Engineering Commons^™

Motor Control Systems Analysis, Design, And Optimization Strategies For A Lightweight Excavation Robot, Austin Jerold Crawford

Graduate Theses and Dissertations

This thesis entails motor control system analysis, design, and optimization for the University of Arkansas NASA Robotic Mining Competition robot. The open-loop system is to be modeled and simulated in order to achieve a desired rapid, yet smooth response to a change in input. The initial goal of this work is to find a repeatable, generalized step-by-step process that can be used to tune the gains of a PID controller for multiple different operating points. Then, sensors are to be modeled onto the robot within a feedback loop to develop an error signal and to make the control system self-corrective …

Mechanical Design Automation: A Case Study On Plastic Extrusion Die Tooling, Allen Prasad Varghese

Theses

The Skills Gap in Mechanical Engineering (ME) Design has been widening with the increasing number of baby boomers retiring (Silver Tsunami) and the lack of a new generation to acquire, practice and perfect their knowledge base. This growing problem has been addressed with several initiatives focused on attracting and retaining young talent; however, these types of initiatives may not be timely for this new group to be trained by an established Subject Matter Expert (SME) group. Automated Engineering Design provides a potential pathway to address not only the Skills Gap but also the transfer of information from SMEs to a …

Furnace System Improvements, Kenji K. Anzai, Ethan Fedor, Patrick Zailaa

Mechanical Engineering

This Final Design Review (FDR) documents the work done by the group to manufacture the system to deliver improvements to the furnace in the Cal Poly microfabrication laboratory (better known as the cleanroom). The document describes the material covered in the Scope of Work (SOW), including background research, customer needfinding, and the problem statement, material associated with concept development and selection for Preliminary Design Review (PDR), material detailing the design and manufacturing plan of the system for Critical Design Review (CDR), and new material detailing the manufacture of the system for FDR.

Research done for the SOW resulted in a …

Finding Balance In Generative Product Design, Alex Lobos

Presentations and other scholarship

Generative design develops complex forms and structures similar to those found in nature, taking advantage of automated tasks and high-scale computing power. This approach benefits designers in the creation systems that are efficient, resilient and visually engaging. These systems follow specific rules for form generation and meet clear design goals in terms of shape, strength, mass, and other physical attributes.

There is a large number of methods for creating generative systems, based on establishing desired outcomes and behaviors for how components relate to each other. Examples of methods include L-Systems, Shape Grammars, Swarm Intelligence, Form Optimization, Lattice Design, and many …

Micro-Manipulation Using Learned Model, Matthew A. Lyng, Benjamin V. Johnson, David J. Cappelleri

The Summer Undergraduate Research Fellowship (SURF) Symposium

Microscale devices can be found in applications ranging from sensors to structural components. The dominance of surface forces at the microscale hinders the assembly processes through nonlinear interactions that are difficult to model for automation, limiting designs of microsystems to primarily monolithic structures. Methods for modeling surface forces must be presented for viable manufacturing of devices consisting of multiple microparts. This paper proposes the implementation of supervised machine learning models to aid in automated micromanipulation tasks for advanced manufacturing applications. The developed models use sets of training data to implicitly model surface interactions and predict end-effector placement and paths that …

3-Dimensional Automated Heat Flux Calibration Device, Victor Raul Chacon, David Madison Morrisset, Alex Michael Schnorr, Kevin Scott

Mechanical Engineering

This document aims to describe the problems in current radiant heat source heat flux calibration techniques and the approach our team took to solve them through automation. The following sections outline the basic premise of the problem we addressed and who our end product benefited. The proceeding sections addresses the research that we have performed regarding heat flux measurements and automation. This research includes current solutions – mostly partial solutions for problems that are similar but not exactly like ours. Following the background research, we define objectives, with specific details that outline how we evaluated different possible solutions, and how …

Human-Robot Collaborative Force-Controlled Micro-Drilling For Advanced Manufacturing And Medical Applications, Parimal Mahesh Prajapati

Mechanical & Aerospace Engineering Theses & Dissertations

Robotic drilling finds applications in diverse fields ranging from advanced manufacturing to the medical industry. Recent advances in low-cost, and human-safe, collaborative robots (e.g., Sawyer) are enabling us to rethink the possibilities in which robots can be deployed for such tedious and time-consuming tasks. This thesis presents a robotic drilling methodology with features of force-control enabled micro-drilling and human-robot collaboration to reduce programming efforts and enhance drilling performance. A Sawyer robot from Rethink Robotics, which offers safe physical interactions with a human co-worker, kinesthetic teaching, and force control, is used as the test bed. The robot’s end-effector was equipped with …

Cal Poly Caramel Counter Top Candy Wrapping Machine, Alexander Miller, Roman Stambaugh, Trevor Steele

Mechanical Engineering

The purpose of this project was to automate the caramel wrapping process for a small batch confectionist. Using a purely mechanical system that is hand-powered, the machine cuts and wraps caramel candies in a double twist fashion.

