HYDROGEN SENSING PROJECT

Industry Sponsored Research · FortisBC

Summary

Designed and delivered a modular hydrogen sensing platform spanning controlled laboratory testing and a portable deployable prototype. The work enabled safe experimentation, data-driven development, and successful delivery of an industry-ready sensing system.

Project Snapshot

  • Client: FortisBC
  • Context: MiNa Lab, University of Victoria
  • Role: Mechanical Design Lead
  • Scope: Mechanical design, prototyping, system integration
  • Subprojects:
    • 4.1 Sensor Development Testing Rig
    • 4.2 Portable Hydrogen Sensing Unit
  • Deliverables: Functional prototypes, full drawing packages, peer-reviewed publication

SubProject 4.1 — H₂ Sensor Development Testing Rig

Designed a laboratory testing rig to expose hydrogen sensors to known concentrations of hydrogen, methane, and ethane under controlled, low-pressure conditions. The system enabled safe, repeatable testing and served as the experimental foundation for later deployable sensing work.

SketchUp Model I was given
My Solidwork Rework
Assembled Unit
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System Architecture

  • Gas injection via mass flow controllers (H₂, CH₄, C₂H₆)
  • Primary mixing chamber followed by a dedicated sensing chamber
  • Intrinsically safe valves and pumps
  • Low-pressure operation governed by lab-developed SOPs and hydrogen safety training

My Contributions

  • Mechanical design of the sensing chamber, iterated through five revisions
  • Design of a custom PCB to control a Raspberry Pi and system actuators
  • Integration of mechanical, pneumatic, and electrical subsystems
  • Preparation of a complete mechanical drawing package (~100 pages)

Iteration and Testing

Design iterations focused on simplifying part count, improving sealing reliability, and reducing operational complexity. Manufacturing-driven changes improved assembly speed and test repeatability while maintaining experimental flexibility.

Provided Sensor Chamber
First Rework
Second Iteration
Final 3 Part Model

Data & Transition to Deployable System

The testing rig generated high-quality sensor data across controlled gas mixtures. This data supported downstream analysis and machine-learning efforts that informed the design and behavior of the portable sensing unit developed in Project 4.2.

Project 4.2 — Portable Hydrogen Sensing Unit

Developed a portable, battery-powered hydrogen sensing unit informed by laboratory testing results. The system reported hydrogen concentration in real-world conditions and was delivered as a polished prototype for client evaluation.

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System Design

  • Aluminum extrusion frame with ACM paneling
  • Modular separation between electrical enclosure and pneumatic system
  • Battery-powered operation with self-cleaning capability
  • Architecture designed to support parallel subsystem development

My Role & Leadership

  • Mechanical design lead for the full system
  • Supervised and mentored a co-op student through four months of development
  • Defined subsystem interfaces to enable parallel electrical and pneumatic work
  • Oversaw fabrication, assembly, and final integration

Outcome

The completed unit met functional requirements and was delivered to the client as a robust, deployable prototype. The modular design and build quality resulted in a highly satisfied industry partner.

Project Outcomes

  • Safe, modular platform for hydrogen sensor development
  • Deployable portable hydrogen sensing prototype
  • Full mechanical drawing packages supporting fabrication and iteration
  • Clear experimental-to-deployment development pathway
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