Engineering Commons^™

Lightweight Racing Suspension, Colin Haynes

Honors Theses

The purpose of this senior design project is to design and optimize the new suspension system for Western Michigan University’s 2020 solar car. The current solar car was 43% heavier than the average solar car, and was the heaviest single occupant vehicle competing in the American Solar Challenge. The scope of the project is to reduce the weight as much as possible from the old 2016 suspension. The new suspension weighed 34.91 lbs less than the 2016 suspension system while maintaining a minimum factor of safety greater than 1.5, compliant with American Solar Challenge regulations. The design consists of a …

Autonomous Vehicle Interior Design, Nathaniel Torchalski

Honors Theses

As technology in the automotive industry advances and self-driving vehicles become more commercially available, design concepts for their interiors must also be developed. Research was conducted on automotive design and autonomous technology, drawing inspiration from production and concept vehicles of the past, present, and future. A survey was conducted to gauge possible consumer needs. Hand sketches, small-scale models, and a Computer-Aided Design (CAD) model was produced. A full-size model was developed using various material-forming processes, including 3D printing, woodworking, clay sculpting, and metal machining. The interior was designed with consideration for safety, comfort, and technological advancements to satisfy the needs …

Methodology Of Topology Optimization, Naziha Khandoker

Honors Theses

The need for lighter products is becoming increasingly essential as it cuts material cost and significant amount of weight, which is a key factor in the automotive and aerospace industries. Topology optimization allows us to achieve that by applying the concept to different structures with the goal of optimal distribution of material within finite volume design domain. Its algorithms selectively remove and relocate elements to achieve the optimum performance. This project performs a study on the effect of each design parameter over mechanical performance using Finite Element Analysis and applies it to set of wing attachment brackets. The optimized brackets …

Autonomous Vehicle Interior Design, Luis Vargas

Honors Theses

As technology in the automotive industry advances and self-driving vehicles become more commercially available, design concepts for their interiors must also be developed. Research was conducted on automotive design and autonomous technology, drawing inspiration from production and concept vehicles of the past, present, and future. A survey was conducted to gauge possible consumer needs. Hand sketches, small-scale models, and a Computer-Aided Design (CAD) model was produced. A full-size model was developed using various material-forming processes, including 3D printing, woodworking, clay sculpting, and metal machining. The interior was designed with consideration for safety, comfort, and technological advancements to satisfy the needs …

Gearbox Baffle Optimization, Megan Arduin

Masters Theses

Current literature reveals there is limited consensus on the placement of baffles within a gearbox to reduce churning losses. Thus, there is a need for a process to identify baffle clearances that result in maximum and minimum churning losses. There are two types of baffles: axial and radial. While both axial and radial baffles cause reductions in churning losses to various degrees, the focus is on the effect of radial baffles. The effect of a board (rectangular plate) baffle location on the churning losses of a single gear gearbox are evaluated using computational fluid dynamics (CFD) implemented in Ansys. Several …

Intracellular Electrometer, Lucas M. Essenburg

Masters Theses

The Western Michigan University Neurobiology Engineering Laboratory conducts re- search in energy-efficient electrical stimulation of biological neurons. Experimental work re- quires an intracellular electrometer to inject nanoamp-level currents into a biological neuron and to measure its membrane voltage response. In order to fully understand the generation of such minute currents, an `in-house' electrometer was designed, constructed, and validated. This required exploration of various design trade-offs including precision of generated nanoamp-level currents vs. susceptibility to noise, portability vs. functionality, and cost vs. functionality. The electrometer was successfully used to stimulate and measure responses of neurons from the medicinal leech Hirudo verbana …

Portable Electrochemical System For Flexible Hybrid Electronics, Anthony Joseph Hanson

Masters Theses

This work focuses on the fabrication and design of a portable electrochemical sensing system for flexible hybrid electronic (FHE) sensors. A three-electrode chemical sensor was fabricated using copper tape on polyethylene terephthalate (PET) substrate, using laser etching process. An electronic circuit was designed to measure the sensor response through electrochemical techniques to detect different concentrations of glucose. The device was calibrated to give the user a concentration value in 5 seconds. The system was also designed to preform tests such as cyclic voltammogram and chronoamperogram for various chemicals. A Bluetooth Low Energy module was used to wirelessly transmit the results …

A Reinforcement Learning Approach To Spacecraft Trajectory Optimization, Daniel S. Kolosa

Dissertations

This dissertation explores a novel method of solving low-thrust spacecraft targeting problems using reinforcement learning. A reinforcement learning algorithm based on Deep Deterministic Policy Gradients was developed to solve low-thrust trajectory optimization problems. The algorithm consists of two neural networks, an actor network and a critic network. The actor approximates a thrust magnitude given the current spacecraft state expressed as a set of orbital elements. The critic network evaluates the action taken by the actor based on the state and action taken. Three different types of trajectory problems were solved, a generalized orbit change maneuver, a semimajor axis change maneuver, …

