Engineering Commons^™

Industrial Automation And Controls Lab: Smart Led Dimmer Control, Trevor J. Beck

Electrical Engineering

Programmable Logic Controllers (PLCs) are rugged industrial computers used extensively in many industries for automation and control. EE 435 is a course being developed to introduce students to PLCs. This project will focus on one section of the course, with the primary objective being to control the brightness of an LED based on input received from an ambient light sensor. The control logic will use a PLC with analog input and output modules to interface with the sensor and actuator hardware. The light sensor will output 4-20mA proportional to the intensity of visible light, measured in lumens. The analog input …

Tank Level Controller Plc Lab, Siddhi Upadhyaya, Teghvir Grewal

Electrical Engineering

The California Polytechnic State University San Luis Obispo’s Electrical Engineering Department is currently developing lab experiments for the new EE435 (Industrial Power Control and Automation) class. In order to support these efforts, fourth year Cal Poly students are expected to develop laboratory experiments that will be conducted during this new class for the semester system. The lab experiment focused on in this project is called the Tank Level Controller. This experiment will introduce EE 435 students to Schneider Electric Programmable Logic Controller (PLC) hardware and software, which is prominent in the automation industry.
This experiment will require students to develop …

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 …

Analyzing Industrialized Construction Methods In Neca Contractors, Frank Lucey

Construction Management

Construction is constantly changing and evolving. Companies are always looking to improve their skills, provide a better finished product, and satisfy their client all while working in a safe environment. Industrialized Construction is an increasing trend in all sectors of construction over the past couple of years, due to the success of creating a more efficient project. Projects that utilized Industrial Construction saved more time and therefore money, while also exceeding the quality of work expected. Industrialized Construction is a very broad term with a lot of subcategories of what goes into it. These methods of increasing efficiency on the …

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 …

Use Of Industrialized Construction Strategies Among Associated General Contractors Of America, Matthew Mackenzie

Construction Management

Industrialized construction (IC) strategies are techniques used on a construction project that allows for significant time and schedule savings. The goal of this study is to analyze trends among general contractors and their experience with these strategies. Associated General Contractors of America (AGC) firms were asked various survey questions including size of firm, experience with several types of IC strategies, and their willingness to use similar strategies in the future. By answering questions about their percentage of use of prefabrication, automation, and BIM for various contract types, delivery methods, and payment methods, trends relating to the use of IC emerge. …

Use Of Industrialized Construction Within Mechanical Contractors Association Of America, Nathan M. Yi

Construction Management

It is a constant battle in the construction industry to improve productivity and efficiency while keeping the cost and schedule as low as possible. This can be made possible through the use of industrialized construction strategies such as, prefabrication, building information modeling (BIM), and automation. In this study, the main purpose of this survey was to collect information about MCAA firms’ knowledge of industrialized construction strategies, their use of them in the past, and their willingness to use them in the future. It also aims to explore the use of industrialized construction and its viability as a path for mechanical …

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 …

Microfluidic Electrical Impedance Spectroscopy System Automation And Characterization, Keaton Frahmann

Master's Theses

In this work, a novel microfluidic cell culture platform capable of automated electrical impedance measurements and immunofluorescence and brightfield microscopy was developed for further in-vitro cellular research intended to optimize cell culture conditions. The microfluidic system design, fabrication, automation, and design verification testing are described. Electrical and optical measurements of the 16 parallel cell culture chambers were automated via a custom LabView interface. A proposed design change will enable gas diffusion, removing the need for an environmental enclosure and allow long-term cell culture experiments. This "lab on a chip" system miniaturizes and automates experiments improving testing throughput and accuracy while …

The Benefits And Challenges Of Automation In The Modular Construction Industry, Allen Le

Construction Management

Modular construction combined with automation technology such as robotics presents benefits and challenges associated with it. Modular construction takes on the traditional building methods and has streamlined the production of modules making it safer, efficient, and productive. Along with innovation and cutting-edge technology such as automation, it offers an alternative building method to the modular construction industry that enhances productivity, worker safety, and efficiency. This research presents an investigation on factors that may be benefited from the adoption of automation but also addresses the challenges in modular construction. Qualitative interviews with designers and consultants in the modular industry were conducted …

Wine Sampler, Lance L. Litten

Computer Engineering

Quality testing is an important part of the wine industry. Without proper quality control, thousands of dollars could be wasted on bottling and recalling hundreds of gallons of wine. Due to this, labs are set up that collect wine samples from the tanks in a wine production plant and test them. A big part of this testing is determining exactly what tanks need to be tested and what tanks are at risk. My project aims to help automate this task by collecting data from the tanks wirelessly and keeping track of simple indicators such as pH and temperature. Automating this …

