Mechanical Engineering Commons^™

Design And Implementation Of Test Stand Upgrades For Investigating Gearset Churning Losses With Baffles, Matthew Martin

Honors Theses

The automotive industry is continually researching ways to decrease energy losses in drivetrain applications. Rotating gear sets in an oil bath suffer frictional losses due to oil churning. The Center for Advanced Vehicle Design and Simulation (CAViDS) consortium has proposed studies to understand and reduce these churning losses. The primary means to reduce these churning losses are to redirect the oil flow using baffles and/or alter the oil viscosity. To perform churning loss optimization under controlled conditions, an existing test stand was upgraded to improve safety, introduce oil temperature control, and allow for the interchange of baffle designs. For safety, …

The Musical Water Fountain, Amy Nielsen

Honors Theses

An affordable musical water fountain was designed over the course of one year. The target consumers for this fountain are middle to upper class homeowners. Based on the design parameters and research found on the topic, the fountain presents an aesthetically pleasing light and water show for residential neighborhoods. The design was sought to be competitive on the market with preexisting fountains. Since it must play music and perform a water and light show all in synchronous, there was confidence in the unique features to sell with today’s consumers. SolidWorks was used extensively to design and model the fountain and …

Electromagnetically Propelled Garage Door, Connor Seifert

Honors Theses

Garage door systems are loud and energy inefficient given their many contact points and need for continual maintenance. Most garage door systems use a loud, bulky electric motor to pull the garage door up and down using a chain. To reduce noise and energy loss due to friction from the electric motor and chain, electromagnetic forces used in Electromagnetic Suspension (EMS) trains were researched and adapted to a garage door system. The electromagnetically propelled garage door (EPGD) system was designed and validated using SOLIDWORKS and ANSYS simulation with significantly less contact points due to non-contact electromagnetic propulsion (EMP). The design …

Fsae Vehicle Instrumentation And Validation, Alexander Anthony

Honors Theses

Formula SAE is a student chapter of the Society of Automotive Engineers (SAE). Each year SAE hosts a collegiate competition for teams of university students to design, build, and compete with a formula-style vehicle. Students from all around the world collaborate to engineer and manufacture a competition worthy racecar. Each component of the vehicle is designed from scratch, using calculated load cases to optimize weight and strength. Once the car is built, students will test and validate their vehicle. Not every team has the opportunity to validate the critical load cases the vehicle is designed around. This senior design project …

Thermal & Efficiency Analysis For A High-Speed Gearbox, Austin Owen

Honors Theses

The aim of this project was to design and build a test stand to validate a thermal model of a high-speed gearbox developed by Western Michigan University’s (WMU) Center for Advanced Vehicle Design and Simulation (CAViDS) consortium. At the completion of this project, the experimental results measured from tests will be compared to those from a Siemens Amesim model of the same gearbox. For these tests, an electric inverter/motor/gearbox package was connected to an intermediate transmission for the purpose of output speed matching to an electric dynamometer. This dynamometer applied a load to the motor/gearbox to replicate its designed running …

Hinging, Propping, And Latching Mechanisms For Sunseeker Solar Car, Zachary Ruppenthal

Honors Theses

In this project, designs for the hinging, propping, and latching mechanisms on the 2021 Sunseeker Solar Car were created. These designs allow for the car’s array of solar panels to be held at any desired angle to maximize collection of solar power and give the team access to the battery and driver compartment. Removable telescoping prop rods with pin attachments are used to set the array at a desired angle. The hinging mechanism allows for the array to be lifted vertically prior to rotation in order to avoid interference with the car’s roll cage. To accomplish this, two four-bar linkages …

Charge Tracing For Determining Electrical Facility Effects On Electric Spacecraft Propulsion Systems., Joseph Backe

Honors Theses

Electric Propulsion Systems are the future of deep space travel. Since its design in 2016 Western Michigan University has been testing a Hall-Thruster from a previous Senior Design Group. One issue with Electric Propulsion Systems is tracing where the electrons go after being used to ionize propellant for spacecraft acceleration. Induced magnetic fields on Earth alter the electron paths found in the vacuum of space.

