is very weird.  I decided to convert to Windows Media Player, and I’ve never been happier.  All of my music (4-5GB) and playlists are synchronized now.  However, because WMP playlists are just xml data with absolute mp3 file locations, syncing the playlists would make it not work on one computer.  I solved this problem by drawing on my 15-123 PERL skillz and writing a quick script to convert the absolute file names into relative file names in the playlists (which are identical between computers) and now my playlists can synchronize too!

I have set up remote desktop and have given my friends an account so they can render on my machine.  I’m curious to see if i start remoting into my workstation when I’m on campus, or if I’ll just keep using my laptop most of the time.

I look forward to installing Synergy which should allow me to control the workstation with the keyboard and mouse on my lenovo (which I love) as well as using my laptop and workstation screens side by side, as if they were one computer.

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Why I Need a Better Computer

by on Jun.06, 2010, under Personal Projects, Workstation

Computing Needs

I don’t do that much with my computer.  I take notes in class with OneNote, and do schoolwork with Microsoft Office.  I browse the internet with Chrome, listen to music on iTunes, watch movies with KMPlayer, and chat with Pidgin.  My biggest computing needs come from 3D modeling in SolidWorks and its components, like the COSMOS FEA pack and the PhotoView 360 Rendering App.  These programs, which I frequently use for my projects, require a large amount of RAM and graphics processing capabilities.  Because there is no computer that is both portable enough to bring to class to take notes on and powerful enough to rotate a >1,000 part 3D model of a racecar, I am convinced that the best solution is to use two well synchronized computers for my two distinct use cases.

Current Computer: ThinkPad X61 Tablet

  • Windows 7 – 64 bit
  • Intel Core 2 Duo L7700 @1.80GHz
  • 4 GB RAM
  • Mobile Intel 965 Express Chipset Graphics
  • 12″ screen @ 768×1024
  • 320?GB ????rpm Hard Drive
  • Docking Station – DVD drive with CD-RW
  • Docking Station – Connects to External Hard Drives
  • Docking Station – Connects to 24″ Samsung monitor @ 1080×1920

Workstation Design

Graphics Card

My primary focus was a graphics card that would let SolidWorks run at its full potential.  I needed a workstation card with openGL support to get the most out of SolidWorks.  I decided on the NVIDIA Quadro FX 580 because of its balance between price and performance.  It connects with the PCI Express 2.0 x16 port, so it began to limit my motherboard options.


Running Finite Elements Analysis always hangs up my laptop (or crashes it) so I wanted a processor that could handle the load.  The Intel i7 family seemed to be my best bet.  I needed to choose between the i7 920 and i7 930, a difference of about 140MHz and $15.  I went with the 920 because it seemed like the more popular model, which would make community support when I try to overclock it much easier.


I wanted to find the cheapest Motherboard I could that would get me by.  I needed the 1366 socket for my processor, a PCI Express 2.0 x16 plug for my graphics card, and room for some RAM.  I found an ASRock board that had just what I wanted and had room for another x16 card with SLI support if I felt the need to expand.


When viewing a model in SolidWorks it loads the assembly and all parts and sub-assemblies and sub-sub-assemblies and sub-parts etc. into RAM.  in order to view the full model of the racecar, I wanted to make sure I had enough RAM.  Because the i7 is tri-channel, I thought 3 x 2GB sticks would be sufficient.  The motherboard wanted DDR3 RAM, so that’s what I got.

Heat Sink / CPU Cooler

Even though the i7 runs at 2.66GHz, because most of the cores arent being used all the time, it is very easy and standard to overclock them to about 4.0GHz.  However, I needed a good cooler to get there.  I chose the CoolerMaster Hyper 212 because of its good reviews and good value.

Power Supply

I wanted to make sure to leave room for expansion, so I didn’t skimp on the power supply wattage.  I found a great series of deals, sales, and rebates that ended up cutting the price of a CORSAIR 650 Watt power supply in half.  I might regret not paying a premium for modular wires, but I think it will definitely get the job done.