X-Beam Alignment System, Whittaker Ian Hamill, Joseph Michael Falcao, Robert Kim-Yan Tam

Mechanical Engineering

The goal of the project was to design, build, and test an automated machine for Micro-Vu that will align a pair of rails to the necessary precision and affix said rails to Micro-Vu's X-Beam as to reduce manual labor and human error.

Automated Din Rail Cut And Punch Machine, Youssif Alkheder, Gaston Charreun, Derrian Flemings, Jonathan Liss

Capstone Design Expo Posters

Our project’s main goal is to optimize the process of punching and cutting DIN rail in a manufacturing setting. The current method for cutting and punching DIN rails is tedious and simply too time consuming. An operator is needed to manually load the DIN rail into the cutter, measure the required length and activate the cutter. While this simple process may not take too long at first glance, companies, like Weidmuller, must be able to produce large-quantity orders to successfully meet the demands of their customers. By turning to automation, we are effectively reducing the amount of time it takes …

Developing A Curriculum For Marine Mechatronics Technicians, Vukica M. Jovanovic, Petros J. Katsioloudis, Ana Djuric, Mileta Tomovic, Thomas B. Stout

Engineering Technology Faculty Publications

A growing trend within the U.S. Navy is to streamline operations by deploying ships with less sailors, who are more highly skilled technicians that are trained to do a wide array of jobs. Modern ships also include various automated systems that require more highly skilled technicians for maintenance. Outdated warship designs are now being replaced with industrial grade automation equipment. Such equipment is being used in warships that encounter harsher environments than what exists in the civilian industry. Hence, there is a need for training in regards to industrial grade automation equipment for military and civilian ship repair partners. Marine …

Fiber Glass Mat Splice Automation, Max Weinstein, Charles Scott Forbes, Max Kilpatrick

Mechanical Engineering

Currently, GAF has two operators manually splice together each roll of fiberglass mat. To save money and resources, GAF wants to automate this splicing process. Our team is responsible for stage 3 of 5 in this automation process. We are responsible for ensuring that the system is able to move autonomously to the necessary positions required for splicing together the rolls of fiberglass mat. We have determined the best solution for accomplishing this movement is to use linear slide actuators. This document will describe the process by which we arrived at our solution, the details of our solution, and a …

Automated Machine Tender, Ryan A. Canfield, Samuel N. Adler, Louis S. Roseguo

Mechanical Engineering

The use of CNC (Computerized Numerical Control) machines automate production in factories through programs controlling manual operations such as milling or lathing. The manufacturing process can be automated beyond the use of CNC machines through the addition of a robotic tender capable of carrying out the same tasks as a human operator. A tender can be integrated into the CNC machine itself, or purchased separately and configured to autonomously operate a particular machine. Smaller companies making limited production runs may not find it economically feasible to purchase large scale integrated machine tenders, but would benefit from a versatile autonomous machine …

Heteromorphic To Homeomorphic Shape Match Conversion Toward Fully Automated Mesh Morphing To Match Manufactured Geometry, Robert Ivan Yorgason

Theses and Dissertations

The modern engineering design process includes computer software packages that require approximations to be made when representing geometries. These approximations lead to inherent discrepancies between the design geometry of a part or assembly and the corresponding manufactured geometry. Further approximations are made during the analysis portion of the design process. Manufacturing defects can also occur, which increase the discrepancies between the design and manufactured geometry. These approximations combined with manufacturing defects lead to discrepancies which, for high precision parts, such as jet engine compressor blades, can affect the modal analysis results. In order to account for the manufacturing defects during …

Economic Analysis And Justification For Automated Welding Systems, Roxanne Raye

Industrial and Manufacturing Engineering

This report looks at designing a new welding process for a company in the Oil & Gas industry, ensuring method consistency and performance quality of their steel drill bit while increasing overall production. The current product is welded manually with a flux core wire, resulting in high cycle times and numerous cases of required rework.

