Engineering Commons^™

The Automated Wheelchair, Jonathan Doksa Kamba Ngoyi

Honors College Theses

Automation refers to the use of technology to execute tasks through programmed instructions and automated control mechanisms to ensure accurate execution. This minimizes human involvement and encompasses various fields, including business process automation. A notable form of automation is assistive technology, which refers to any device or software that enhances individuals' learning, communication, or overall functionality. This can range from advanced tools like computers to simpler aids like walking sticks. Assistive technology aims to promote inclusivity and participation, particularly among individuals with disabilities, the elderly, and those with non-communicable diseases.

The Automated Airport Wheelchair is a culmination of prior projects …

Partial Discharge Mitigation In Power Modules Using An Automation-Driven Design Rule Development Method, Shilpi Mukherjee

Graduate Theses and Dissertations

Power modules used for the conversion and conditioning of electrical power for applications like electric vehicles, more-electric aircraft, the power grid, etc., are largely designed manually by engineers. Design automation of power modules is starting to gain recognition as a timely and necessary alternative to intuitive manual design and fabrication. With increasing need for wide bandgap materials that can operate at higher voltages, and the need to make modules more compact, hazards like electrical breakdown are more likely. Partial discharge (PD) is a silent and invisible precursor to electrical breakdown. It is compounded with compaction, creating a potential for electrical …

Developing Control System For Manufacturing Processes, Md Shahriar Forhad

Theses and Dissertations

Process control has been a critical component in today's manufacturing industry. Industrialists nowadays want reliable control to assure precision manufacturing. Modern control systems must be more dynamic, so that any needed modifications may be made quickly to accomplish the desired product change. For innovative research and development, system customization is critical to ensure freedom for experimental works. In addition, full control of manufacturing systems is necessary to realize and implement Industry 4.0. Often, it is difficult to achieve such control due to limited access to proprietary equipment. To this end, this thesis focuses on developing a custom control platform for …

A Benchtop Robotic Automation Approach For Manufacturing Prefilled Syringes, Yehua Zhong

All Theses

Automation and robotics have become a staple in the biological manufacturing sector due to their ability to efficiently work without operator inputs, with a high degree of accuracy and repeatability. Industrial robotic arms, in particular, present themselves as valuable tools for biological manufacturing scenarios that require customized solutions due to their ease of programming and flexibility. The traditional hospital-focused healthcare system was organically developed to address acute conditions, however, in recent years, due to the unprecedented occurrence of emergencies happening more frequently, fast and efficient drug production becomes important [17]. This thesis represents the use of a benchtop robot and …

Eagle Medical Tray Denesting & Debris Removal Process, Nicholas Allen Ungefug, Noah Chavez, Susana Shu-Lin Okhuysen, Michael Augustine Pennington

Industrial and Manufacturing Engineering

Eagle Medical Incorporated is a contract medical device packaging and sterilization company. The company purchases thermoformed medical packaging trays, which maintain the sterility of medical devices, from various manufacturers. To ensure packaging quality and to prevent cleanroom contamination, Eagle Medical inspects and sterilizes each blister tray that they order. This process is an essential non-value-added activity that creates a bottleneck. Cleanroom employees must stop packaging medical devices and attend to the processing of blister trays and packaging solutions. The blister trays arrive at Eagle’s facility in nested stacks. Vibration and movement during shipping further compresses the stacks, which makes separation …

Polygait Conveyor Upgrade, William J. Schafer, Carolyn E. Palmer, Carly A. Tudor, Bryan C. Cordutsky

Mechanical Engineering

The PolyGAIT Conveyor Upgrade Mechanical Engineering Senior Project consisted of the complete design process to construct an operational “smart” control system for the conveyor belt loop on Cal Poly’s campus. As requested by project sponsor Dr. Tali Freed, an Industrial & Manufacturing Engineering professor at Cal Poly, the control system requirements included connecting existing conveyor components together, such as Radio Frequency Identification (RFID) reader tunnels, photo eye motion sensors, motor powered rollers, and diverting elastic bands. The main design problem is when packages with RFID tags are moving at industry high speed (10 ft/s) they are occasionally not scanned by …

Design And Control Of Next-Generation Uavs For Effectively Interacting With Environments, Caiwu Ding

