Engineering Commons^™

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 …

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 …

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 …

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 …

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 …

Rapid Composter, Shannon Shinozaki, Avin Atencio, Jonathan Fraser, Lukas Kolbl, Russell Occhipinti

Mechanical Engineering

This project was created with the intent of automatically composting equine bio waste to be reused as plant fertilizer. The system consists of four subsystems: power generation and storage, automatic controls, aeration, and structure. Each subsystem may be manufactured independently, then put together. This system will not have access to power outlets, so it was designed to be solar-powered.

Power Thyristor Controller For Speed Control Of Dc Motor, Alejandra Zapata, Morgan Erich Boehme, Abdullah Mohammed Awidah, Payton Robert Chalstrom

Electrical Engineering

In this work, a Power Thyristor Controller for Speed Control of DC Motor has been developed with the purpose of replacing an existing simulation experiment, aiming to effectively implement the principle of learning by doing. The primary objective of the experiment setup is to illustrate the fundamental principles and operational mechanisms underlying the firing angle and controlled bridge rectifier. The new experiment is taking advantage of the existing FCRO4100 Single Phase Firing Board that was donated to the University by ENERPRO. The pre-programmed microcontroller is connected to the thyristor bridge rectifier that’s powered by 24VAC. Additionally, a DC motor will …

Gasifier Wall Wash Manifold, Ashley Sieu Che, Gintaras Julius Baipsys, Peyton Joseph Archibald, Michael Thomas Kieran

Mechanical Engineering

The objective of our Gasifier Wall Wash Manifold Project is to design three different manifolds that will uniformly distribute water on the inner diameter of a pressure vessel. Also, the distributed water should completely cover the circumference of the inner walls. From extensive research of current solutions as well as the conduction of technical analyses, we were able to produce three designs that would be able to meet our engineering specifications. Time constraints led to the fabrication of one manifold design along with a test rig. With a fully functional test rig, we saw positive results from our design verification …

Sunsation’S Solar Powered Picnic Table, Michelle M. Barnett, Christopher Barber, Casey Durham, David Mason

Mechanical Engineering

Team SunSation is an interdisciplinary senior design project group that was tasked with developing a semi-permanent seating area for Cal Poly's electrical engineering courtyard. The EE courtyard is populated with plastic folding tables and chairs that are slowly falling apart. Dale Dolan, the head of the EE department, requested that a table design be developed that incorporates the use of solar panels. The addition of the solar panels to the table would help promote clean renewable energy as well as provide shade to those sitting in the courtyard.

The solution that SunSation arrived at is broken up into mechanical/structural, electrical, …

Mmteg Heatsink Design, Peyton Nienaber, Kadin Feldis, Alec Savoye, Jack Waeschle

Mechanical Engineering

In this document, Cal Poly Senior Design Team F16 presents a summary of its work developing a suitable heatsink for Gas Technology Institute’s Methane Mitigation Thermoelectric Generator. After several months of iterating between experimental testing and simulated heat transfer, a suitable prototype was selected for use in further refining simulation parameters. This was called the structural prototype and it allowed Team F16 to confirm several remaining unknowns relating to component thermal conductivity. All documentation of this process can be found in Preliminary, Critical, and Interim Design Review documents (PDR, CDR, IDR), included in this report. Having a realistic model …

Baker/Koob Final Report: Solar Solution For Mini Mars Rover, Jonathan Cederquist, Cole Korchek, Derick Louie, Michaella Ochotorena, Collin Petersen

Mechanical Engineering

This project focused on designing, building, and testing a functional prototype of a collapsible solar array on the mini Mars rover being developed by client and sponsor, Mr. Rich Murray. Although many previous collapsible solar arrays have been deployed for space missions, the previous solar-powered Mars rovers only deployed their arrays once upon landing. This solar array will be able to collapse and deploy multiple times to allow for greater rover mobility and stability when the rover is not charging. This system is critical to the success of the rover project because it provides power without which the rover cannot …

Solid Thermal Storage As An Energy Storage Device In Insulated Solar Electric Cookers: Thermal Modeling And Experiment, Michael Antonio Fernandez

Physics

The use of solid thermal storage (STS) as an energy storage device in insulated solar electric cookers (ISEC) was explored using a thermal simulation before retrofitting an existing cooker without energy storage and testing it under several conditions. STS sizing, material selection, and geometry were examined from both theoretical and practical perspectives and re-examined following experimental results. Characterization of the system’s thermal interfaces and methods to improve their thermal conductivities were investigated resulting in several performance enhancements to the system.