The use of automation systems will be analyzed for their increased consistency, quality, safety, and production estimates. Specifically robotic cell design will be considered, since it can work on more parts with fewer operators, adding efficiency and flexibility to the production floor. Other areas of …

Forest Sign Maker, Victor Espinosa Iii, Kevin Ly, Lisa Yip

Mechanical Engineering

Executive Summary:

The Inyo National Forest is arguably one of the most beautiful locations in California, containing natural masterpieces such as Mount Whitney and the Ancient Bristlecone Pine Forest. Despite its magnificence, the Inyo National Forest can be a treacherous region. The Friends of the Inyo take pride in being able to facilitate the viewing experience for all outdoorsmen by maintaining the mountain trails, which includes providing adequate trail signage.

Unfortunately, there is a fundamental issue with the recent state of trail signage in the Inyo National Forest: the rate at which signs are being vandalized or naturally destroyed is …

Development And Demonstration Of An Automation And Control System For Coal Spirals, Manoj Mohantya, Baojie Zhang, Haibo Wang, Ajay Mahajan, Hamid Akbari, Zeeshan Bashir, Saravan Ramamoorthy, Joesph Hirschi

Dr. Ajay Mahajan

Coal spirals are widely used in coal preparation plants in Illinois and around the world to clean fine coal, typically in the 1 × 0.15 mm size range. Despite their popularity and the trend toward increased automation in modern coal preparation plants, adjustments to the critical process variable for coal spirals, that is, product splitter position, continue to be done manually. Since spiral feed in a plant tends to fluctuate on a regular basis, suitable manual adjustment of splitter position in tens or hundreds of spirals operating in a plant is nearly impossible. As a result, the clean coal yield …

Development And Demonstration Of An Automation And Control System For Coal Spirals, Manoj Mohanty, Baojie Zhang, Haibo Wang, Ajay Mahajan, Hamid Akbari, Zeeshan Bashir, Saravan Ramamoorthy, Joesph Hirschi

Dr. Ajay Mahajan

Coal spirals are widely used in coal preparation plants in Illinois and around the world to clean fine coal, typically in the 1 × 0.15 mm size range. Despite their popularity and the trend toward increased automation in modern coal preparation plants, adjustments to the critical process variable for coal spirals, that is, product splitter position, continue to be done manually. Since spiral feed in a plant tends to fluctuate on a regular basis, suitable manual adjustment of splitter position in tens or hundreds of spirals operating in a plant is nearly impossible. As a result, the clean coal yield …

Semi-Automated Glass Mat Splice Operation For Asphalt Shingle Line, Justin Bracci, Harry Zhao, Chad Linafelter

Mechanical Engineering

The following report details the senior project sponsored by GAF Materials Corporation, Shafter, CA in regards to semi-automating a glass-mat splicing table for asphalt roofing shingle production. Herein includes details, research, design, and analysis regarding the semi-automation of the gluing processes for the splicing table. A working prototype was manufactured and tested for the future implementation onto GAF’s production line or further senior project involvement.

Automated Foosball Table, Jim R. Stefani, Alex J. Herpy, Brett Gordon Jaeger, Kevin S. Haydon, Derek Alan Hamel

Mechanical Engineering

This project is the second iteration of an automated foosball table for Yaskawa America as a trade show display. The table is meant to provide an interactive experience which highlights the speed and precision of the Yaskawa hardware. The first iteration of the project was mainly focused on creating the physical hardware for the system and to begin the basic programming for the system. This phase of the project was focused on finalizing the physical hardware of the system, implementing the vision system and to continue the basic programing of the system AI. A third team will be assigned to …

Design Of An Automatic Wood Trimming Machine, Van Ho, Nicholas Maskal, Andrew Rutland

Mechanical Engineering

This final design report, prepared for Sunrise Arts by the Cal Poly design team Mahogany Automation, details the year-long process in which the team of three engineering students designed and built an automated wooden -plank edge trimming machine that incorporates anti-jamming and continuous loading features. The team has examined current woodworking machines and features available on the industrial and commercial market, and used these as guides along with device requirements set by the project sponsor, Bruce Palmer. The focus has been on designing the simplest and most cost effective device that allows operators to make production runs of wooden slats …

Automated Foosball Table Year 1: Final Project Report, Juan David Gutierrez-Franco, John Inlow, Jesse Graham, Larry Huang

Mechanical Engineering

This project is a first iteration of an automated foosball table designed and created using servomotors provided by Yaskawa to create an interactive tradeshow display where guests can play against the algorithms developed in the PLC (programmable logic controller) controlling the servomotors. There will be a second iteration of the project done by a different team directly following this one. The motion components were selected with the intent to be able to surpass the reaction times and speeds of expert human players. There are a total of eight servomotors, four controlling linear actuators for translation of rods, and four controlling …

Application Of Machine Learning And Parametric Nurbs Geometry To Mode Shape Identification, Robert Mceuen Porter