One solution is the EP TEMPEST. The EP TEMPEST is an electron tracer designed by the Air Force Research Laboratory. The goal of this project is to design an electron tracer like the EP TEMPEST …

Automated Form-Fill-Seal Loader, Amara Crosby

Honors Theses

Keystone Solutions Group requires a space, money, and time saving machine that can automatically load swabs and other similar sized devices into a new Multivac R245 form-fill-seal machine. Currently, Multivac “auto-loaders” are very costly and take up a great deal of space. A portable, easy-to-mount, automated swab loader was designed and initially prototyped. This design can be moved throughout the cleanroom with current material handling devices and contains enough storage to run continuously for upwards of a half an hour.

Autonomous Vehicle Camera Mount Application, Yuan Sheng Sit

Honors Theses

Autonomous vehicles consist of many complex systems, an extensive set of hardware components, and various computing algorithms that constantly work in harmony to provide selfdriving capabilities to a vehicle. This project focuses on developing a universal mount for a ZED 2 stereo camera used in data collection for autonomous driving applications. The main purpose of the mount is to reduce dashboard, windshield, and lens glare that affect the quality of data collection for autonomous driving applications. Software such as Ansys and SOLIDWORKS are used to simulate stress, strain, and thermal distributions on the mount to better understand the strong and …

Software Tool For Analyzing The Bending Strength Of Gear Teeth, Tayla Hall

Honors Theses

Current finite element (FE) models for gear analysis are computationally expensive. We will develop a software tool in Excel to efficiently assess the effect of different root geometries on gear tooth bending strength. The tool will assess the change in root stress as the root fillet shape is changed, using a 2-D model of a representative gear tooth using an A to B comparison. This is assumed to correlate to equivalent stress reduction in an actual gear. The tool will be validated by comparing the root stress found using the software to a FE analysis of root stress using ANSYS. …

Design Of A Carbon Fiber Composite Monocoque Chassis For A Formula-Style Vehicle, Alexander Carline

Honors Theses

Western Michigan University’s Formula SAE team, Bronco Racing, designs and manufactures a formula-style vehicle to compete annually at an international collegiate design and racing competition. In order to remain competitive, Bronco Racing required a lighter chassis for the 2021 vehicle. To achieve this, the full 2020 carbon fiber monocoque chassis system was redesigned to be lightweight while considering packaging constraints, the Formula SAE rules, and design parameters set by Bronco Racing. The monocoque geometry was modeled using SolidWorks and the carbon composite was simulated, tested, and verified using ANSYS and quasi-static load frame testing. The newly designed 2021 monocoque chassis …

Design Of A Carbon Fiber Composite Monocoque Chassis For A Formula Style Vehicle, Mitchell Hiller

Honors Theses

Western Michigan University’s Formula SAE team, Bronco Racing, designs and manufactures a formula-style vehicle to compete annually at an international collegiate design and racing competition. In order to remain competitive, Bronco Racing required a lighter chassis for the 2021 vehicle. To achieve this, the full 2020 carbon fiber monocoque chassis system was redesigned to be lightweight while considering packaging constraints, the Formula SAE rules, and design parameters set by Bronco Racing. The monocoque geometry was modeled using SolidWorks and the carbon composite was simulated, tested, and verified using ANSYS and quasi-static load frame testing. The newly designed 2021 monocoque chassis …

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 …

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.

Design Of Force Versus Displacement Test Stand, Andrew Fritchley

Honors Theses

Performing mechanical design around sensors is a critical skill which all engineering students should be familiar with. Of equal importance is gathering and correctly interpreting electrical data from engineering tests. The aim of this project is to design a force versus displacement test stand for applications related to the measurement of spring force-displacement correlation. The design uses a strain gauge load cell, and a magnetic linear encoder to provide accurate, repeatable force and travel measurements. A mechanical design to mount each sensor was created based initial project constraints. Finite element analysis was performed on all critical components to ensure that …

Structural Reinforcement Of Streamline Tubing, Peter Grohs

Honors Theses

Structural integrity of suspension components is important to the safety and the longevity of vehicles. Streamline tubing, an aerodynamically shaped material used in high performance vehicle controls, can be prone to failure if not properly analyzed for its asymmetric geometry. The component was redesigned as a composite structure using modern materials to make a highly aerodynamic product stiffer, stronger, and lighter per unit weight than a conventional all steel design. Finite element analysis was conducted and five prototypes using different materials were constructed and tested. This method of maximizing component lightness and stiffness using the beneficial properties of each material …

