Mechanical Engineering Commons^™

Automation Of Data Analysis In Formula 1, Adam Joseph Mourad, Prescott Jeanne Delzell, Patrick Conner Mccabe

Industrial and Manufacturing Engineering

This paper explores economic solutions for Formula 1 racing companies who are interested in data visualization tools. The research was conducted on the current development of data gathering, data visualization, and data interpretation in Formula 1 racing. It was found that a large chunk of racing companies within the league needs an affordable, effective, and automated visualization tool for data interpretation. As data collection in Formula 1 arises, the need for faster and more powerful software increases. Racing companies profit off-brand exposure and the more a racing team wins, the more exposure they receive. The goal of the paper focuses …

Mechanized Advent Calendar, Oma Skyrus, Sigrid Derickson, Tyler Koski, Daniel Clifton

Mechanical Engineering

Within this document, the “Naughty and Nice” team will describe the details associated with the completion of this project, which involves creating an animated advent calendar for the Cambria Christmas Market. The problem, the customers and stakeholders, and the general goals of the project are introduced. The team conducted background research; how this research helps in finding a solution or supporting the needs of the sponsor is illustrated. Initial research includes interviews with the sponsor and potential users, patent and existing product searches, and some technical research pertaining to the subject. The team found that there are not many existing …

Katie's Jogger, Megan Guillermo, Erin Wint, Abdullah Sulaiman, Kathryn Mangiaracina

Mechanical Engineering

Edward Robinson is an avid runner who would like to take his daughter on runs. His daughter, Katie, is 100% wheelchair bound and currently does not fit in any commercial joggers on the market. The project team was expected to design, build, and test a custom working prototype of a jogger that the sponsor can use to take his daughter on runs. This entire project was performed over a span of three quarters.

Bicycle Drivetrain Power Measurement Study, Luke Costello, Nick Musolino, Ryan Miller, Jose Aguirre

Mechanical Engineering

The overarching goal of this project was to experimentally compare the bottom-bracket (BB) powermeter developed by Level Engineering, Inc., against off-the-shelf powermeters and a dynamometer. To do this, a significant amount of testing was performed. Level Engineering facilitated this testing by providing the project team with three testing apparatus – an In-Situ tester, a Stationary Tester, and a fatigue tester. The In-Situ tester was a bicycle outfitted with the BB prototype and a PowerTap powermeter. The Stationary Tester was a bicycle with a BB prototype, and the rear wheel replaced with a dynamometer. Finally, the fatigue tester made to apply …

Dynamic Pressure Sensing For The Flight Test Data System, Marc Y. Goupil

Master's Theses

This thesis describes the design, assembly, and test of the FTDS-K, a new device in the Boundary Layer Data System (BLDS) family of flight data acquisition systems. The FTDS-K provides high-frequency, high-gain data acquisition capability for up to two pressure sensors and an additional three low-frequency pressure sensors. Development of the FTDS-K was separated into a core module, specialized analog subsystem, and practical testing of the FTDS-K in a flow measurement mission. The core module combines an nRF52840-based microcontroller module, switching regulator, microSD card, real-time clock, temperature sensor, and trio of pressure sensors to provide the same capabilities as previous-generation …

E.M.B.E.R. Home Protection, Kylie Fernandez, Daniel Santoro, Ryan Kissinger, Christopher Slezak

Mechanical Engineering

Despite the increased danger of wildfires in states such as California and Colorado, there is yet to exist a product that can autonomously extinguish the spot fires that ignite from windblown embers. This device could reduce countless civilian casualties and prevent millions of dollars in property damage. This is not to mention allowing homeowners to evacuate with a greater peace of mind. Mass ownership of this product would be analogous to the “herd immunity” of vaccines, where neighbors ultimately protect each other and save money through self-insurance.

