The problem
Develop an initial inertia-reel concept for a new product line and establish a credible path from design assumptions to future validation.
Design approach
I produced one complete assembly prototype, integrated commercial off-the-shelf components, and iterated key custom components through approximately five design revisions each. The mechanism was developed in parallel with a dynamic model to identify the assumptions most worth testing.
Modeling and validation planning
The MATLAB model incorporated shaft viscous drag, pivot friction, linkage inertia, target deployment acceleration, and deployment-pawl geometry. I also drafted the initial test plan that would guide subsequent validation work.