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Hitch Cart “Landing Gear”, Rebekah White, Jose Raygoza, Randy Hernandez, Brandon Leon

Mechanical Engineering

This report aims to allow our sponsor, to review our design process of the Hitch Cart Landing Gear Prototype. In the design overview section of this report, we discuss the primary design modifications we made to the wheel mechanism of the existing hitch cart prototype, including the addition of the ACME screws and the folding brackets. This allows our sponsor to see the intended improvements made to the past prototype and understand the primary goal of our project. Then, in the implementation section, we cover the entire manufacturing process to allow our sponsor to understand what manufacturing steps must be …

Formula Integrated Monocoque Development, Hayden Wagner, Aaron Fang, Elijah Schulz, Carson Smith

Mechanical Engineering

Every year the Cal Poly Racing FSAE club set out to create two separate race cars to compete in the upcoming formula combustion and formula electric competitions. Both the combustion and electric formula cars operated on the same vehicle platform with the powertrain systems being the main difference between the two cars. Cal Poly Racing FSAE is the only school in California to run a full carbon fiber monocoque chassis, with each chassis design operating on a roughly four year design cycle. A new FSAE senior project team has set out to improve upon the previous chassis design as the …

Autolacing The Dml, Harrison Hong, Chanh Tu Derek Lam, Candice Espitia, Paolo Navarro

Mechanical Engineering

The design challenge present is the design of a system to efficiently speed up the lacing of the dry mat loop (DML), part of the GAF production line. For this year, the scope of the project focuses on research and creating a proof of concept for the mechanism responsible for moving the mat within the DML. Compiled research focuses on competitor solutions, material properties, and possible mover mechanisms to be integrated into the major design. Competitor solutions provide an idea of raw material manipulation options. Material properties and possible mover mechanisms provide the foundation for ideation and concept prototyping. The …

Facility Thermal Balance And Transport, Giovanni V. Minnite, Silas O R Goldfarb, Cole J. Houston, Dominique Aguilera, Cole M. Silva

Mechanical Engineering

This Final Design Review (FDR) report outlines the senior design project completed by a team of five mechanical engineering students at California Polytechnic State University, San Luis Obispo for Senior Industrial Engineer, Mr. Tom Bass, of Entegris, Inc. The team developed an innovative system to address the issue of ice accumulation on cryogenic vaporizers at the Entegris facility. Ice buildup, caused by the extremely low temperatures of the cryogenic fluid, reduces the efficiency of vaporizers and places additional stress on the system. To combat this, the team designed and constructed a prototype that utilizes a thermal transport loop to transfer …

Robot Rodeo, Daniel Rickers, Tyler Vaughn, Vinayak Sharath, Berent Baysal, Promit Das Gupta

Mechanical Engineering

This document outlines the Final Design Review (FDR) for an autonomous robot developed in response to the Naval Surface Warfare Center (NSWC) Ship Maintenance Robot Rodeo Challenge. Through extensive analysis, we selected a design concept, built a verification prototype, and tested the prototype in the NSWC Robot Rodeo Competition. The design overview portion of this report will present the details of our design while explaining how it will function. Next, is our implementation section, which provides evidence about our procurement, manufacturing, and assembly of our product. Our design verification follows and explains the tests that we conducted on the robot …

F56: Rocket Thrust Vector Control, Ethan Douglas Anderson, Yiming Trent Jia, Sahil Sampat

Mechanical Engineering

This Final Design Review (FDR) report compiles relevant information regarding the Rocket Thrust Vector Control senior project as sponsored by Ethan Anderson from Cal Poly Space Systems (CPSS). Documented in this report is our progress from the months following our Critical Design Review (CDR) completion. This consists of a brief overview of the design our thrust vector control (TVC) system and its subassemblies with design changes noted, a thorough walkthrough of our procurement, manufacturing, and assembly process for creating our verification prototype (including software), a breakdown of how we verified each of our specifications through inspection and testing and the …

Ross Dam Micro Hydro Project, Marirose Evenden, Tyler Reents, Elena Ryan, Tevan Kim

Mechanical Engineering

The Ross Dam and reservoir in Angels Camp needs a reliable power source for powering its SCADA system which monitors its water level and flow rate. Currently, the existing hydro power supply is very unreliable and needs to be replaced with a micro hydro generator system that can consistently produce power to charge the onsite batteries. This paper details the design and implementation of a micro hydro Pelton wheel replacement system designed by our senior project team.