Theses and Dissertations

In any design, the dynamic characteristics of a part are dependent on its geometric and material properties. Identifying vibrational mode shapes within an iterative design process becomes difficult and time consuming due to frequently changing part definition. Although research has been done to improve the process, visual inspection of analysis results is still the current means of identifying each vibrational mode determined by a modal analysis. This research investigates the automation of the mode shape identification process through the use of parametric geometry and machine learning.In the developed method, displacement results from finite element modal analysis are used to create …

Development Of Feature Recognition Algorithm For Automated Identification Of Duplicate Geometries In Cad Models, Aravind Shanthakumar

All Theses

This research presents a feature recognition algorithm for the automated identification of duplicate geometries in the CAD assembly. The duplicate geometry is one of the seven indicators of the lazy parts mass reduction method. The lazy parts method is a light weight engineering method that is used for analyzing parts with the mass reduction potential. The duplicate geometry is defined as any geometries lying equal to or within the threshold distance with the user-defined orientation between them and have the percentage similarity that is equal to or greater than the threshold value. The feature recognition system developed in this research …

A Case Study For Financial Feasibility Of Automated Costing Support In A Small Machine Shop, Benito A. Gonzalez

Theses and Dissertations - UTB/UTPA

A knowledge-based cost estimating expert system is chosen by a Mexican machine shop. Differences between the traditional experience-based system employed and the automated system are studied. Data is gathered to analyze time effectiveness, accuracy and payback of the software. Data from seventy part models is recorded to study the time experiment, and data from fifty part models is used to study the accuracy and consistency. Data is analyzed by calculating mean, standard deviation, and test of hypothesis. The results indicate that the software is faster than the traditional quoting system; however, the payback point is high. Also, results show the …

Design And Automated Operation Of A Condensation-Induced Depressurization System, Fen Du

Dissertations

Typical examples of the use of the vacuum environments in industry include vacuum coating, vacuum drying, vacuum packing, vacuum casting, vacuum heat treatment, vacuum cooling for food storage and leakage detection. Most of these applications require a comparatively small volume of vacuum environment. However, there are also many applications where enormous vacuum chambers are needed. For example, a large vacuum chamber is used to simulate the conditions of space.

This study investigates the design and the automated operation of a vacuum generation system based on the idea of the condensation-induced depressurization with prefilled condensable medium in a confined, adiabatic chamber. …

Improving Manufacturing Processes Through Energy Monitoring, Andrew Grzelak

Purdue Polytechnic Masters Theses

Energy efficiency and sustainability are very popular topics in the current field of manufacturing. With the increase in use of automation technology as well as the recent growth in the area of energy management, there is much focus on the overall improvement of manufacturing processes. For this research a project was completed to create a system that could improve both process efficiency as well as decrease energy consumption. By taking a look at the machine level energy consumption of an automated piece of manufacturing equipment, by eliminating waste in process, both energy efficiency and operational efficiency can be improved.

Using …

Application Of Parametric Nurbs Geometry To Mode Shape Identification And The Modal Assurance Criterion, Evan D. Selin

Theses and Dissertations

The dynamic characteristics of a part are highly dependent on geometric and material properties of the part. The identification and tracking of vibrational mode shapes within an iterative design process becomes difficult and time consuming due to the frequently changing part definition. Currently, visual inspection of analysis results is used as the means to identify the shape of each vibrational mode determined by the modal analysis. This thesis investigates the automation of the mode shape identification process through the use of parametric geometry and the Modal Assurance Criterion. Displacement results from finite element modal analysis are used to create parametric …

Automating The Fret Slotting Process Using A Plc Controlled 1.5 Axis Mill, James Stratton

Purdue Polytechnic Masters Theses

Stratton, James A. M.S., Purdue University, August 2011. Automating the Fret Slotting Process Using a PLC Controlled 1.5 Axis CNC Mill. Major Professor: Richard Mark French.

Can automation assist small job shops and hobbyists in the production of stringed instruments? This research set out to answer the question using a quantitative approach to determine if an economical CNC machine could be produced in such a fashion as to seamlessly join the workshop as an affordable, yet precise instrument to aid in the production of stringed instruments. The key was to incorporate common industrial automation equipment into the operation of the …

Edwards Automation Final Project Report, Benjamin (Ben) Johnson, Joel Masters, Matthew (Matt) Stewart

Mechanical Engineering

The body of this work has been created for Edwards Lifesciences in conjunction with senior project requirements. As such, the information produced and contained within is under a non‐disclosure agreement. As per request by sponsor, the body of the work will not be submitted to any outside parties, and the title page will serve as proof of completion.