Engineering Commons^™

Fiberglass Mat-Roll Carryover, Bryce Youngson, Aaliyah Ramos, Johann Cayaban, Tony Ledesma

Mechanical Engineering

The asphalt shingle is a type of roof shingle that uses asphalt for waterproofing. Its low cost and easy installation make it one of the most common roof covers in North America. General Aniline and Film (GAF) is one of the nation’s largest manufacturers of roofing materials and produces asphalt shingles at their Shafter, California manufacturing facility. To manufacture asphalt shingles, a base material of fiberglass passes through a series of processes that sequentially add asphalt, ceramic-coated mineral granules, and thermoplastic adhesive. The fiberglass base-material arrives at the manufacturing facility in large rolls that workers must periodically splice together in …

Critical Radius Of Insulation, Maria N. Ambrose, Samuel J. Sayre, Travis W. Martin, Matt T. Sterling

Mechanical Engineering

The critical radius of insulation is a counterintuitive concept within the study of heat transfer. The theory states that adding insulation to a cylindrical or spherical object will increase the rate of heat loss rather than decrease it, if the radius (thickness) of the insulation is at its “critical” value. The Critical Radius of Insulation Senior Project is designed to demonstrate this phenomenon to Heat Transfer students via a portable apparatus. The concept will be demonstrated with a cylindrical object which is heated by way of a separate voltage source. Thermocouples will display the temperature of the cylinder while insulation …

Model Block Press Design, Ben Todd Van Hamersveld, Chester Wong, Alexander Wing-Jon Giannousis

Mechanical Engineering

This project’s goal is to redesign the Center for Vocational Building Technology (CVBT) BP9 earth block press, which makes 1/3 scale compressed earth blocks to build demonstration model homes in Thailand. The full-scale block press, the BP6, provides a sustainable and affordable technique for constructing habitable homes in Thailand. The BP9 serves as a tool to inform the public of the advantages of human-powered earth block presses through demonstration. The BP9 press design has multiple problems: it is too expensive to manufacture, there is too much friction when used, it has several weak points due to users unintentionally applying excessive …

Deployable Cover For Cubesat Fuv Imager, Edwin J. Rainville, Patrick J. Rainville, Jeff Wagner

Mechanical Engineering

The goal is to develop a deployable cover for a far ultraviolet imager cube satellite that will be used to map the earth’s auroras in the ionosphere. The deployable cover is used to protect the Far Ultra-Violet (FUV) sensor and lenses, house two mirrors which are used to filter unwanted light and expose optics when deployed. The deployable cover consists of a door, an actuator, a lockout mechanism, and an “open position” indicator. This project also includes designing a fixture for testing the optical alignment of the deployable cover after launch and during orbital conditions. The subassembly is required to …

Process Improvement And Lift Design For The Installation Of A Metrology Machine Assembly, Dalt J. Lasell, James Mitchell O'Meara, Matthew Steensma

Industrial and Manufacturing Engineering

The objective is to work with Onto Innovations, a leading provider of semiconductor metrology and manufacturing solutions, to develop a system that safely installs a 250lb optics plate into the Atlas III: one of their metrology machines. Based in Milpitas, CA, Onto Innovations utilizes a variety of operations to create different products and assembles each product on site. The 250lb optics plates are WIP that are transferred between fixtures and the Atlas III using a combination of lifts and human workers. The WIP have long lead times, high tolerances, and large costs associated with their manufacturing process.