Outlined in this report is our design overview of the system and how our project will redesign and optimize the use of the …

Quarter Car Suspension Model, Jack Miller, Alexander Eckhardt, Jonathan Lam, Max Gardenswartz

Mechanical Engineering

Dr. Porumamilla, Professor of Mechanical Engineering at Cal Poly, needs a way to demonstrate the concept of base excitation to the mechanical engineering students in the Mechanical Vibrations (ME 318) Lab. A mass-spring-damper model represented by a quarter-car suspension has been selected to represent this concept. A team of four students was assigned to design such a model as a senior design project. This document will explain the testing procedures, how were the results, and if they achieved our requirements. Furthermore, the document will explain how we assemble our product and manufacturing steps. Additionally, Critical Design Report (CDR) design changes …

Scitechatorium Exhibit, Adam Khan, Cole Busch, Logan Femling, Alan Onuma

Mechanical Engineering

This document outlines the final stages of development and analysis of our interactive children’s exhibit for the Bellevue-Santa Fe Charter School’s SciTechatorium. We will showcase the final form of our ball and track display, giving a detailed look at each component and subsystem.

To describe how our final prototype will be built we have included a detailed manufacturing summary for our design. Our models have been designed with manufacturability in mind, and we have outlined which processes were used to produce all our parts.

There are also detailed descriptions of testing that were conducted to verify the performance of the …

F21 - Variable Damper, Harrison Pomerantz, Anthony Mendoza, Owen Wilks

Mechanical Engineering

This document outlines the final design phase for the Solar Turbines Variable Damper project, aiming to enhance the safety and serviceability of gas turbines enclosure ventilation system. The primary focus of this project is to address the challenge of maintaining optimal internal pressure within the gas generator enclosures while enabling remote control of the damper position.

In this report, the full system design is described in detail. Then, the part procurement, manufacturing, and assembly of the variable damper and test stand is provided to outline the steps and processes taken to complete the final prototype. After discussing the final prototype, …

Port Adapter For Unported Pressure Sensors, Peter Kristjaan Tomson, Yasser Fahad Aldaoud, Terak Benjamin Hornik

Mechanical Engineering

Boundary layer research is an exciting and ever-changing field in fluid mechanics; thus, the need for high-quality empirical data is ever-growing in importance. Dr. Westphal, a professor at California Polytechnic State University, San Luis Obispo’s (Cal Poly) Mechanical Engineering Department in conjunction with Northrup Grumman is conducting just such research. Dr. Westphal has elected to make the change to pressure sensors that do not come with a built-in port to connect to pitot-static tubes. This necessitates a solution to adapt an unported pressure sensor to his testing apparatus which requires a tubed connection. This document outlines the Final Design Review …

Focused Led Sintering, Dylan Defazio, Nilav Maulik, Branden Majors, Michael Fontillas

Mechanical Engineering

This report provides a detailed overview of the final design of our light-emitting diode (LED) focusing system. Our system incorporates a converging lens and a specially designed "glass funnel," which acts as a thick fiber optic that narrows the light to a fine point through internal reflection. The glass components of our system are precisely housed in a part made using advanced computer-numeric controlled (CNC) Mill and CNC Lathe manufacturing processes. This ensures high precision and durability of the overall system. Our LED focusing system is designed with a 60-watt stage light. The decision to use a glass funnel as …

Cal Poly Battle Bot, Jyotaaver S. Nirula, Johnathan W. Waldmire, Andrew D. Peterson, Nathaniel Ab Davis

Mechanical Engineering

This senior project endeavored to design, construct, and optimize a 120lb robot combatant tailored for the competitive arena of combat robotics. The project is a collaborative effort between mechanical, computer, and electrical engineering students at Cal Poly, combining diverse expertise to achieve a unified goal. Our competition, RoboGames, was in April of this year in Northern California.