Analyzing Impacts Of Transportation And Non-Transportation Activities On Human Health With An Advanced Platform For Collecting Travel And Physical Activity Data, Raed Abdullah Hasan

Dissertations

Recently much attention is paid to the lack of physical activities that may cause the health problems in many counties. Travel activities provide a certain amount of physical activities, and the active transportation, such as walking and cycling, becomes more important as an essential element of transportation. The active transportation is expected to contribute to improving human health by reducing cardiovascular disease, obesity, and premature death. However, detailed relationship between the transportation choices and human health has not been well understood. Therefore, there is a need for investigating traveler behaviors and how their choices affect physical activities and public health. …

Extending The Capabilities Of Von Neumann With A Dataflow Sub-Isa, Martin Cowley

Masters Theses

Instruction set architectures (ISAs) such as x86, ARM, and RISC-V follow the control flow model of computation, where a program is defined as a sequence of instructions. Early processors executed instructions one-by-one based on the control flow of a program. Dataflow is an alternative model of computation that uses the availability of data to drive instruction execution. Any instruction can be chosen for execution, independent of the instruction order, as long as the data is available for that instruction. While modern processors incorporate concepts of the dataflow model in the microarchitecture, the implementation of the ISA, the amount of instruction …

Multiple Ssid Framework For Rss-Fingerprint Based Indoor Positioning Systems, Ahmed Kareem Abed

Dissertations

Location-Based Indoor positioning systems significance stems from the bloom of recent applications in various fields such as in tracking services for an elder or a patient within large living communities, mobile robot localization, and several other security applications. Currently, Global Positioning Systems (GPS) are the most widely used location-sensing technique. However, satellite-based GPS signals require line of sight (LOS) to work correctly, which is something cannot be achieved inside buildings. Fortunately, wireless LAN can be employed in indoor positioning systems (IPS), and since all large buildings such as malls, hospitals, airports, schools, and museums have hundreds of Wi-Fi access points, …

Estimation Of The Fatigue Life Of Additively Manufactured Metallic Components Using Modified Strain Life Parameters Based On Surface Roughness, Peter Grohs

Masters Theses

In this study, a method is developed to estimate the effects of surface roughness on the fatigue life of additively manufactured titanium Ti6Al4V, aluminum 7075–T6, and steel 4340 alloys through modified strain life parameters using finite element analysis (FEA). This method is highly beneficial to the fatigue analysis of as-built additively manufactured metal components, which possess rough surfaces that reduce fatigue life significantly but are challenging to analyze directly using finite element simulation because of complex geometries, i.e., modeling an exact surface profile is arduous.

An effective stress concentration factor, incorporating roughness data, is defined to quantify their effects on …

Syrup Process Optimization, Anelis Susana Chiluisa Calvache

Honors Theses

The purpose of this project involves the optimization of a marshmallow syrup process, sponsored by the owners of the line, the Kellogg Company was the sponsor. This report shows the work that was done for the period of three months, and covers the objective of the project, as well as the problem statement. The Kellogg Company currently produces a Syrup as an ingredient in the production of several cereal bars. The process is divided in four sections: Gelling Mix Tank, Syrup Mix Tank, Syrup Cool Tank and Syrup Use Tank. The entire process itself takes around 80 to 120 minutes …

Evaluation Of Data Collection Operations For Real-Time Influenza Surveillance During An Emergency, Yuwen Gu

Dissertations

It is unclear how data collection operations for surveillance alter the disease portrayal that influenza reported trends attempt to provide during an emergency. This study developed a model that simulates the collection and testing of influenza specimens after an outbreak is declared in Michigan. It performed simulation based optimization to understand which operational factors affect the biases between the growth rates of original and observed influenza incidence trends, and to quantify the predictive power of the influenza incidence trends at different points of data collection. The results show that emergency driven high risk perception increases the reporting, which leads to …

Methodology To Qualify And Monitor A Chemically Bonded Sand System Used In Foundries, Prayag Pravinbhai Patel

Dissertations

The goal of this dissertation is to establish a new quality control framework that combines a statistical process control (SPC) approach to casting quality for chemically bonded sand systems used in foundries. Foundries in the United States use the American Foundry Society standardized sand testing to monitor chemically bonded sand systems. These standardized tests are inefficient for two reasons. Firstly, standard tests are based on mechanical, physical, chemical and thermal properties of a sand system that do not consider interaction between these properties, but sand casting processes are inherently thermo-mechanical, thermo-chemical and thermo-physical. Secondly, these tests can only detect large …

Fatigue Performance Of Rc Beams Strengthened With Near Surface Mounted Cfrp Composites, Tamer Ghaith Mousa Eljufout

Dissertations

Bridges have a fundamental role in improving the effectiveness of highways and providing an expedient and express traffic system. Over time, Reinforced Concrete (RC) bridges degrade due to gradually increased traffic loads and environmental deteriorations. Subsequently, service loads might cause higher stresses in concrete and steel reinforcement than stresses considered in the design stage. This affects the structural performance of RC beams and leads to sudden fatigue failure. As such, there is an essential need for rehabilitation to avoid hazards and tragedies.