Onto Innovations identified …

Automation Of Data Analysis In Formula 1, Adam Joseph Mourad, Prescott Jeanne Delzell, Patrick Conner Mccabe

Industrial and Manufacturing Engineering

This paper explores economic solutions for Formula 1 racing companies who are interested in data visualization tools. The research was conducted on the current development of data gathering, data visualization, and data interpretation in Formula 1 racing. It was found that a large chunk of racing companies within the league needs an affordable, effective, and automated visualization tool for data interpretation. As data collection in Formula 1 arises, the need for faster and more powerful software increases. Racing companies profit off-brand exposure and the more a racing team wins, the more exposure they receive. The goal of the paper focuses …

2-Axis Electric Off-Road Bucket Seat Bases, Brennan K. Slater, Alexander P. Croteau, Spencer M. Kubik

Mechanical Engineering

Off-road vehicle bucket seats are currently restricted to a single position relative to the floor of the vehicle. Drivers and riders desire the ability to adjust their seat position to increase comfort and allow for a greater size range of riders to fit safely within the cabin or roll cage. To develop a viable solution, the team has gone through an extensive design process and has constructed a functioning prototype. This Final Design Report encapsulates the entire design process and concludes with recommendations for changes we would make looking both back in review as well as moving forward with further …

Waste Gasification, Glyn D. Lewis, Nash Taylor, Nicholas L. Ordonez, David S. Mccallum

Mechanical Engineering

This document summarizes the work the IGT Team has conducted on the topic of waste to energy gasification over the Cal Poly Winter, Spring, and Fall quarters of 2019. The project is being carried out by four Cal Poly Mechanical Engineering students: Nash Taylor, Glyn Lewis, David McCallum, and Nicholas Ordonez and the sponsor of this project is Tod duBois. The team’s original goal was to successfully create a system that compiles residential solid waste on a small scale, gasifies it, and measures the typical syngas outputs, so that the team may assess the viability of gasification of household waste …

Mechanized Advent Calendar, Oma Skyrus, Sigrid Derickson, Tyler Koski, Daniel Clifton

Mechanical Engineering

Within this document, the “Naughty and Nice” team will describe the details associated with the completion of this project, which involves creating an animated advent calendar for the Cambria Christmas Market. The problem, the customers and stakeholders, and the general goals of the project are introduced. The team conducted background research; how this research helps in finding a solution or supporting the needs of the sponsor is illustrated. Initial research includes interviews with the sponsor and potential users, patent and existing product searches, and some technical research pertaining to the subject. The team found that there are not many existing …

Katie's Jogger, Megan Guillermo, Erin Wint, Abdullah Sulaiman, Kathryn Mangiaracina

Mechanical Engineering

Edward Robinson is an avid runner who would like to take his daughter on runs. His daughter, Katie, is 100% wheelchair bound and currently does not fit in any commercial joggers on the market. The project team was expected to design, build, and test a custom working prototype of a jogger that the sponsor can use to take his daughter on runs. This entire project was performed over a span of three quarters.

Mad Jack Alpine Touring Model Design, Austin Gasbarra, Gillian Stargensky, Madeleine Mccool, Brannon Smudz

Mechanical Engineering

Skiing is a sport enjoyed by millions of people every year, yet ski boots are very uncomfortable and cost- prohibitive, resulting in a low conversion rate of first-time skiers to lifetime skiers. Additionally, Alpine Touring (AT) is seeing a surge in popularity as ski resorts become more expensive, but few companies are developing affordable products in this realm. Mad Jack Snow Sports has developed a product that they believe addresses some of the main issues associated with skiing, but they want to develop their product line further. The problem statement and scope state that the purpose of this project is …

Flight Test Data System For Strain Measurement, Zachary David Wilson

Master's Theses

This thesis describes the design and evaluation of two devices to be included in the next generation of the family of devices called the Boundary Layer Data System (BLDS). The first device, called the Quasi-Static Strain Data Acquisition System, is a continuation of the BLDS-M series of devices to be known as the Flight Test Data System (FTDS) that uses a modular approach to acquire non-flow, quasi-static mechanical strain measurements. Various breakout boards and development boards were used to synthesize the device, which were housed by a custom PCB board. The system is controlled by the Simblee^TM System on …

Design, Modeling And Control Of A Two-Wheel Balancing Robot Driven By Bldc Motors, Charles T. Refvem

