Wade Doll10/1/2013

Select projects I am proud to have lead or been a major contributor…

All images and videos were obtained from public domain

The worlds most precise AWJ machine

Position repeatability of +/-0.0001” and motion accuracy of +/-0.0004”

Matched thermal expansion and stability

Zero backlash motion control system featuring optical encoders with 0.000004” resolution

Highly engineered and analyzed for rigidity and vibration control

Design goal of this server was to drastically reduce TCO (OPEX+CAPEX)

Cooling fan power <1.0% of rack power Can operate with 50c ambient air (or 45c water) Total power train efficiency >90% (that’s cord to

chip, not just PSU) Nearly 1,000 servers (multi-core) in a standard

19” rack. Around 40kW/rack… Also designed versions with many-core cpu’s,

Infiniband networks and storage Game changing performance and technology of

this server blows away the competition. I can’t show all the cool stuff inside for

proprietary reasons, I was also vague for the same reason…..

Same upgradable architecture used since 2003 in Sandia’sRedstorm system through today's XE6 product

Doubled the socket density from 96 to 192

Tripled the power from 16kw to 50kw per cabinet

Increased the socket power by 50% from 90w to 135w

Even with all this, was able to cool & power with higher air temperatures than the original 2003 system with only minor, ingenious hardware upgrades….

Uses an evaporator coil flooded with R134a mounted in the hot exhaust of the rack.

Removes the heat before it enters the room; more efficient than CRAC units and at <1/4 the footprint.

First used in Oak Ridge’s Jaguar

Used in Cray’s MTA-2 systems shipped in 2002

Uses fluid (water, flourinert, oil ..etc) pumped around the blade to cooling caps on the ASICS.

This was done way before it was in vogue…..

Integral part of Sandia’s Red Storm supercomputer data security

Mechanically (required by customer) breaks network connections between groups of racks

Aligns, mates and un-mates thousands of signal pins simultaneously.

Has operated thousands of cycles without connector damage

Partnered with a Turbo-design company for the original aero design

Capable of 11.0” H2O at 3,500cfm (fan is about 16” dia with a 5hp motor

Later made improvements to increase electric-hydraulic efficiency to 90%. Compare this to the best muffin fans available at ~50%

The Cray XT5 Jaguar Supercomputer http://www.youtube.com/watch?v=WuFG-8BCB_Q http://www.youtube.com/watch?v=WIGLvu9pLqo&feature=

related http://www.youtube.com/watch?v=zx677CceBAc&feature=re

lated http://www.youtube.com/watch?gl=JP&v=ehCgG9yZQmg http://www.youtube.com/watch?v=OE9PDcuJgMA&feature=

related

Skid mounted cryogenic system made it economical to recover, clean and liquefy “low quality” natural gas

Novelty revolved around low cost installation and CO2 separation.

Typical installations included land fills, stranded wells and digesters.

Largest transport cask licensed in the US (Trupact III)

Intended for over the road transport on conventional ISO trailer

Designed to stringent NRC guidelines

That’s a picture of it being drop tested!

Achieved what was previously considered impossible: creating an ultra high pressure Down-hole Pump, powered by conventional mud pumps at the surface.

Design solutions involved the latest high performance materials, coatings, and processes

Monumental stress, fatigue and sealing challenges were addressed and solved

Continuous operation pumping abrasive slurry at over 35,000 PSI.

Abrasive fluid jet aided the bit in fracturing the rock.

Achieved 1.5x conventional drilling rates at depths over 10,000’.

The technology was based on a steerable micro-tunneling system that could install underground cable without surface disruption

Revolutionized the construction industry

Nothing existed; everything had to be designed from scratch: pump units, dollies, booms, steering tools, pipe…etc

Designs used pistons and helical gears to transfer linear hydraulic force to rotary motion

Precise and repeatable rotary control

Challenges included: sealing, manufacturability, stresses and materials

Used in booms, steering and construction equipment

Several more pending…