There are products on the market, generally in the commercial domain, that can …

A Rotating Aperture Mask For Small Telescopes, Edward L. Foley

Master's Theses

Observing the dynamic interaction between stars and their close stellar neighbors is key to establishing the stars’ orbits, masses, and other properties. Our ability to visually discriminate nearby stars is limited by the power of our telescopes, posing a challenge to astronomers at small observatories that contribute to binary star surveys. Masks placed at the telescope aperture promise to augment the resolving power of telescopes of all sizes, but many of these masks must be manually and repetitively reoriented about the optical axis to achieve their full benefits. This paper introduces a design concept for a mask rotation mechanism that …

A Novel Fiber Jamming Theory And Experimental Verification, Jared Richard Chafetz

Master's Theses

This thesis developed a novel theory of fiber jamming and experimentally verified it. The theory relates the performance, which is the ratio between the stiff and soft states of a fiber jamming chamber, to three relative design parameters: the ratio of the wall thickness to the membrane inner diameter, the ratio of the fiber diameter to membrane inner diameter, and the number of fibers. These three parameters, when held constant across different chamber sizes, hold the performance constant. To test the theory, three different types of fiber jamming chambers were built in three different sizes. Each chamber was set up …

Baja Sae Ecvt Mechanical Design, Tyler Lee Connel, Will Daniel Antes, Matt Stephen Balboni, Benjamin James Colard, Julian Edward Finburgh

Mechanical Engineering

This objective of this project was to design, manufacture, and test the mechanical systems of an electronically-controlled continuously variable transmission (eCVT) for the Cal Poly Baja SAE vehicle.

Teaching Top-Down Approaches To The Engineering Design Process, Joshua E. Katz, Joshua E. Katz

STAR Program Research Presentations

One of the main focuses of metacognition is to have students think about their learning. By bringing the engineering design process with educational psychology together, it can lead to a society that thinks more in-depth on various topics. The goal of the internship was to utilize and teach top-down educational and instructional objectives. Throughout the project, we followed a modified progression of the System Architecture Methodology to help other interns think in a top-down fashion. The purpose of this procedure is to create and induce new innovative and creative ideas for different projects. As teaching this methodology was tasked, research …

Electronic Cvt - Controls, Alec William Hardy, Jessalyn Leora Ann Bernick, Nicholas Esteban Capdevila, Tristan Charles Perry

Mechanical Engineering

The following document outlines the design process, manufacturing, and testing of the control system for an electronically controlled continuously variable transmission (ECVT). This control system was integrated into the custom designed and manufactured mechanical transmission system created in parallel by another senior project group. The transmission was designed for use in the Cal Poly Baja SAE vehicle. Through researching customer needs, competition requirements, previous and alternate CVT designs, and vehicle characteristics, we were able to determine the requirements and specifications for our unique system. Input, output, speed, and durability requirements guided our hardware selection. The primary components which comprised our …

Cisco Nexus 9200 Robustness Redesign, Colin Berge, Ethan Gold, Cole Christopherson, Rahul Makhijani

Industrial and Manufacturing Engineering

Certain configurations of Cisco's Nexus 9200 product experienced issues with bending during shipping. Two solutions were developed to eliminate this problem: an external brace that could quickly address the problem yet was expensive and unsustainable, and a redesigned chassis, which was more economical but came with a longer time to implement. Real world packaging and shipping conditions were simulated in SolidWorks and Finite Element Analysis was used to model the stresses experienced when the product is dropped. Both designs were found to significantly reduce stress in critical areas, thus reducing the chance of failure and the cost of the problem. …

Heat: Hydraulic And Electric Animation Team, Tyler J. Couvrette, Michael J. Cain, Sara T. Novell, Dexter K. Yanagisawa

Mechanical Engineering

Each New Years’ Day, the Cal Poly Rose Float presents a flower-covered float to the world at the Tournament of Roses parade. This floral display, paired with moving mechanical animations, shows off Cal Poly to the world. This project strove to keep Cal Poly on the cutting edge of technology both in parade floats, and in engineering, by creating a completely electric-powered animation system.

To accomplish this, a group of students set out to make the fully electric animation system that can power both the hydraulic and electric mechanisms on the Float. This was accomplished through months of planning and …

Fluid Power Vehicle Challenge - The Incompressibles - Final Design Report, Nicholas Gholdoian, Russell Posin, David Vitt, Alex Knickerbocker, Kyle Franck, Julian Rodkiewicz

Mechanical Engineering

This report provides a comprehensive description of the research, analysis and design work that The Incompressibles have completed thus far in the senior project process. This document includes all the work that The Incompressibles have completed for the team’s Preliminary Design Review (PDR), Critical Design Review (CDR), the work leading up to the 2019 FPVC competiton and the competition results. This report includes the initial research that the team completed for the fluid power competition, first iterations of designs, final iterations of designs, manufacturing results and processes, and finally testing and results from competition. With a new design for the …