The mechanical engineering team assumed primary responsibility for the physical components of the battle bot, focusing on three pivotal components: a robust drivetrain, armor, and a highperformance vertical spinner. These elements constitute the foundation of the battle bot's offensive and defensive capabilities, crucial …

3d-Printed Remote Controlled Aircraft, Sebastian Bessoudo, Jose Ramirez, Manny Ruiz, Andrew Edwards

Mechanical Engineering

The Senior Project for the 3D Printed Aircraft presents a compelling challenge to the team: design and fabricate an aircraft for the Cal State LA 3D-Printed Fixed-Wing Aircraft Competition, comprising three distinct events: Flight, Design, and Simulation. The objective of the flight competition is to achieve the longest flight duration, while the design event emphasizes innovation and originality. In the Simulation contest, our aircraft's CAD model undergoes Computational Fluid Dynamics analysis to assess its aerodynamic performance. These competitions are slated for May 2024.

While building the aircraft has its limitations due to the source of our construction being only 3D …

Automated Expanding Fireplace, Fermin Moreno, Eduardo Hernandez, Wilbert Quiterio, Ben Hoefer

Mechanical Engineering

The Final Design Review (FDR) encompasses information regarding the final design verification prototype (FVP), manufacturing, testing, and future recommendations for the Expanding Fireplace Senior Project sponsored by the SLO Civic Ballet. The project aims to create the frame of an expanding fireplace set piece for The Nutcracker production at the Cal Poly Performing Arts Center in December 2024. The current set piece being used has unfavorable features that will be addressed with the new design. The current set piece being used has unfavorable features that have been addressed with the new design we have developed. Our sponsors have proposed several …

Miniature Train Engine, Jason Patrick Lacson Del Castillo, Renato Andrew Dilauro, Sophia Theresa Tiu, Robert John Pallares Iii

Mechanical Engineering

This report details the redesign of the Mini Train Prop for the SLO Civic Ballet’s The Nutcracker, aiming to create a lighter, more user-friendly, and easily maneuverable train. The Final Design Review (FDR) includes the design process, manufacturing plan, and justifications for decisions made. Key improvements are reducing the train's weight, automating the fake wheels, and enhancing maneuverability with a neutral pin and lever system. In this report we detail the significant changes since the Critical Design Review (CDR). The implementation covers procurement, manufacturing, and assembly, while design verification ensures compliance with cost, weight, turn radius, and structural integrity specifications. …

Supermileage Competition: Vehicle Chassis, Enrico Miguel Sangalang, Walter Oppelt, Adam Ponce, Vincent Corella

Mechanical Engineering

The Supermileage Urban Concept Vehicle Chassis Project was proposed by the Cal Poly Supermileage club. The goal of this project is to deliver a fully assembled vehicle chassis by the end of the 2023-2024 school year to be used by the club in the 2025 Shell Eco-Marathon competition. The competition requires a four-wheeled vehicle to comply with various requirements outlined in the Shell Eco-Marathon rulebook, such as dimensions and some safety requirements. The team selected a backbone-style chassis as the design direction. This design consists of a main structural beam that supports all other chassis and vehicle components. This main …

Rapid Composter, Cate Seay, Clarisbet De Jesus, Lesley Milena Estrada, Reese Dennett

Mechanical Engineering

This Final Design Review documents the efforts of a team of mechanical engineering students from California Polytechnic State University, San Luis Obispo as they work towards completing their assigned senior design project. This team was tasked with designing and developing an onsite rapid composter for the Girl Scouts of California’s Central Coast. The selected design concept that will be explained focuses on creating a composter that is child-safe, portable, weatherproof, solar-powered, and requires minimal manual user input. This report will not only provide a detailed description of the chosen design but will also supply an extensive design justification. This mainly …

Nsf-Eri Evolution Of Liquid Sheet Edges Project: Soap Film Frame Withdrawal And Positioning Apparatus, Samir S. Patel, Sophia Young, Nicole N. Morgan

Mechanical Engineering

The experimental investigation of instabilities along retracting liquid sheet edges seeks to answer a fundamental fluid mechanics question. We’ve successfully delivered an experimental apparatus to conduct research and answer this question. This document chronicles a design overview of our apparatus, our manufacturing process, our design verification, and recommendations for future steps. The final product is a document outlining our final design (i.e., our ‘Final Design Review’ (FDR)).

