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How Should I Help My Cousin Succeed With His Ambitious Engineering Project Without Taking Over? (PhD supervisors please pitch in)

LondonNight

Mechanical
Nov 21, 2024
4
Let’s take a pragmatic approach to this situation. I want to describe things as they are without sugarcoating, to better convey the challenge I'm facing and get advice.

I graduated in mechanical engineering and have been passionate about technical projects since childhood. DIY projects were my thing growing up, and I’ve always enjoyed researching engineering topics, even those I might never use practically, like railway systems, nuclear power plants, or steam power plants.

One of my proudest achievements is a project I worked on with my cousin over the course of four years during summer breaks. I was in university, and he was in high school at the time. Together, we built a fully functional railway speeder. I was responsible for the engineering aspects, such as designing load-bearing components, electric circuits, and mechanical systems. My cousin focused on the creative side: naming the project, choosing the color scheme, and designing the interior layout. He also helped me a ton in drilling holes, cutting material, polishing or sanding, basically he was my right hand when it came to building the physical object itself.

The project turned out great and even became my bachelor’s thesis, for which I wrote a 100-page paper. It was a big success and something I’m incredibly proud of.

Fast forward to now. My cousin is in his first year of university, and he wants to start working on his own bachelor’s thesis project—an ambitious one. He’s set on building a 10 kW steam-powered electric generator, not a small mock model but a full-scale working system. His design includes a monotube steam generator, an uniflow motor driving an electric generator, and its gonna be a closed steam system with no lubrication—an incredibly complex undertaking. He has four years to complete it.

Here’s where things get tricky. Over the years, I’ve done extensive research into steam power systems as a hobby and have a pretty solid understanding of how such a system could/should be built. My cousin, however, is still in the early stages of his engineering journey. His experience is limited to the railway speeder project we worked on and his high school robotics group, where he built small robots for competitions. From what I’ve observed, his approach is still very trial-and-error, which is fine for learning but not ideal for tackling a complex project like this.

Naturally, he’s asked me to help him design and build the generator. I want to help, but I don’t want to overshadow his learning process. This is his project, and I want it to stay that way. If I take over and provide all the answers, he won’t develop the skills he needs as an engineer. On the other hand, this is an extremely challenging project, and without guidance, he might not succeed.

The complexity of the project leaves little room for trial-and-error. Mistakes in the early design stages could lead to significant setbacks, and there’s simply not enough time to start over repeatedly. I’ve already envisioned how the system should work, but I don’t want to hand him a blueprint and say, “Here, build this.” I want him to do the research, learn, and come to his own conclusions—just as I did when I first started exploring steam power systems - precisely so that he grows his skills as an engineer.

So, here’s my dilemma: How do I strike the right balance? I want to help him succeed with the project, but I also want him to grow as an engineer. I don’t want to take over, but if I don’t help enough, the project might likely not be built in the available time frame, and that will be considered a failure to build it for its purpose (to serve as a bachelor thesis project), and will demoralize him incredibly, not to mention that he won't have a working project which is required to finish the bachelors degree.

What’s the best approach to take in a situation like this? How can I provide the support he needs without undermining his opportunity to learn and take ownership of the project? If you’ve been in a similar situation or have advice on mentoring someone through a complex engineering project, I’d love to hear your thoughts.
 
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I am not a PhD supervisor by any means, but I have been mentoring and teaching engineers and technicians in my area of expertise for more than three decades, out in the "real world" of industry.

The proposed project has a lot of scope, certainly. Maybe see if some of the things interest him more than others - does he want to do the piping? How about the thermodynamics of steam generation and (efficient) use of volume and pressure? Or is it in the fact that things "move" (i.e. the electrical generator itself and the physics of the drive train)? Sound him out - and maybe offer some suggestions on the parts he doesn't want/feel comfortable with?

At the early decision phase, nudge him in a direction where he can still make mistakes but can correct them (fairly easily) during his preferred trial-and-error approach. It seems you might have a few tricks up your sleeve if things get really dicey - so hold that in reserve. And remember it IS a project, so it doesn't have to be perfect.
 
LondonNight,

You mention steam. Who is responsible for safety with this thing? Are you qualified? Boilers are an excellent thing to not learn by trial and error.
 
LondonNight,

You mention steam. Who is responsible for safety with this thing? Are you qualified? Boilers are an excellent thing to not learn by trial and error.
It's a monotube boiler, who will absolutely not be fired up without me being on site. Those don't explode, at most what can happen is a pipe ruptures and it hisses out steam inside of the boiler's enclosure. The boiler will use wood fire, so there's no gas to burn or explode.
 
Perhaps sit down with himnad break it down into both the stages of the project - concept, design, procurement, construction, safety/risk, commissioning and operation and then also the component parts - boiler, piping, steam motor, generator, control system, electrical components and then discuss how long each one of those is going to take, both from a manhour point of view and a physical point of view. Then see if the enormity of what he's doing, never mind the costs, comes home.

A 10kW system is pretty big. Where is that power going to go? The grid won't want it so what does he plan to do with 10kW of electric power you need to throw wood into every few minutes.