Insulated Solar Electric Cooker Immersion Heater, Emily Burnside, Kaeley Dicks, Joshua R. Stevens, Brady Banks

Mechanical Engineering

This report is the final design review (FDR) report for our team completing the Insulated Solar Electric Cooker (ISEC) Immersion Heater mechanical engineering senior project. The goal of this project is to standardize and perform analysis on a preexisting, inexpensive solar-powered immersion heater for cooking use in developing countries, reducing the adverse effects presented by traditional biomass cooking fires. We also designed a manufacturing process to improve repeatability and to reduce labor investment of heater production. The ISEC research team from the California Polytechnic State University Physics Department have been working on the development of this immersion heater and have …

A Methodology For Verification Of Structural Standards For A Seating System By Finite Element Analysis, Zachary Kelly Dworaczyk Wiltshire

Master's Theses

Currently California Polytechnic State University has a patent pending on a new type of seating system designed to increase the functionality of public transportation vehicles. The patent is based on the work completed by a senior project group in 2016, whose design showcased the feasibility of the idea. Further development was completed by a second senior project group, the Adjustable Seating Systems, in 2019. The intent of the Adjustable Seating Systems group was to develop a seating system with the intent of commercialization and implementation in paratransit vehicles with future development into large buses and trains.

Seating systems used in …

Compact Rake Boundary Layer Data System Module, Nathan Jeffry Hoyt

Master's Theses

This Thesis describes the design, assembly, programming, and evaluation of the BLDS-M-RAKE, the newest addition to the family of devices called the Boundary Layer Data System (BLDS). The BLDS-M-RAKE is a continuation of the BLDS-M series of devices, a modular approach with updated electronics for boundary layer measurements. The BLDS-M-RAKE records data from a number of sensors, intended to be routed to an array of probes, or rake. Through preliminary testing, a new flexible manifold design from molded silicone and the hardware used on the RFduino development boards from the BLDS-M proof-of-concept modules were validated for use in the final …

Cooking Hand Multi-Tool, Amanda D. Meares, Amy H. Wilson, Ethan G. Littlejohn, Duania A. Evans

Biomedical Engineering

The purpose of this project was to devise a solution for Jorge Segura, a US Marine who was wounded in Afghanistan and had to have his non-dominant arm amputated above the elbow. His current prosthetic attachments are not suited to cooking tasks, so he needed a way to cook more effectively with either prosthetic attachments or accessibility devices. The main tasks that he needed help with was holding down food on cutting boards and stabilizing pots, pans, and bowls especially when stirring. After background research, exploring commercially available devices, and talking with our challenger, our solution was to design three …

Additive Manufacturing Powder Removal: Viper 2.0, Andrew D. Epperson, Sean Mccracken, Melissa O'Neil, Alex Ward

Mechanical Engineering

This report presents the final design review of this senior project team. The project is being sponsored by Lawrence Livermore National Laboratory, a federal design agency. Lawrence Livermore National Laboratory is interested in improving their metal additive manufacturing process. The goal of this senior project is to improve the efficiency and safety of a method currently being used to remove metal powders for additively manufactured components. A senior project team in 2017-2018 created the Vibration Induced Powder Evacuator and Reclaimer (VIPER), a device that uses a vibration motor to shake a printed part until it is clean from excess powder. …

Cal Poly Satellite Positioning Systems: "Thrust Or Bust!", Josh W. Neiman, Milena A. Milich, Gerardo Ramirez, Joshua A. Tran

Mechanical Engineering

Satellites need a way to make precise corrections to their orbit and positioning. The purpose of this project is to design a gimbal mechanism for Astranis that orients an ion thruster along a requested vector. The gimbal must produce any vector within a 2.5° cone in a thirty-minute window. Current systems are expensive and not well suited to this application. The design must be operable in a space environment and optimize mass, size, and reliability. Our design toggles between four discrete positions to achieve an average thrust vector. The gimbal accomplishes this using four solenoids that tilt a plate about …

