Portfolio

Mohamed Samy Afifi

Mechatronics MBD Engineer

An engineer with a solid technical foundation in robotic system design, control algorithms, and sensor-actuator integration, gained through hands-on projects.
I’ve worked on developing systems such as 3D printers, PCB CNC machines, laser cutters, hot wire CNCs, autonomous vehicles, and specialized devices like neck coolers, solar cell cleaning robots ...etc. Also, I led a team in building a Cube Satellite platform, focusing on deployment mechanisms.
As a teaching assistant, I guided students in embedded systems development and contributed to academic research, publishing on optimal fractional order PID control. Currently, I am a Model-Based Design Engineer at Valeo, applying my expertise on thermal system applications in the automotive industry.

Projects Highlights

3U-Cube Satelite

A three-unit CubeSat with a mission to record the Earth's surface. My team was responsible for developing the mechanical structure, as well as the deployment mechanisms for antennas and solar panels. The project objective was to create a fully functional CubeSat for destructive testing on Earth, using the data to develop a launch-ready model.

Assembly Video Testing Video More

BurnWire Foam CNC Machine

Development of the mechanical design and tightening mechanism of a burn-wire CNC machine.
It was dedicated to cutting foam into specific shapes for rifle gun suppressors.

Vending Machine

The hot beverage and snacks vending machine consists of five main subsystems:
Coin Detector: Identifies coins based on their dimensions and material. Cup Dispenser: A single-input actuator mechanism that dispenses one cup with each trigger. Ingredient Dispenser: Dispenses a specific amount of ingredients based on the user's selection. HMI : Includes a keypad and an LCD display for customer interaction. Serving Subsystem: Moves the cup through the various refilling stages.

Driver In The Loop Simulator

The goal is to provide a comprehensive simulation environment that supports Software-In-the-Loop (SIL), Hardware-In-the-Loop (HIL), and Driver-In-the-Loop (DIL) testing. This environment enables integrating the driver into the simulation loop, allowing for the collection of crucial data to test software and hardware systems as well as assess driver reactions to specific scenarios.

Can Crusher

This DIY can crusher is designed for effective, high-force crushing, using a compact setup to minimize manual effort. Powered by an 8.8 kg-cm DC motor, it operates a crank and shaft pump that magnifies the input force by 20 times, making it powerful enough to crush a can completely within 20 seconds. The project demonstrates a practical application of force multiplication through mechanical advantage, optimizing the input motor power to achieve substantial crushing force efficiently.

Solar Panels Wiper

This DIY solar panel cleaner is designed for autonomous operation, ensuring efficient and regular maintenance of solar panels. Equipped with a dust sensor and voltage feedback system, the machine can detect dust buildup and performance drops, activating automatically to clean the panels as needed.

Laser Cutting Machine

This project focuses on the development of a robust laser cutting machine with a cutting bed size of 100 x 80 cm and a powerful 150W laser. The machine is designed with a durable metal frame to ensure structural stability and longevity, suitable for high-precision and heavy-duty cutting applications. The layout integrates user-friendly control interfaces and efficient motion control systems, optimized for various industrial cutting and engraving tasks.

OMR Machine

This project entails the development of an Optical Mark Recognition machine designed to automatically grade bubble sheets using infrared (IR) sensing technology. The system operates by detecting the color contrast between black and white marks and leverages a 2D Cartesian mechanism to navigate and scan the sheets accurately.

Smart Soil System

Precision irrigation is a unique sustainable agricultural approach that allows the application of water and nutrients to the plant at the right time and place and in small measured doses in order to provide it with optimal growing conditions
Usually used in areas where rainfall is irregular or dry times or drought is expected
Can be used in the case indoor plants or gardens
Take care of your plant when you travel

U-Arm

Cartesian 3D printer

DIY 3D printer is a Cartesian Fused Deposition Modeling (FDM) machine with a build volume of 15cm x 15cm x 20cm.

Neck Cooler

This portable neck cooler is designed for use in hot climates, using the Peltier effect to cool the blood flow around the neck, which helps regulate body temperature. Lightweight and rechargeable, it offers a customizable fit for optimal comfort, making it suitable for outdoor activities or daily wear in high temperatures.

Optimal Fractional Order PID Control of Sensorless BLDC Motor

This paper presents the implementation of a Fractional Order PID (FOPID) controller for regulating the angular speed of a Brushless DC (BLDC) sensorless motor. The controller is optimized using the Flower Pollination Algorithm and Genetic Algorithm (GA) to determine the optimal values for the fractional order system parameters and PID parameters of the controller. A comparison between the results obtained from FOPID and PID controllers is conducted, focusing on the strengths of FOPID in terms of rising time, overshoot, and settling time when controlling the angular speed of the BLDC motor. The simulation results unequivocally demonstrate that FOPID is the optimal choice for angular speed control, yielding a satisfactory transient response, particularly with regards to the critical rising time aspect, which holds significance across a wide range of applications involving BLDC motors.

Published in: 2023 IEEE International Conference on Omni-layer Intelligent Systems (COINS)

DOI : 10.1109/COINS57856.2023.10189249

M. Samy Afifi

T.A.@NileUniversity

Work Experience

Model Based Design Engineer (Current Job)

@Valeo

Currently act as Feature Owner for High Voltage Coolant Heater products, working closely with Stellantis and Jaguar Land Rover (JLR) OEMs. Responsible for leading feature development and integration to ensure alignment with OEM specifications and performance standards.

Teaching Assistant

@Nile University

Instructed senior students in embedded systems development, delivering a comprehensive and practical syllabus. Conducted research and published a conference paper on optimal fractional-order PID (FOPID) control for brushless DC (BLDC) motors.

Mechanical Design Engineer

@First Group CNC

Manufacturing of mechanical spare parts used in Railways, automotive and Oil industry.
Designing and manufacturing of vacuum and injection molds.

Mechtronics Engineer

@Celestial ALTIUM Lib.

Developed high-quality electronic component models, encompassing both mechanical and electrical aspects, to ensure accuracy and functionality in design and simulation applications.

Reach Me

[email protected]Linked in Twitter Github