Cal Poly Fluid Power Vehicle Challenge 2022, Sangmin Sung, Eddy Rodriguez, Travis Welch, Jeremy Baechler, Kevin Pauls

Mechanical Engineering

In this report, the Featherweight Cycles design team puts forth the scope and overview of their design project, discusses background research and competitor analysis, and presents the project’s final design and manufacturing plans. The overall goal of this project is to fabricate and compete in the Fluid Power Vehicle Challenge, hosted by the National Fluid Power Association. To better define the design process, the team researched previous year’s designs from Cal Poly, as well as winning designs from the last two years to form a baseline of knowledge about competing schools’ designs. After researching multiple design paths, Featherweight Cycles chose …

System Performance Model And Control System For A Small-Scale Horizontal Axis Wind Turbine, Niko Banks

Master's Theses

Predicting the performance of wind turbines is a key part of the turbine design process and operation, as predictive models play a large role in determining potential power output and efficiency at different operating conditions to help maximize production. On small-scale wind turbines performance models become more complex, as the rotor aerodynamic performance depends not only on the tip speed ratio, but also on the flow Reynolds number. An accurate predictive model that includes this behavior on small-scale wind turbines can be used to find the optimal operating conditions for power output, and is also a critical component of the …

Performance Loss Rate And Temperature Modeling In Predictive Energy Yield Programs For Utility-Scale Solar Power Plants, Katelynn M. Dinius

Master's Theses

The Gold Tree Solar Farm, designed by REC Solar, has a rated output power of 4.5 MW and began operation in 2018 to provide electricity to Cal Poly’s campus. Gold Tree Solar Farm site terrain consists of rolling hills and uneven slopes. The uneven typography results in interrow shading, requiring a modified tracking control algorithm to maximize power production. Predicting a utility solar field’s lifetime energy yield is a critical step in assessing project feasibility and calculating project revenue. The MATLAB-based predictive power model developed for this field overpredicted power in the middle of the day. The purpose of this …

Consumer-Ready Insulated Solar Electric Cooker, Simon Ford, Sachin Gokhale, Brendan Lynn, Richard Nguyen

Mechanical Engineering

An insulated solar electric cooker, or ISEC, converts solar energy into electricity to cook food, boil water, provide heat or even help charge batteries. In this project, the focus is an ISEC with a phase change material (PCM) that helps store heat when the solar energy input is minimal, such as after the sun has set. Although a successful ISEC already exists that utilizes PCM, this product can be improved in many ways. The specific revisions investigated in this report are the improvement of the thermal efficiency with the implementation of a vacuum-sealed outer pot, the reduction of the overall …

Cal Poly Wind Power: Wind Turbine Prototype, Sophie A. Spencer, Maggie Nevrly, Michael Reyna, Loi Q. Nguyen

Mechanical Engineering

The Cal Poly Wind Power (CPWP) club is competing in the Collegiate Wind Competition (CWC) hosted by the National Renewable Energy Laboratory (NREL). The CWC is hosted annually by NREL to increase the number of skilled workers prepared to work in the wind energy industry. Our senior project team is one of several design teams contributing to the CPWP prototype turbine design including the pitching mechanism, blade design, generator, and shaft. The scope of this project is to design the yaw mechanism, tower, and nacelle. The goal is to create components that function well with other planned components and are …

Sustainable Energy Storage, Jacob S. Grillo, Alyse C. Coonce, Jack R. Linchey, Nick P. Schnorr