Master's Theses

The focus of this document is on the design, modeling, and control of a self-balancing two wheel robot, hereafter referred to as the balance bot, driven by independent brushless DC (BLDC) motors. The balance bot frame is composed of stacked layers allowing a lightweight, modular, and rigid mechanical design. The robot is actuated by a pair of brushless DC motors equipped with Hall effect sensors and encoders allowing determination of the angle and angular velocity of each wheel. Absolute orientation measurement is accomplished using a full 9-axis IMU consisting of a 3-axis gyroscope, a 3-axis accelerometer, and a 3-axis magnetometer. …

Dynamic Pressure Sensing For The Flight Test Data System, Marc Y. Goupil

Master's Theses

This thesis describes the design, assembly, and test of the FTDS-K, a new device in the Boundary Layer Data System (BLDS) family of flight data acquisition systems. The FTDS-K provides high-frequency, high-gain data acquisition capability for up to two pressure sensors and an additional three low-frequency pressure sensors. Development of the FTDS-K was separated into a core module, specialized analog subsystem, and practical testing of the FTDS-K in a flow measurement mission. The core module combines an nRF52840-based microcontroller module, switching regulator, microSD card, real-time clock, temperature sensor, and trio of pressure sensors to provide the same capabilities as previous-generation …

Hybrid Iii 95th Percentile Large Male Finite Element Model Neck Alteration, Eric Riley Day

Master's Theses

The motivation behind the project was to update the Livermore Software Technology Corporation (LSTC) Hybrid III 95th percentile finite element model, such that the neck assembly response under varying simulated loading conditions equals that of the federally regulated Hybrid III 95th percentile anthropomorphic testing device (ATD).

The family of Hybrid III crash test dummies approximate the physical properties and response of the human body in a frontal automotive crash. The Hybrid III is used to assess the effectiveness of vehicle restraint systems. LSTC offers Hybrid III finite element models for use in their Multiphysics simulation software package, LS-DYNA. The Hybrid …

E.M.B.E.R. Home Protection, Kylie Fernandez, Daniel Santoro, Ryan Kissinger, Christopher Slezak

Mechanical Engineering

Despite the increased danger of wildfires in states such as California and Colorado, there is yet to exist a product that can autonomously extinguish the spot fires that ignite from windblown embers. This device could reduce countless civilian casualties and prevent millions of dollars in property damage. This is not to mention allowing homeowners to evacuate with a greater peace of mind. Mass ownership of this product would be analogous to the “herd immunity” of vaccines, where neighbors ultimately protect each other and save money through self-insurance.

There are products on the market, generally in the commercial domain, that can …

A Rotating Aperture Mask For Small Telescopes, Edward L. Foley

Master's Theses

Observing the dynamic interaction between stars and their close stellar neighbors is key to establishing the stars’ orbits, masses, and other properties. Our ability to visually discriminate nearby stars is limited by the power of our telescopes, posing a challenge to astronomers at small observatories that contribute to binary star surveys. Masks placed at the telescope aperture promise to augment the resolving power of telescopes of all sizes, but many of these masks must be manually and repetitively reoriented about the optical axis to achieve their full benefits. This paper introduces a design concept for a mask rotation mechanism that …

A Novel Fiber Jamming Theory And Experimental Verification, Jared Richard Chafetz

Master's Theses

This thesis developed a novel theory of fiber jamming and experimentally verified it. The theory relates the performance, which is the ratio between the stiff and soft states of a fiber jamming chamber, to three relative design parameters: the ratio of the wall thickness to the membrane inner diameter, the ratio of the fiber diameter to membrane inner diameter, and the number of fibers. These three parameters, when held constant across different chamber sizes, hold the performance constant. To test the theory, three different types of fiber jamming chambers were built in three different sizes. Each chamber was set up …

Baja Sae Ecvt Mechanical Design, Tyler Lee Connel, Will Daniel Antes, Matt Stephen Balboni, Benjamin James Colard, Julian Edward Finburgh

Mechanical Engineering

This objective of this project was to design, manufacture, and test the mechanical systems of an electronically-controlled continuously variable transmission (eCVT) for the Cal Poly Baja SAE vehicle.