Boat-Lift Design And Analysis, Nathan Schick

Honors Theses

A current in production 6000 lb. rated boat-lift is being sold at “Great Lake Lifts”. The lift was tested experimentally and proved to hold at least 8000 lb. The design team successfully modeled the current lift on Ansys to help the customer understand where the weakest points in the design were. Following the creation of the initial lift design, the design team proposed and tested modifications that could be made in order to make the lift more structurally sound. The initial lift had a maximum deflection of 0.43846 inches, a maximum stress of 15880 psi, and a safety factor of …

Low-Cost Control Engineering Experiments, Megan Arduin

Honors Theses

The disciplines found within the area of motion and controls is a vital element of each engineer’s education. The ability to understand and then control dynamic systems is a fundamental skill required for many working engineers today. The aim of this project is to further develop the tools and methods available to teach and prepare engineering students to effectively design control system architecture, and then successfully implement their design into real world systems. The main goal is to design an apparatus that can be used to teach control system methods and has an affordable price. There are few experiments where …

Design Of A Cubesat Separation Mechanism, Ross Hiller

Honors Theses

CubeSats are compact, relatively inexpensive satellites that are often used for space research. In order to perform research related to electric propulsion devices, the Western Aerospace Launch Initiative (WALI) requires a medium-sized CubeSat capable of separating into two bodies while in orbit. Intentional separation is not common in CubeSats, so two original concepts were designed and simulated using 3D CAD and finite element analysis software. These designs were compared based on factors including weight, cost, size, and their potential to fail due to creation of debris or binding between components, in order to determine which will more effectively execute the …

Reprinter, Christian Brower

Honors Theses

Additive manufacturing (3D printing) is a rapidly growing technology, though, expensive printing filament and wasted material make it less affordable and an unsustainable process. The RePrinter combats these issues by recycling scrap 3D printed plastic parts and household plastics, such as pop bottles, and creates filament for fused deposition modeling (FDM). This product is a fully automated system which grinds, extrudes, and spools the filament for immediate use in FDM. The RePrinter works to control the extrusion speeds and tensions to optimize precise filament dimensions for quality 3D printing, while delivering the product in a timely cost effective manner.

Biogas Separator And Storage Tank, Brandon Nimtz

Honors Theses

The general concept of this project is to design, simulate, and build a biogas separator system that will also store the separated methane and carbon dioxide within pressure vessels. This system is constructed of many subcomponents that will combine to separate the biogas and store the methane (CH4) and carbon dioxide (CO2). The components included in the project consist of a liquid-gas separator vessel, two heat exchangers, one methane gas compressor, and one pressure vessel each to hold methane and carbon dioxide each. While the base goal in this project was to design and simulate the necessary parts to theoretically …

Attitude Determination Control Testing System (Helmholtz Cage And Air Bearing), Nicolas Theoret

Honors Theses

The WALI team at Western Michigan University requested a test environment to validate their CubeSat’s de-tumbling control system and hardware. The test environment required a Helmholtz cage and spherical air bearing. The Helmholtz cage provides an adjustable magnetic field to simulate low earth orbit; the spherical air bearing simulates the friction free environment the CubeSat will experience in space. In conjunction, the two components create an adjustable system that simulates a satellite in low earth orbit.

Least Cost Analysis For Solar Photovoltaic Maintenance Of The Wmu Miller Auditorium Array, Kelsey Pitschel

Honors Theses

The solar photovoltaic array at Miller Auditorium is a 50 kW DC system that has relied on five seasonal angle adjustments and no cleaning measures to reach an average of 64.7 MWh annual energy generation since 2012 1 . This amount of energy generation yields $7,046 in annual energy savings based on current market pricing for end use electricity of $0.1089/kWh 2 . The current adjustment schedule based on seasonal tilts accounts for an annual costs between $760 and $848, but actual adjustments have historically not taken place according to the existing schedule. The analysis focuses on optimizing net energy …