Mechanical Engineering

This Final Design Review document covers the work we, students at California Polytechnic State University – San Luis Obispo, have performed in collaboration with Mr. Harish Bhutani and Dr. Mohammad Noori. The project’s intent is to create an energy storage system for off-grid and developing region applications using alternative technologies to lithium-ion battery storage. We plan to manufacture and assemble a scale model of the energy storage system to prove effectiveness and practicality. This system will store enough energy to power basic appliances and essential devices for a house or community. The chosen design direction will be a flywheel, as …

Sustainable Tiny Home, Abigail Jessica Jones, Vince John Bugni, Sean Robert Paddy, Cameron Michael Gross

Mechanical Engineering

As housing prices and environmental concerns continue to increase, many people are looking for cheaper and more sustainable ways to live. A solution to both problems is building homes with smaller footprints which incorporate renewable energy and water-reclamation systems. In addition, adding a roof pond system to the dwelling also reduces the need for heating and cooling. The roof pond system uses a water bladder on the roof which acts as a heat-sink and moveable insulation panels. This document contains the process for our final design along with results from testing the verification prototype.

Implementing A Data Acquisition System For The Training Of Cloud Coverage Neural Networks, Weston C. Montgomery

Master's Theses

Cal Poly is home to a solar farm designed to nominally generate 4.5 MW of electricity. The Gold Tree Solar Farm (GTSF) is currently the largest photovoltaic array in the California State University (CSU) system, and it was claimed to be able to produce approximately 11 GWh per year. These types of projections come from power generation models which have been developed to predict power production of these large solar fields. However, when it comes to near-term forecasting of power generation with variable sources such as wind and solar, there is definitely room for improvement.

The two primary factors that …

Power Output Modeling And Optimization For A Single Axis Tracking Solar Farm On Skewed Topography Causing Extensive Shading, Logan J. Smith

Master's Theses

Many utility-scale solar farms use horizontal single axis tracking to follow the sun throughout the day and produce more energy. Solar farms on skewed topography produce complex shading patterns that require precise modeling techniques to determine the energy output. To accomplish this, MATLAB was used in conjunction with NREL weather predictions to predict shading shapes and energy outputs. The MATLAB models effectively predicted the sun’s position in the sky, panel tilt angle throughout the day, irradiance, cell temperature, and shading size. The Cal Poly Gold Tree Solar Farm was used to validate these models for various lengths of time. First, …

Smud Solar Regatta, Logan Garby, Nam Le, Jacob Singer, Alejandro Carrera, Laura Casas

Mechanical Engineering

The Sacramento Municipal Utility District (SMUD) hosts the Solar Regatta every year in Rancho Seco, CA, a competition which consists of teams building a solar powered boat to compete in three races: the sprint race, endurance race, and slalom race. The Cal Poly Solar Regatta team was informed mid-project by SMUD that the competition has been canceled once again for spring 2021, but the team decided to move forward with the construction of the boat. The previous Cal Poly team from 2019/2020 designed the hull and propulsion system of the boat. The 2020/2021 team worked with the previous team in …

Field Testing The Effects Of Low Reynolds Number On The Power Performance Of The Cal Poly Wind Power Research Center Small Wind Turbine, John B. Cunningham

Master's Theses

This thesis report investigates the effects of low Reynolds number on the power performance of a 3.74 m diameter horizontal axis wind turbine. The small wind turbine was field tested at the Cal Poly Wind Power Research Center to acquire its coefficient of performance, C­_p, vs. tip speed ratio, λ, characteristics. A description of both the wind turbine and test setup are provided. Data filtration and processing techniques were developed to ensure a valid method to analyze and characterize wind power measurements taken in a highly variable environment. The test results demonstrated a significant drop in the …

Cal Poly Microgrid Fixed Pv Array, Christopher L. Ewert, Justin R. Syracuse, Donald A. Syracuse, Jason M. Kehl

Mechanical Engineering

The Mechanical Engineering Department at California Polytechnic State University of San Luis Obispo would like an adjustable, fixed angle solar panel mount to help educate students on basic solar energy principles. Our team has developed a unique sawhorse design utilizing ideation techniques and design selection tools. The selected design allows for multiple panel adjustability and control of both azimuth and tilt angle. Safety concerns are addressed with action plans to mitigate risk. Concept prototypes to justify gearbox functionality and subsystem cohesion was utilized to reduce manufacturing issues. Manufacturing began in March 2020 and proceed through until the end of the …

