Working Details

• Phase 1: Concept & Alignment: Developed a perpendicular poppet‑valve layout actuated by a precision cam‑follower; follower bearings were synchronised to the cam profile to ensure zero‑lash timing throughout the stroke.

• Phase 2: Motion Linearisation & Pneumatics:  Created a radial force‑closed, rolling cam follower precisely machined to the RDFD motion program. SVAJ analysis generated a mathematical function that linearised follower motion, while a closed‑loop pneumatic circuit delivered ~90 psi to the cylinder at 55 % overall efficiency.

• Phase 3: Prototype Fabrication: Machined the cam, follower shaft, and housing from brass and aluminium; inlet flow was split into twin reciprocating ports that powered the paired strokes, governed by a self‑adjusting electro‑pneumatic e‑valve.

• Phase 4: Durability & Failure Review: Conducted failure‑theory analysis after 1 000 test cycles, then projected fatigue life to the billion‑cycle regime under nominal use. Translational wear, friction coefficients, and tolerance stack‑ups were recorded to refine bearing and seal selection.

Together these stages yielded a compact, serviceable valve that met leakage, efficiency, and longevity targets while maintaining manufacturability.