Hard Drive

Because I already have external hard drive with all of my data, I didn’t see the need for anything fancy.  I found a good deal on a 1TB 7200rpm hard drive that is more than enough for me.  I may regret not buying a small solid state drive to speed up the time it takes for me to boot and the time it takes to start programs.


I wanted an inexpensive case that was portable enough to be moved once or twice a year whenever I change where I live.  I also wanted to avoid any cheesy gamer cases with blue lights and annoying bells and whistles.  The CoolerMaster 335 seemed like a good, plain, simple, robust, economic option.

Optical Drive

I never use CDs or DVDs.  At Carnegie Mellon, the internet and intranet are so fast that it doesn’t make sense to transmit data any way besides the campus network.  I will not install an optical drive in the workstation, but if I need a CD drive desperately, I can always link to the docking station on my laptop.  I’m planning on installing the OS with my roomate’s 8GB USB thumbstick.


I’m going to be using the same Samsung 24″ 1080×1920 I already have with my laptop and docking station, except I can switch inputs between laptop and Workstation.

Keyboard and Mouse

While I plan on using the old wireless Logitech USB mouse I already have when I need to, I prefer the Trackpoint mouse on my Lenovo laptop.  It’s so much easier to transition from keyboard to mouse when the mouse is already next to your right pointer finger.  Temporarily I will borrow a roboclub keyboard, but eventually I might indulge in this keyboard from Lenovo.  Also, I know there is some software out there that can link my laptop to my Workstation and let me use the keyboard and Trackpoint on my X61 to control my Workstation



  • Windows 7 – 64 bit
  • Intel Core i7 920 OC @ 4.0GHz
  • 6 GB RAM
  • NVIDIA Quadro FX 580
  • 24″ screen @ 1080×1920
  • No Optical Drive
  • 1TB 7200rpm Samsung Hard Drive
  • Trackpoint keyboard?


I expect that when I’m in my dorm I will be using this computer, controlled from my laptop input with some synch program running between them.  While on campus I can take notes/go online with my laptop, but remote into my workstation for any serious business.  While off campus, depending on the internet connection, I might still be able to remote into the workstation to do serious work if I needed to.  The last component (i7 920) should arrive Monday, and I look forward to putting this together in the robotics room with the help of my friends.

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by on Jun.06, 2010, under Overhead

Purpose of the Blog

This summer, besides working at NREC on the Strawberries Project, there are a few goals/projects I am working on.  Hopefully this blog will help me keep on pace to get everything done by the end of the summer and keep my friends and family up to date on what exactly I do with my time.  If I’m committed and get positive feedback, I might even continue once the school year starts.

Robotics ClubRobOrchestra Project

After taking over the RobOrchestra project one Richie P. left, I’ve been trying to add as many new instruments as possible.  The group got nearly $1000 from the URO for a Vibraphone project.  The proposed timeline has the mechanical design completed before the Fall semester, so this project will probably take priority.  Luckily, my roommate Mike Ornstein is also on the project, so he should be able to keep me in line.  I’m also still thinking about alternative string plucking and fretting options for an upgrade to or replacement of the Whamola instrument developed last year.

Formula SAE – Custom Software

After being appointed “Full Model Guy” for the next year on the Formula team, I decided I wanted to use some of my Solidworks API knowledge/interest/enthusiasm to help organize the team.  I’ve spent several hours staring at a blank computer screen though, because I’m having trouble defining what exactly I want to make.  I definitely want to make a piece of software that can extract features from a part and use it to generate a cost report document in Excel.  Beyond that, I can’t decide how much of a version control system/custom property manager I want to make, and what kind of interface (web, add-in, both?) I want in it.

New Custom Workstation Computer

This is a personal project, although I am getting tons of advice from tons of experienced friends.  Once the parts finish arriving on Monday, I’ll take some photos and post some specs.


I’m in the middle of a lot of other projects which I should continue working on casually over the summer.  There are other RobOrchestra instruments, electronics, and coding to be done.  I also have SAE design and fabrication commitments to take care of.  If I get around to it, I might try to make some backdated posts which give a little more background about those projects.  You can also expect me to share random Solidworks or Machining tips I come across as well.  Hopefully this blog will become a very thorough and accurate representation of my technical hobbies and interests.

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