Verification Engineer

IronRidge, residential solar mounting hardware

 

I helped ship more than 10 products over two years at IronRidge.

As a verification engineer, I designed and executed testing programs to develop concepts from low fidelity prototypes into high volume products. I also built out our organization’s first testing lab by acquiring testing equipment and building testing fixtures.

 
 
 
Leading Testing for IronRidge's Flagship Product

 

I led verification testing for one of IronRidge’s largest product launches to date, the Universal Fastening Object (UFO). This hardware secured solar panels to our rail mounting system, with minimal installation time. My responsibilities included designing test programs, conducting testing, and managing timelines with UL certification. I also conducted production validation testing at suppliers’ sites in China and Taiwan, as IronRidge’s sole Verification Engineer representative. 

Product Family

Rail

Splice

Grounding

Lug

Rail

Fastener

A selection of products I owned verification efforts for

UFO

UFO Product Evolution

UFO Predecessor 1

UFO Predecessor 2

UFO

Prototype

UFO

First Article

UFO Solar Panel Installment Detail

Many of my verification efforts aimed at optimizing design features that minimized the time required to install the fastener.

Solar panel: solid

stopper_module_on.jpg

Solar panel: transparent

stopper_module_blend.jpg
ufo_stopper.gif
 
 
 
Testing Methods

 

I assessed components’ performance with respect to: structural integrity, electrical bonding (grounding), usability, and environmental resistance (moisture, temperature and UV).  I evaluated aluminum, steel and polymer components, in addition to product coatings.

Accelerated Aging (UV)

Accelerated Aging (humidity)

Electrical Bonding

Installed hardware

(electrical continuity through rail)

Component-Level Loading (Instron)

(compression)

Assembly-Level Loading (unloaded)

Assembly-Level Loading (loaded)

 
 
 
Designing Test Fixtures

 

I designed a set of structural loading fixtures for our Instron. I used finite element analysis to design some assemblies to transfer 10,000 pound loads with minimal deflection. The fixtures were designed to provide for efficient and repeatable testing.

 
 
 
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