Dissertations

In this dissertation, the design and control of a novel multirotor for aerial manipulation is studied, with the aim of endowing the aerial vehicle with more degrees of freedom of motion and stability when interacting with the environments. Firstly, it presents an energy-efficient adaptive robust tracking control method for a class of fully actuated, thrust vectoring unmanned aerial vehicles (UAVs) with parametric uncertainties including unknown moment of inertia, mass and center of mass, which would occur in aerial maneuvering and manipulation. The effectiveness of this method is demonstrated through simulation. Secondly, a humanoid robot arm is adopted to serve as …

A Computer Vision-Based Method For Bolt Loosening Detection, Savannah Burdette

Honors Theses

Routine bolt-loosening inspection plays an essential role in managing and preventing the degradation of our nation’s highway bridges over time. Neglecting to perform these inspections could result in public safety concerns. The study of this thesis develops a cost-effective method of bolt-loosening detection based on computer vision. To this end, two input images of the bolted connections are collected at two different inspection times. The feature points are then identified from the input images, based on which a geometric transformation matrix is applied to correct any perspective differences between the two images. Next, we select the image patches of the …

Chemical Clean Automated Loader, Jordyn Bryner

Williams Honors College, Honors Research Projects

TTM Technologies (TTM) is a global printed circuit board (PCB) manufacturer. The work described in this report was completed in the TTM North Jackson, Ohio location. This plant focuses primarily on the manufacturing of rigid and rigid-flex PCBs for the aerospace and defense industry. TTM North Jackson has an ongoing labor dependency issue due to the shortage of workers the nation is facing. To solve this problem, TTM has focused the efforts of their new engineers and interns on automating processes that are labor dependent. The goal is to provide design guidance to be used later by TTM to automate …

Grinding And Super-Finishing Test Machine Project, Michael Simon

Williams Honors College, Honors Research Projects

A research project in The University of Akron to study grinding and super-finishing of silicon nitride ceramic was initiated by Dr. Siamak Farhad and sponsored by the Timken Company, with the assistance of undergraduate students Michael Simon, Ryan Hosso and Mathew Rozmajzl. The study required analysis of forces and scratches generated during grinding processes of silicon nitride samples. A testing assembly was designed and constructed to record the forces generated during grinding and super-finishing of silicon nitride samples in a computer-numerical-control machine. Silicon nitride samples were subjected to desired grinding and super-finishing operations and all forces generated during the process …

Towards Real-Time Energy Efficiency Analysis Of A Hydraulic System, Montasir Mamun Mithu

Masters Theses

The study aims at developing a real-time data analysis system for the energy efficiency study of hydraulic systems. It also aims at implementing automation for hydraulic systems so that energy efficiency can be improved using the real-time approach. This research uses a system-level experimental methodology. A linear push system hydraulic prototype is developed for the study. The prototype contains hydraulic actuator, shock absorber, electronic flow control valve, and electronic sensor. This prototype is used to experiment with different operating conditions to characterize hydraulic system behavior. A real-time data analysis system is developed using LabVIEW and an Open Platform Communication (OPC) …

Development Of A Low-Cost, Photovoltaic-Powered, Automated Water Recovery System, David E. Daley

Master's Theses

An existing water filtration system at the Channel Islands Marine & Wildlife Institute (CIMWI) wastes approximately 25 gallons of water per day rinsing out solid waste under light load. To reduce CIMWI’s water and energy consumption, an automated system was designed and built to recover the rinse water and return it to the existing filtration loop. Models for fluid system requirements, basic energy needs, and photo- voltaic energy generation were created to aid in component selection. Basic sensors and electronics were programmed in Python for use with a Raspberry Pi single board computer to collect and process water recovery data …

Cnc Feed Drive Control, Ryan J. Funchess, Caleb P. O'Gorman, Nick J. Desimone, Juan M. Majano, Samuel K. Wong

Mechanical Engineering

This document serves as the Final Design Report (FDR) for a senior project developed by our team: four senior Mechanical Engineering students and one computer engineering student at California Polytechnic State University, San Luis Obispo (Cal Poly). While the project was completed for, and sponsored by, Professor Simon Xing of Cal Poly, the remainder of the university’s controls professors will be indirectly benefited from this project. Our goal was to design and implement a functional CNC Feed Drive to be used for educational demonstrations and data collection. This document discusses our early product research and benchmark goals, which established constraints …

Automated Bottling Station - Packaging System, Lauren Nicole Zinzilieta

Honors College Theses

This report focuses on the packaging system used at the end of the FESTO bottling station that is located in EP 2355. The system will be made up of an x-y 300 mm x 300 mm gantry system, an Arduino, two micro-stepping stepper drivers, and two 152.4 mm (6 in) single acting cylinders with a 3D printed bracket attached to both. The gantry system will be located at the end of the conveyor belt and will be programmed to pick up three bottles at a time and then will move a specified number of steps in both the x and …

Smart Home Pet Feeder, Andrew Markja, Simona Zdravev, Timothy Zubek, Christian Jackson

Williams Honors College, Honors Research Projects

The goal of this project was to design a Smart Home Pet Feeder that will allow the owner to feed their pet using 4 different methods. The methods are: manually, scheduled, app/url, Alexa/Google. The advantages of this design are that it will become convenient for pet owners who are busy and unable to make it back to their house to feed their pets remotely or for those who enjoy the use of technology from within their home for no-trouble feeding.