Teaching Top-Down Approaches To The Engineering Design Process, Joshua E. Katz, Joshua E. Katz

STAR Program Research Presentations

One of the main focuses of metacognition is to have students think about their learning. By bringing the engineering design process with educational psychology together, it can lead to a society that thinks more in-depth on various topics. The goal of the internship was to utilize and teach top-down educational and instructional objectives. Throughout the project, we followed a modified progression of the System Architecture Methodology to help other interns think in a top-down fashion. The purpose of this procedure is to create and induce new innovative and creative ideas for different projects. As teaching this methodology was tasked, research …

Electronic Cvt - Controls, Alec William Hardy, Jessalyn Leora Ann Bernick, Nicholas Esteban Capdevila, Tristan Charles Perry

Mechanical Engineering

The following document outlines the design process, manufacturing, and testing of the control system for an electronically controlled continuously variable transmission (ECVT). This control system was integrated into the custom designed and manufactured mechanical transmission system created in parallel by another senior project group. The transmission was designed for use in the Cal Poly Baja SAE vehicle. Through researching customer needs, competition requirements, previous and alternate CVT designs, and vehicle characteristics, we were able to determine the requirements and specifications for our unique system. Input, output, speed, and durability requirements guided our hardware selection. The primary components which comprised our …

Human Powered Vehicle Trainer, Nicholas Hung Nguyen, Gregory Reece Bridges, Jacinta Garcia, Mitchell Sidney Smith

Mechanical Engineering

This Final Design Review (FDR) document describes the final design and completed prototype of a Mechanical Engineering senior project team at California Polytechnic State University, San Luis Obispo. The project goal is to create an adjustable human powered vehicle training bike for George Leone that allows a rider to gain confidence with the unique reclined bike geometry ahead of the World Human Powered Speed Challenge at Battle Mountain, Nevada. This document outlines the customer’s needs and technical research performed which together determine the project’s scope and engineering specifications. Next, we present the initial idea generation process and its results, along …

Retaining Ring Material Wear Analysis And Testing, Thomas Headland, Barten Hansen, Austin Fisher, Kevin Hurtado

Mechanical Engineering

The chemical mechanical planarization (CMP) of wafers for integrated circuits is an essential – yet expensive – step in their manufacture. CMP machine down-time due to the replacement of process consumables, such as wafer retaining rings, is a significant contributor to the process cost. To reduce the operational cost of their CMP machines, Revasum is interested in exploring new designs and materials for wafer retaining rings to increase their operational lifetime. Background research showed that there is currently no suitable method for testing new retaining ring designs and materials for wear characteristics specific to the CMP process. Available wear testing …

Commercial Vehicle Research Buggy For Active Driver Assistance Systems, Fernando Mondragon-Cardenas, Nathaniel Mccutcheon Furbeyre, Ricardo Steven Lickiss Tan Iv

Mechanical Engineering

This is the Final Design Report for Daimtronics, a senior project team sponsored by Professor Charles Birdsong of Cal Poly and by Daimler Trucks North America. This team integrated mechatronic systems into a scale semi-truck chassis using existing mechanical and software systems from three separate Cal Poly senior projects over the recent years: Daimscale, MicroLaren, and ProgreSSIV. The goal was to have a user-friendly platform capable of executing autonomous driving algorithms that are programmable at a high level in Simulink and Robotic Operating System (ROS). Advanced driver assistance and autonomous vehicle algorithms were not within the scope of this project, …

Uav Catapult, Sean Drew Huxley, Benjamin Richard Lacasse, David Matthew Garcia, Jordan Joseph Cearns