Thermal Energy Storage For Load Shifting, Jordan Benton Lopez Corley, Weston Cruz Montgomery, Taylor Glenn Harms

Mechanical Engineering

The following document accounts for the progress made in the prototype development of our design solution since the Critical Design Review, and our group’s response to recent world events which greatly impacted planned activities. Our design challenge is to develop a thermal energy storage system which will sequester the energy from a photovoltaic (PV) array during the day and allow for its dispersal at night in the form of near boiling water. Looking at our user’s needs, we broke our design solution into four components: water heating, storage, distribution, and controls. Research of all components was conducted to ascertain which …

Design Of Structural Stand For High-Precision Optics Microscopy, Sara T. Novell

Master's Theses

Lawrence Livermore National Lab (LLNL) is home to the National Ignition Facility (NIF), the world’s largest and most energetic laser. Each of the 192 beamlines contains dozens of large optics, which require offline damage inspection using large, raster-scanning microscopes. The primary microscope used to measure and characterize the optical damage sites has a precision level of 1 µm. Mounted in a class 100 clean room with a raised tile floor, the microscope is supported by a steel stand that structurally connects the microscope to the concrete ground. Due to ambient vibrations experienced in the system, the microscope is only able …

Portable Calorimeter For Fire Experiments, Kayla Collins, Kara Hewson, Christopher Chen, Joel Keddie

Mechanical Engineering

Executive Summary

An oxygen consumption calorimeter works by measuring the heat release rate of a burning substance. This value is calculated by measuring the oxygen and byproducts in smoke from afire.In order to get these values two types of sensors were used. A non-dispersive infrared sensor (NDIR) that measured CO and CO2 and a zirconium O2 sensor were used to find their respective gas concentrations.The design to calculate the heat release rate is focused on maximizing sensor accuracy and portability while simplifying the manufacturing by using off-the-shelf components. The goal included making the system simple to recreate and package in …

Fluid Power Vehicle Challenge, Jacob Torrey, Kayla Londono, Bryson Chan, Aaron Trujillo

Mechanical Engineering

The FPVC combines mechanical engineering disciplines to design and manufacture a vehicle that utilizes hydraulic power. The FDR covers the final manufacturing process and verification processes developed during the front end of research and analysis built upon the Critical Design Review (CDR) and the PDR (Preliminary Design Review). This report showcases the design decisions and extensive research that supports the continuing efforts by the Team Pump My Ride, to build upon the accomplishments of Cal Poly’s previous team, The Incompressibles. The FDR presents how Team Pump My Ride produced the design changes from the CDR and PDR to achieve improvements …

Heat: Hydraulic And Electric Animation Team, Tyler J. Couvrette, Michael J. Cain, Sara T. Novell, Dexter K. Yanagisawa

Mechanical Engineering

Each New Years’ Day, the Cal Poly Rose Float presents a flower-covered float to the world at the Tournament of Roses parade. This floral display, paired with moving mechanical animations, shows off Cal Poly to the world. This project strove to keep Cal Poly on the cutting edge of technology both in parade floats, and in engineering, by creating a completely electric-powered animation system.

To accomplish this, a group of students set out to make the fully electric animation system that can power both the hydraulic and electric mechanisms on the Float. This was accomplished through months of planning and …

Insulated Solar Electric Cooker With Phase Change Thermal Storage Medium, Justin Brett Unger, Nathan Robert Christler, Matthew Weeman, Marcus Edward Strutz

Mechanical Engineering

This final design review document outlines the senior design project carried out by a team of four mechanical engineering students at the California Polytechnic State University – San Luis Obispo under the sponsorship of Dr. Peter Schwartz of the Cal Poly Physics department. The aim of this project was to improve upon the design of previously developed Insulated Solar Electric Cookers (ISECs) by adding a thermal storage system to allow for quicker cook times and the ability to cook food at non-peak solar hours. The team’s goal was to develop a working prototype utilizing a phase change medium as the …