Implementation Of An Autonomous Guided Vehicle (Agv), Allen St. Myers, Alan Miller

Williams Honors College, Honors Research Projects

This report thoroughly represents a proposal to AAM Metal Forming Minerva for the implementation of an AGV (Autonomous Guided Vehicle) Unit. Our recommendations are made with consideration to existing manufacturing processes and demonstrate how using an AGV would be a net positive investment for the company. By first examining the current operating costs, a three-tiered proposal is tailored based on increasing investment cost. Each tier increase encompasses the previous tiers’ proposed improvements while also growing in complexity and investment cost. The results of our research indicate that our Tier 2 proposal will provide the most benefit to our facility now …

Autonomous Drone-Based Sensor Package Deployment To The Underside Of Structures, Sabrina Rose Carroll

Theses and Dissertations

The objective of this project is to design, develop and experimentally test an Unmanned Aircraft System (UAS, commonly known as a drone) for the deployment of sensor packages to the underside of structures. This work begins with an in-depth review of existing automation techniques for various drone applications focusing on applications requiring interaction with the environment. Further reviewed is the impact of structures above the UAS during flight on the behavior of the aircraft.

Considering these topics, the development of a custom drone is presented to address the difficulties of delivering a package to the underside of a structure. Starting …

Automated Drone Calibration System, Jackie Kelly Jong-Mee Paik, Zach Nathan Richter, Tyler Wilson Van Den Berg, Ryan Alexander Zhan, Matthew Ward Carlson

Mechanical Engineering

The final design review of the Inspired Flight Calibration Team senior project will detail the process used to complete a verification prototype of a drone calibration device and discuss lessons learned and suggestions for improving this device. Going from brainstorming and conceptual prototyping all the way through verification prototyping and testing, we were able to design a gyroscopic device that met Inspired Flight’s needs for the flight sensor calibration of their drones. The mechanical design involved comprehensive CAD models and hands-on manufacturing. The mechatronics side of the project worked heavily with electrical wiring and writing custom software to communicate and …

Fox Factory Bearing Assembly Rundown And Torque Automation Project, David Ethan Daley, Eric Michael Forrester, Christopher Enrique Hansen, Riley Jacob O'Connor

Mechanical Engineering

A machine design was created to partially automate the rundown and torque of a Fox Factory shock bearing housing. This machine is needed at the factory to keep line associates safe by reducing ergonomic strains associated with this stage in the shock assembly process. Due to the lack of applicable torque drivers for this operation, an open ended, geared drivetrain was designed to allow for engagement of the bearing housing while allowing clearance for the shock shaft that the bearing rides on. This open drivetrain is held by a structure of linear rails and bearings to allow the line associate …

Rinse Tank Salinity Automation, George Pahoundis

Williams Honors College, Honors Research Projects

Manufacturing processes are often consisted of many different processes and sub-processes. Each of these carries its own level of importance and impact to the overall picture. In this particular sub-process, salt is rinsed from a product via a rinse tank: a tank whose salinity may not exceed a certain level and whose temperature must not fall below a certain level. This setting is a prime opportunity to implement an automated control system to allow these parameters to be met with upmost efficiency. With potential savings in excess of $20,000 per year and an estimated payback period of 8 weeks, the …

Automated Runout Measurement Tool, Ethan Tisch

Williams Honors College, Honors Research Projects

A new measurement process and tool is to be developed to improve the existing method for measuring runout on the commutators of brushed DC product.

After an armature is manufactured, the commutator is inspected by placing the completed rotor assembly in one of several non-standard measurement fixtures. An indicator is then positioned on the commutator. A trained operator proceeds to rotate the armature while taking runout and bar-to-bar measurement at various positions along the length of the commutator.

This existing process is slow, costly, and unreliable. For these reasons, there is substantial economic pressure to develop a superior method for …

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 …

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 …

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.

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.

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 …

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 …