Also what is going to be the point or research or usage? otherwise its just someone making a small steam powered electric generator. Great project as a hobby for sure, but a university project?

Perhaps get him to look at buying some elements already designed and constructed as apacakge by others and then optimising some aprt of it, but again I get back to what is the purpose of this? Just to research, design and build something or actually do it to test or prove or investigate a different way of doing that makes it easier, cheaper, more efficient?

The brain storming bit is often the most fun.

So what about a portable mirror solar powered steam system to be used off grid in remote areas / disaster relief where power for phones and other devices is vital?

Basically any "renewable" electricity generation scheme is going to be better than just burning wood ( and you're going to need quite a lot of trees for 10kW). There's a lot of homemade water powered stuff or small wind powered ones out there which needs a better design to improve it, make it cheaper, simpler etc.
 
Perhaps sit down with himnad break it down into both the stages of the project - concept, design, procurement, construction, safety/risk, commissioning and operation and then also the component parts - boiler, piping, steam motor, generator, control system, electrical components and then discuss how long each one of those is going to take, both from a manhour point of view and a physical point of view. Then see if the enormity of what he's doing, never mind the costs, comes home.

A 10kW system is pretty big. Where is that power going to go? The grid won't want it so what does he plan to do with 10kW of electric power you need to throw wood into every few minutes.

Also what is going to be the point or research or usage? otherwise its just someone making a small steam powered electric generator. Great project as a hobby for sure, but a university project?

Perhaps get him to look at buying some elements already designed and constructed as apacakge by others and then optimising some aprt of it, but again I get back to what is the purpose of this? Just to research, design and build something or actually do it to test or prove or investigate a different way of doing that makes it easier, cheaper, more efficient?

The brain storming bit is often the most fun.

So what about a portable mirror solar powered steam system to be used off grid in remote areas / disaster relief where power for phones and other devices is vital?

Basically any "renewable" electricity generation scheme is going to be better than just burning wood ( and you're going to need quite a lot of trees for 10kW). There's a lot of homemade water powered stuff or small wind powered ones out there which needs a better design to improve it, make it cheaper, simpler etc.
You have some good points. I'll think about it. Thank you for taking the time to respond.
 
I am not a PhD supervisor by any means, but I have been mentoring and teaching engineers and technicians in my area of expertise for more than three decades, out in the "real world" of industry.

The proposed project has a lot of scope, certainly. Maybe see if some of the things interest him more than others - does he want to do the piping? How about the thermodynamics of steam generation and (efficient) use of volume and pressure? Or is it in the fact that things "move" (i.e. the electrical generator itself and the physics of the drive train)? Sound him out - and maybe offer some suggestions on the parts he doesn't want/feel comfortable with?

At the early decision phase, nudge him in a direction where he can still make mistakes but can correct them (fairly easily) during his preferred trial-and-error approach. It seems you might have a few tricks up your sleeve if things get really dicey - so hold that in reserve. And remember it IS a project, so it doesn't have to be perfect.
Thanks for the reply. I have to work with myself mentally a little, because as I am right now, I keep forgetting that it is a project, and it doesn't have to be perfect.
 
You have some good points. I'll think about it. Thank you for taking the time to respond.
Something that would be good maybe is how to use all the waste heat conventional systems throw away at 40, 50, 60, 70C using some of the newer chemicals.
 
What's the actual scope of work being proposed?

Creating a CAD concept and basic analysis for a 10kW boiler, engine, and generator is doable over a few months. Building them OTOH would require months of fabrication, cost more than my degree in materials, and cost more than most Capstones in consumables alone. Even if you cobble a used generator onto a restored antique engine and run it off air, you're looking at $$thousands.

Being a Capstone not due for four years, the other big question that cannot be answered is what the project requirements will be in four years' time. Schools' and professors' expectations vary and change. Many require students to work through the entire development cycle with a realistic, small project - develop a business case, develop/analyze/build/test a concept, estimate and reduce costs, research and address maintenance/repair, regulatory, and end of lifecycle concerns/costs, etc. Others treat it as a glorified craft project - doodle CAD for anything imaginable, cobble a model or prototype, write a report showing bad application of engineering principles, and if well-written the student gets an A or B. About ten years ago my former employer was solicited and sent me to judge/award a trophy for the "best" Capstone at my wife's alma mater ("top" engineering school) - an extended bicycle fork with a lawn mowing reel replacing the wheel. I was polite to the students but told the dean and several faculty members that I thought the class was a waste if nobody including the faculty was taking it seriously and there was nothing learned. Not surprisingly, that school's grads frequently struggled with employment bc they'd never been taught basic engineering process, norms, or skills.
 
Building a 5" steam engine from castings is about 2 years work. That doesn't include design time. Your project is simpler in detail, but much bigger physically.



image_2024-11-22_102302272.png

Here's a15 hp steam engine, and an 8 kW genny, 105 kg

image_2024-11-22_102447237.png
 
Or in a more sensible context, the entire powerplant is of similar size to a Stanley Steamer's. A couple of 4" double acting pistons. I get what you are saying about the safety of monotubes but 600 psi steam is not gentle.
 

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