Human-Assisted Fluid Power Vehicle, Aaron Huntoon

Honors Theses

The rising cost of energy has prompted industrial and technology companies to research and implement renewable or green energy sources in every aspect of their business. This green technology can consist of sources such as: solar, wind, fluid, or others to create energy from renewable sources. The use of these various sources reduces the pollution associated with standard methods of energy development, and it will ultimately drive costs down to benefit the general population. One of the largest benefactors to the use of renewable energy sources is the transportation industry. Billions of people rely on various modes of transportation every …

Designing An Accessible Hall Effect Thruster, Matthew Baird

Honors Theses

A group of three Mechanical Engineering students have selected to design a 200 W Hall Effect Thruster to fulfill the Mechanical and Aeronautical Engineering senior design project. Preliminary studies were performed on the theory behind electric propulsion and plasma physics. The group designed the Western Hall Thruster and used COMSOL Multiphysics® simulation software to refine the magnetic circuit. The group then fabricated and performed magnetic testing of their thruster in Western Michigan University’s Aerospace Laboratory for Plasma Experiments. This testing will seek to prove that a standard research HET can be built by universities without substantial financial resources.

Design Of A Tandem Rotor Hovering Vehicle, Brent Kostich

Honors Theses

An investigation of thrust vectoring and an examination of existing tandem rotor dynamics were used to develop a structural body for a tandem rotor vehicle, derive the equations of motion of the system, and simulate a dynamic model of the vehicle. A vehicle prototype was constructed while further application of remote control capabilities, flight testing, and control development were researched. The dynamic simulation was based on a linear model of the system so as to open the possibility of implementing a control system. The simulation results show that thrust synchronization yields a predictable motion response. The prototype constructed did not …

Design And Fabrication Of An Instrumented Cane For The Blind, Aaron Dean

Honors Theses

The most commonly used tool for navigation by the blind is the white cane. A greater understanding is essential in improving the design and performance of these canes. An existing cane was modified with integrated force and acceleration sensors, in order to study the relation between cane vibration characteristics and obstacle or drop-off detection. Data was gathered by these sensors, and then transmitted wirelessly to a computer workstation, where it was recorded and analyzed. Exertion of the forearm muscles was also measured. Care was taken to insure that the cane sensors and transmitter are ergonomically unobtrusive for the user. The …

Design And Analysis Of A Cold Gas Propulsion System For Stabilization And Maneuverability Of A High Altitude Research Balloon, Mitchell Brownell

Honors Theses

The need for a cold gas propulsion system is crucial to the scientific industry which allows for maneuvering and stabilizing a high altitude research balloon and propose an inexpensive, light weight design that researchers can reproduce. The methodology to the design of this system was based on factors that are all dependent upon one another. The parameters that directed the decisions made throughout this design project was the thrust needed to rotate the unit, and the allowable weight permitted by federal regulations. The frame was designed with a gas storage system, gas transmission system, and nozzle assembly which was integrated …

Subtalar Fusion Fixture Design And Test, Nathan Ortiz

Honors Theses

Subtalar arthrodesis is performed when cartilage in the talo-calcaneal (the ankle) joint is degraded in a patient and there are multiple approaches to this surgery. Using synthetic bone material, fixtures were cast from aluminum, using the process of evaporation pattern casting, and epoxy. This casting was used to grip the calcaneus bone of the foot in order to load it mechanically, simulating different scenarios that would be encountered during walking. The relative displacement of the ankle joint was measured using a digital image correlation (DIC) program that was modified to work in both two- and three-dimensional space. This program can …

Noise And Vibration Reduction Of A Clothes Dryer, Daniel O'Hare

Honors Theses

As placement of washers and dryers becomes common in apartment buildings and high rises, noise generated by the dryer becomes a nuisance to the inhabitants. Whirlpool Corporation is experiencing this issue first hand with their Horizon model long vent dryers. A focus was placed on noise and vibrations caused by the dryer motor, because its vibrations are transferred throughout the structure of the dryer. The motor causing sound problems was a modified motor from the standard model, including a speed-increasing attachment in order to operate the fan at an increased speed. Through sound and vibration measurements, structural and airborne noise …