Automated Expanding Christmas Tree, Ben Mosemann, Zoey Camarillo, Xiomara Medina, Will Tedone

Mechanical Engineering

The Civic Ballet of San Luis Obispo (SLO) needs a new expanding Christmas tree for their 2024 production of The Nutcracker. This Final Design Review Report outlines pertinent information regarding the Cal Poly Mechanical Engineering Senior Project of Team F14 (“D.R.E.I.D.E.L.S.”), who was tasked of designing and building the new expanding Christmas tree frame. Our team’s name, “D.R.E.I.D.E.L.S.,” stands for Design and Research of Expansion Integrated Dramaturgy Ergonomic Leveraging Systems. We thought this would be a fun, creative, and ironic name for our team.

In this report, our team will discuss how we procured the materials required and manufactured and …

Advanced Wildfire Hose Clamp, Sean King, Christopher Tokarse, Connor Buchinski, Isaac Maddox-White

Mechanical Engineering

This report describes in detail the manufacturing, assembly, and testing of our hose clamp. We start with a review of the changes we have made to our design since our last report, namely a new automatic latching system, and continue with our manufacturing and assembly processes. Then we detail our testing procedures that we created to evaluate how well our design meets user needs and discuss the results of our tests. Unfortunately, our design did not meet our residual flow rate criteria and showed excessive leaking when clamped, so we end with some discussion of the issues our design has, …

Spring Rate Measurement Of A Pneumatic Mountain Bike Tire, Joseph D. Balderama, Alexandre Kachlakev, Duncan Wyke, Luki Rosen

Mechanical Engineering

The Final Design Review (FDR) presents a comprehensive overview of the spring rate measurement project for a pneumatic mountain bike tire. This report details the project's design, its implementation, and how it met all specified requirements. It also includes a discussion of the project's findings and recommendations for future work, assuming continuation of the project. The primary goal is to develop a device that allows professional race teams or experienced mountain bike riders to parameterize tires based on their spring rate in addition to internal pressure.

Since the Critical Design Review (CDR), the design has undergone significant changes due to …

2024 Marine Energy Collegiate Competition, Nora Riedinger, Miles Mikkelsen, Brendan Stratford, Derek Tom, Zach Kwast, Harmon Yanikian-Sutton, Kennedy Urcelay, Tori Thomas, Brady Caron

Mechanical Engineering

PolyWave Energy is the second team from California Polytechnic University at San Luis Obispo to compete in the Marine Energy Collegiate Competition. PolyWave Energy consists of Mechanical Engineering, Electrical Engineering, and Business Administration students who have worked together from September 2023 to May 2024 on designing, building, and testing a marine power device to serve a selected market.

In response to the escalating concerns surrounding carbon emissions, climate change, and the depletion of fossil fuels, California Polytechnic State University’s Polywave Energy team has developed a sustainable and reliable energy source for Autonomous Underwater Vehicle (AUV) charging. Through extensive research of …

Solar Farm, Parker Folsom, Jon Copeland, Julia Fay, Aiden Taylor

Mechanical Engineering

This senior project focused on creating a portable single-axis solar follower. The purpose of this solar follower is to allow for single-axis tracking of the sun at various points on our sponsor's property to gather information on solar power production. This data will be utilized to locate future sites for a utility-scale solar farm.