Carbon Fiber Reinforced Polymer (CFRP) composites are becoming widely used to strengthen RC bridges. Near Surface Mounted (NSM) …

Assessing Infrastructure Elements Using Automated Object Detection Technique In Smart City Applications, Majid Mastali

Dissertations

Nowadays, road features are becoming more complex leading to more complicated complaints regarding urban environments. Point Cloud Data (PCD) processing is an essential element for detecting objects and analysing human driving behavior to identify the variables defining challenging objects and maneuvers in smart cities. PCDs include a range of processing, including indirect processing (e.g., data converting, cleaning process) and direct process (e.g., pass through elevation filter, statistical outlier removal, normal estimation as well as classification). Static and dynamic object detection and analysis are typically considered the most sophisticated options subsumed under PCDs. They involve direct evaluation of both static and …

Development Of Heat Transfer Correlations For Low-Reynolds Numbers, Flows In Horizontal Circular Pipes, Latif Eyada Ibraheem

Dissertations

Turbulent flows are intrinsic to most fluid-based engineering systems, including internal combustion engines. In these devices, mixing, scalar transport and heat transfer are both critical for proper operation and challenging to model. In previous work, Kreun et al. [1] modeled a pre-heated intake manifold of a Diesel engine for cold-start simulations. Accurately predicting the heat transfer at the intake port proved to be a challenging task. Existing heat transfer correlations yielded predictions which were (at best) within 20% of the measured values. The discrepancy was attributed to a mismatch between the range of applicability of existing heat transfer models and …

Emergency Department Triage Process Improvement, Tessa Williams

Honors Theses

This senior design project was completed at Ascension Borgess Hospital located in Kalamazoo, Michigan. The mission of Ascension Borgess Hospital is to provide patient centered care. In 2018, 562 patients left the Emergency Department (ED) without being seen, which is a large safety risk for the patients and hospital. Based on this, as well as other obstacles, this project focused on meeting the mission of Ascension Borgess by improving key ED metrics that impact patient centered care. In order to meet that mission, this study aims to improve patient experience, safety and quality of the care provided, profitability for the …

Communication Debugging Platform, Husam Beitello

Honors Theses

More and more products are becoming “connected” devices, integrating multiple communications subsystems into their design. These subsystems increase the complexity of a design, and require extensive testing and debugging before they reach an end user. The purpose of the project was to create a prototype for a peripheral device that enables bidirectional communication between a typical smartphone and another target device communicating using the infrared, Bluetooth, and/or CAN communication protocols. Such a device could then be used to debug the behavior of a product relying on these forms of communication, by running test procedures referred to as scripts from the …

Improving Efficiency Of Manufacturing Cells, Conner Deneen

Honors Theses

Mann + Hummel is a tier one automotive supplier located in Portage, Michigan. The industry sponsor for this project is Director of Operations, Dan Kempisty with his supporting team, and the academic advisor for this project is Industrial Engineering Professor, Dana Hammond. The following report focuses on improving the efficiency of Cell 301 A and Cell 301 B which manufactures the air intake manifold for the Toyota Camry and Highlander. Topics analyzed in attempts to improve efficiencies include the following; standard operating procedures, line balancing, improving quality, reducing scrap, and analyzing non-value-added tasks. Time studies were conducted on each operator …

Thermal Adaptation Of A Vacuum Chamber, Jacob Russell

Honors Theses

The process of adapting a preexisting vacuum chamber to perform thermal vacuum testing is a rare process in the testing industry. A closed vacuum system that was designed without thermal capacitance in mind will hinder the development of additional thermal system capabilities and prove difficult from a cost standpoint. Generally, building a thermal vacuum system from scratch will cost on the order of $10,000 to $100,000 depending on the system requirements regarding control and thermal capacitance within the chamber. This project will explore the cost of such an adaptation, attempting to minimize expense, and potentially provide the “Western Aerospace Launch …

Replacement Of A Liquid Filling System For Corrosive Materials, William Breining

Honors Theses

An aging liquid filling system in contact with highly corrosive materials required replacement to protect personnel and surrounding equipment. The current system was investigated to identify areas where efficiency, safety, and productivity could be improved. Several competing solutions, including fillers and bulk chemical storage, were determined along with the corresponding economic and safety studies. The completed study provides information for filler and storage options and provides the necessary legwork for purchase of a replacement system.