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 …

Plant Growing Control With Modicon M580, Brittany M.Y. Won, Eileen T. Tran

Electrical Engineering

Currently, the Industrial Power and Controls lab is being developed by the Cal Poly Electrical Engineering department. The lab is equipped with recently donated Modicon M580 Programmable Logic Controllers (PLCs) from Schneider Electric. In addition to PLCs, Schneider Electric also donated Human Machine Interfaces (HMI) and input/output modules. This project focuses on the creation of a lab experiment that will give future Cal Poly electrical engineering students hands-on experience with this equipment. To show students the broad range of PLCs and the role that electrical engineering plays in various industries, this experiment focuses on the agriculture industry, but more specifically, …

Dc Treasure Box, Michael A. Derrenbacher

Electrical Engineering

An all in one DC resource would enable electronics students to prototype circuits for labs and projects without the need for the lab equipment present on campus. The labs on campus can be physically far, closed, or overcrowded, preventing students from accessing the equipment. Roughly 75% of upper division electrical engineering students do not own power supplies, with even fewer students owning a source measurement unit (SMU). There is a significant need for a product capable of providing standard lab equipment functionality. The functionally this project provides are positive and negative DC power supplies, 4-Quadrant SMU, analog inputs and outputs, …

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 …

Protection, Automation, And Frequency Stability Analysis Of A Laboratory Microgrid System, Christopher Eric Osborn

Master's Theses

Due to increasing changes in the power industry, Cal Poly San Luis Obispo's electrical engineering department introduced a set of initiatives to adequately equip students with the skills and knowledge to interact with new technologies. Specifically, the department proposed a microgrid and power systems protection and automation laboratory to strengthen students' knowledge of microprocessor-based relays. This paper outlines a microgrid laboratory system that fulfills the initiative's goal and proposes a collection of laboratory experiments for inclusion in a new laboratory course at Cal Poly. The experiments provide students with practical experience using Schweitzer Engineering Laboratory (SEL) relays and teach fundamental …

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.

Smartfarm, Nathan A. Oto, Caleb Fink

Computer Engineering

The overall expectation of this product is to create an autonomous Arduino library that accurately and robustly collects plant environment data from the Smart Farm board. The Smart Farm PCB is split into two primary functions: Data Acquisition(DAQ) and Power Control. Each function of the PCB is controlled by an Atmega 328P Microcontroller. The primary concern for this report is the functionality of the DAQ microcontroller.

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 …

Design Of Inexpensive And Easy To Use Diy Internet Of Things Platform, Samuel R. Jaffe

Master's Theses

This thesis focuses on the design and implementation of a new, inexpensive, and less complex system for a Do-It-Yourself (DIY) Internet of Things (IoT) platform. The hardware aspects focus on a new chip called the ESP8266 which contains both microcontroller and WiFi connectivity capabilities in an extremely affordable package. The system uses the Arduino IDE to program the ESP8266, which is known to be an extremely user-friendly environment. All other software is both free and easy to use. Past methods of creating IoT projects involved either expensive hardware, often ranging from $50-$100 per node, or complicated programming requiring a full …

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 …

Solar Decathlon Instrumentation And Controls, Timothy Ambrose, Mateo Begue, Andrew Elliott

Mechanical Engineering

The Instrumentation and Controls team has designed a control and instrumentation system for the 2015 Cal Poly Solar Decathlon house that will monitor temperature, humidity, and energy usage throughout the house and control the phase change material duct. It will relay information to the user through a tablet application developed by the Computer Science team. The team has also designed a lighting control scheme for use with Lutron’s HomeWorks QS lighting control system.

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 …

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.

Wirelessly Controlled Smart Outlet, Andrew Godsil, Ariel Dubinsky

Electrical Engineering

Popularity of home automation devices has increased greatly in recent years due to higher affordability and simplicity through smartphone and tablet connectivity. For the purpose of this experiment, we have developed the Smart Outlet: a stand-alone communication unit, used to connect home outlets to the internet. The Smart Outlet controls lighting and simple appliances throughout the home, remotely, using wireless commands from the web. A Google Calendar interface directly controls the outlets’ function by scheduling them with dedicated calendar events. The calendar’s interface can even be accessed from multiple different platforms (i.e. phones, computers, tablets) for the convenience of all …