The final design of the solar follower comprises four subsystems: two legs, the frame, and the panel assembly. This modular design allows for portability and adjustability on challenging terrain. Following the design stage, our team purchased and manufactured all of the necessary components. All manufacturing work …

Bird Trail Stairway Access Replacement, Mackenzie Wright, William Spellman, Nicholas Buccino, Jack Long

Mechanical Engineering

Dana Adobe & Cultural Center, a non-profit organization in Nipomo, California, seeks to restore access to the Bird Trail located on their site. This project aims to design and manufacture a replacement stairway for safe creek bed crossing on the trail. Within this document, we have detailed our system design, function, and justification for our design. The procurement, manufacturing, and assembly plan have been outlined along with tests we completed.

One of the most important functions of our design is for the structure to be retractable so that it can be removed from the creek bed when needed. To address …

Cal Poly Bsae Brake Caliper, Carter Henry Foye, Benjamin Leistiko, Nathan Berger, Colin Williams

Mechanical Engineering

In the past, the Cal Poly Racing Baja SAE team has used off-the-shelf brake calipers for their vehicle. Off the-shelf calipers have been either oversized, resulting in a heavy and hard to package system, or undersized, resulting in an unreliable system that does not provide adequate braking power. The goal of this project was to provide a caliper that meets the requirements of Cal Poly’s Baja SAE team. Our final design consisted of a two piece CNC machined caliper that uses the complex piston seal geometry from an existing mountain bike brake caliper. Using an existing caliper as a reference …

Snap It & Send It, Samantha Gonzales, Brienne Berger, Kelsea Clays, Jessica Schmok

Mechanical Engineering

This report details the final design, manufacturing and assembly, testing procedures and results, as well as future design recommendations of a device aimed at enhancing the mountain biking experience for individuals with limited thumb strength. This project particularly focused on the experience of our sponsor, Cal Poly Mechanical Engineering Professor Andrew Kean. Our team's objective was to create a secure, ergonomic handlebar grip system that does not require thumb strength and is adaptable to various mountain bike models. The final design utilizes a rigid hook that snaps onto mountain bike handlebars with a long, flat piece that slides into a …

Cal Poly Fluid Power Vehicle Challenge 2024, J. Mason Gray, Ryan D'Amour, Alberto Acho Lopez, Christian Ferrandino, Johnathan Dietz

Mechanical Engineering

In this Final Design Review, the Cal Poly Fluid Power Vehicle Team competed in Norgren’s 2024 Fluid Power Vehicle Challenge. The design need of the competition was for college teams to compete with human-powered, hydraulic-driven vehicles in an endurance race, a sprint race, an efficiency race, and a regenerative power race. The competition need was to design a vehicle to win in as many races as possible, achieving the highest overall score and winning the competition. With a design emphasis on the endurance and sprint race, the Cal Poly team designed a fluid power system that fastened to a purchased …

Removable Equipment Climate Canopy, Jessica Perez, Sabine Heid, Zil Panchal, Anali Salazar

Mechanical Engineering

The Climate Canopy Project has developed an improved solution for creating an adjustable shade mechanism tailored specifically for users of pull walkers. Through extensive research, goal setting, and a comprehensive framework our project has examined the challenges faced by individuals who rely on walkers for mobility. Our stakeholder requires a product that is lightweight, removable, and compact. This study dissected the designs of previous products on the market and aimed to build a product that aligns with our sponsor’s desires.

This report presents the main goals for the design and manufacturing process, along with key design features utilized to produce …

Exhaust Manifold Pressure As Engine Tuning Parameter, Kieran Truth Cunningham, Adam Sullivan Mathews, Connor Richard Smullen

Mechanical Engineering

In this project, the exhaust manifold absolute pressure (EMAP) of a 1986 Toyota Corolla was analyzed across a variety of load cases and was compared with the mass air flow (MAF) of the intake, simultaneously. Correlations were found in the trends of EMAP and MAF sensor readings that may prove helpful in tuning engines that have difficulty in accommodating a MAF sensor. These correlations were found in areas of the powerband where aftermarket tuned engines typically have poor airflow sensing. An equation was developed to spoof MAF input using EMAP and other engine operating parameters.