Mechanical Engineering

This document outlines the Senior Design Project proposed by Dr. Aaron Drake that was assigned to a team of Mechanical Engineering students at California Polytechnic State University, San Luis Obispo. The purpose of this project was to design, build, test, and finalize a launching system for two small, fixed wing, unmanned aerial vehicles (UAVs) owned by Dr. Drake and Cal Poly. The goal was to create a system that was both portable and reliable to use, only requiring a two-person team to use effectively in the field. The most important design requirements were determined to be the launch speed, assembly …

Adaptive Paddle Board, Alexander Holthaus, Alexander Holthaus, Garrett Holmes, Garett Jones

Mechanical Engineering

This Final Design Review (FDR) document outlines the Adaptive Paddle Board senior project, done by four Mechanical Engineering Students at California Polytechnic State University and provides detail on the project and what the team has accomplished. The goal was to create a universally adaptive paddle board that can be used by the Central California Adaptive Sports Center for a wide range of persons with disabilities. This document highlights current research from patents and existing products, details regarding customer specifications, results from concept generation, the manufacturing and testing that went into the final design, and the process taken to get there. …

Cisco Nexus 9200 Robustness Redesign, Colin Berge, Ethan Gold, Cole Christopherson, Rahul Makhijani

Industrial and Manufacturing Engineering

Certain configurations of Cisco's Nexus 9200 product experienced issues with bending during shipping. Two solutions were developed to eliminate this problem: an external brace that could quickly address the problem yet was expensive and unsustainable, and a redesigned chassis, which was more economical but came with a longer time to implement. Real world packaging and shipping conditions were simulated in SolidWorks and Finite Element Analysis was used to model the stresses experienced when the product is dropped. Both designs were found to significantly reduce stress in critical areas, thus reducing the chance of failure and the cost of the problem. …

Redesign Of Cubesat For Beam Charging, Kuba Preis

Industrial and Manufacturing Engineering

This paper is intended to be a study in the applications of the design freedom granted by additive manufacture in the design of a 1U CubeSat frame. The main loads experienced by a CubeSat are structural (during launch) and thermal (solar radiation). Beam charging is an emerging technology which involves charging a CubeSat using a laser beam. In this paper, a CubeSat frame was redesigned to account for the structural loads induced during launch and the thermal loads induced when beam charging. The thermal, weight, design, and structural requirements for a new CubeSat design were derived. The 1U CubeSat frame …

Modifying Casting Parameters To Improve The High Temperature Ductility Of Investment Cast Nickel-Based Superalloy Pwa 1455, Lars Alexander Hedin, Cole Magnum Introligator

Materials Engineering

PCC Structurals, an industry leader in superalloy investment castings, has observed inconsistencies in the stress rupture performance of polycrystalline nickel-based superalloy PWA 1455. PCC has changed their casting parameters to reduce the thermal gradient during cooling but have been unable to correlate these changes with an increase in stress rupture elongation. Metallographic examination of past samples indicated microstructures composed of non- equiaxed dendritic grains with mean diameter of .021 inches along the test axis. A similar study on polycrystalline superalloys has indicated that excessive superheat temperatures above the liquidus can result in large grains identical to those observed, limiting the …

Fluid Power Vehicle Challenge - The Incompressibles - Final Design Report, Nicholas Gholdoian, Russell Posin, David Vitt, Alex Knickerbocker, Kyle Franck, Julian Rodkiewicz

Mechanical Engineering

This report provides a comprehensive description of the research, analysis and design work that The Incompressibles have completed thus far in the senior project process. This document includes all the work that The Incompressibles have completed for the team’s Preliminary Design Review (PDR), Critical Design Review (CDR), the work leading up to the 2019 FPVC competiton and the competition results. This report includes the initial research that the team completed for the fluid power competition, first iterations of designs, final iterations of designs, manufacturing results and processes, and finally testing and results from competition. With a new design for the …