Design Of A Thrust Stand For Electric Propulsion, Hannah Watts

Honors Theses

Thrust stands are the industry standard device for measuring the low levels of thrust generated by electric propulsion devices. Western Michigan University’s Aerospace Laboratory for Plasma Experiments is home to several electric propulsion devices and is in the process of obtaining a pulsed plasma thruster in partnership with the Western Aerospace Launch Initiative. The lab currently has no way of measuring the true thrust force generated by these devices. A thrust stand has been designed specific to the micro-Newton thrust range and the constraints inherent to the facilities in which it will operate.

The Urban Development Of Bronson Circle, Matthew Moulton

Honors Theses

Many suburban streets, and specifically Bronson Circle, in the city of Kalamazoo are in poor condition and in need of repair. Along with a new pavement design and additional drainage considerations, a complete redesign of the street’s cross-section with the concept of a “Complete Street” was created. A redesign of the site, traffic, pavement, drainage, and lighting were completed to lessen the street’s impact on the environment and make it more user friendly for all modes of transportation. This complete street design can be adjusted for terrain and used for any comparable urban street.

Included in this report is an …

3d Printing Robotic Arm On Linear Rails, Thomas T. Steele

Honors Theses

Typical 3D printers are bound by the printing bed volume relative to the printer frame volume. A 3D printing robotic arm set upon sliding linear rails was designed and built. The arm was 3D printed with a traditional 3D printer designed using Autodesk Inventor. This product reduces printer size while increasing bed area and reduces cost with use of 3D printed parts.

Assessing The Effectiveness Of The Collegiate Aviation Safety Reporting System (Casrs) At Western Michigan University's College Of Aviation, Logan Brown

Honors Theses

Aviation is a safety focused industry that intends to continually improve safety. Many safety models have been created, but right now the most prominent model is the International Civil Aviation Organization’s (ICAO) Safety Management System (SMS). It has four components: safety policy, safety risk management, safety assurance, and safety promotion. NASA’s nationwide reporting system, the Aviation Safety Reporting System (ASRS) incorporates these four components, as does the program created by Western Michigan University’s College of Aviation. Termed the Collegiate Aviation Safety Reporting System (CASRS), it was created to bring NASA’s program to a local scale. This paper examines international safety …

Optimal Energy Management For Forward-Looking Serial-Parallel Hybrid Electric Vehicle Using Rule-Based Control Strategy, Abhijit Bhaskar Jadhav

Masters Theses

In today’s sophisticated era of technology, resolving environmental problems is a matter of grave concern. Developing hybrid electric vehicles is a good step towards environmental preservation, since they use less fuel compared to conventional vehicles because of the combination of electric and mechanical energy. A hybrid electric vehicle reduces dependence on fossil fuels and hence lowers emissions. Specifically, a hybrid powertrain that includes a conventional gasoline engine and a brushless DC motor offers great potential to meet stringent CO₂ regulations and fuel economy requirements. This thesis focuses on the effects of initial state of charge (SOC) stored in Hybrid …

Network Equivalents Applied To Transient Analysis Of Large Distribution Systems, Ghassan Abdul-Hussein Bilal

Dissertations

Frequency domain (FD) methods for electromagnetic transient analysis of electric power systems offer outstanding simplicity and accuracy when dealing with distributed parameter elements and components that exhibit frequency-dependent behavior. However, the use of FD methods is usually restricted to the simulation of small and simple networks, since it is commonly believed that their application implies a very large computational burden when compared to time domain methods. This study demonstrates that FD methods can accommodate the detailed simulation of large distribution networks within acceptable computer times and in a very straightforward manner, thus offering an attractive complement or alternative to common …

Hardware/Software Co-Design Of A Reconfigurable Accelerator Platform For Fuzzy Logic-Based Spatial Image Processing Filters, Aous Hammad Kurdi

Dissertations

Rapid development in the architecture and fabrication technology of field programmable gate array (FPGA) and system on a chip (SoC) in the last two decades is dramatically increasing the reliability of those devices as a cost-effective alternative for traditional real-time image processing systems. Module reusability nature of FPGA and SoC development decreases design and implementation time noticeably. On-site reconfigurability allows for intensive design alterations to occur at a small cost. This study is presenting the design and implementation of a new hardware accelerator for an edge detector on Xilinx 7 series FPGA devices based on a fuzzy logic approach. The …