C6 Wheels, Samuel L. Pizot, Luke Martin, Josh Warner, Jonah Levis

Mechanical Engineering

This document details the C6 Wheels project being undertaken for senior design. The objective is to design and manufacture carbon fiber reinforced polymer wheels for the Cal Poly Formula Society of Automotive Engineers (FSAE) team. The wheel shells will be used on FSAE’s competition vehicles. FSAE requested the wheels to improve the handling characteristics of their vehicles by reducing the unsprung and rotational mass. They have attempted carbon fiber wheels previously but have not yet run any on their vehicles. FSAE specifically proposed the design of carbon fiber shells with an aluminum center as opposed to full carbon fiber wheels …

Nano Fab Lab 63, Brian K. Deemer, Josh Clemons, Nick Brodine, Delaney Fitzsimmons

Mechanical Engineering

Lawrence Livermore National Laboratories (LLNL) has several steps in the production process for ceramic nanofiber tubes that they would like to improve - electrospinning, cutting, rolling, sealing and heat treating. We undertook the challenge to deliver LLNL with a semi-automated process that efficiently integrates the steps of cutting, rolling, and sealing to save time and improve control over end dimensions. In this document, we discuss the technical background of the manufacturing steps currently followed to create nanofiber tubes, identify which steps are incorporated in our prototype and explain how they will interface with one another, define the design requirements, present …

Atmospheric Water Harvesting: An Experimental Study Of Viability And The Influence Of Surface Geometry, Orientation, And Drainage, Carson T. Hand

Master's Theses

Fresh water collection techniques have gained significant attention due to global dwindling of fresh water resources and recent scares such as the 2011-2017 California drought. This project explores the economic viability of actively harvesting water from fog, and techniques to maximize water collection. Vapor compression and thermoelectric cooling based dehumidifier prototypes are tested in a series of experiments to assess water collection capability in foggy environments, and what parameters can increase that capability. This testing shows an approximate maximum collection rate of 1.25 L/kWh for the vapor compression prototype, and 0.32 L/kWh for the thermoelectric cooling prototype; compared to 315 …

Evaluation Of Tensile Properties For Selective Laser Melted 316l Stainless Steel And The Influence Of Inherent Process Features, Paul Swartz

Master's Theses

Optimal print parameters for additively manufacturing 316L stainless steel using selective laser melting (SLM) at Cal Poly had previously been identified. In order to further support the viability of the current settings, tensile material characteristics were needed. Furthermore, reliable performance of the as-printed material had to be demonstrated. Any influence on the static performance of parts in the as-printed condition inherent to the SLM manufacturing process itself needed to be identified. Tensile testing was conducted to determine the properties of material in the as-printed condition. So as to have confidence in the experimental results, other investigations were also conducted to …

Adapted Trailer Hitching System, Joseph Neil Hearn, Maxwell M. Selna, Maximilian D. Cossalter, Eric B. Ringsrud

Mechanical Engineering

This report highlights the entire design process of an adapted trailer hitching system for Taylor Morris: a navy veteran and quadruple amputee. This begins with problem definition through customer and product research. Objectives are generated after the problem is defined and the boundary of the project is set. This outcome of the project focuses on modifications/improvements to the vehicle side of the problem and leaves the trailers untouched. Engineering specifications are developed to constrain the concept design direction, which ultimately dictates the outcome of the final design. The final design is used as a basis to manufacture a structural prototype …

Reduce, Reuse, Reengineer, Neil Ryan Robertson, Anthony James Beers

Architectural Engineering

Our senior project is a research exploration of renewable energy. We recognized there is a major need in the world for the advancement of green power sources. For our project, we wanted to go beyond what we have learned in our Cal Poly architectural engineering classes and to use some of our own creativity to investigate the possibilities of renewable energy from a structural perspective. The guiding question we asked ourselves was, “as architectural engineering students, how could we shift our world to use more renewable energy?” To start our journey off, was the original inspiration from the work of …

Modifying Casting Parameters To Improve The High Temperature Ductility Of Investment Cast Nickel-Based Superalloy Pwa 1455, Lars Alexander Hedin, Cole Magnum Introligator

Materials Engineering

PCC Structurals, an industry leader in superalloy investment castings, has observed inconsistencies in the stress rupture performance of polycrystalline nickel-based superalloy PWA 1455. PCC has changed their casting parameters to reduce the thermal gradient during cooling but have been unable to correlate these changes with an increase in stress rupture elongation. Metallographic examination of past samples indicated microstructures composed of non- equiaxed dendritic grains with mean diameter of .021 inches along the test axis. A similar study on polycrystalline superalloys has indicated that excessive superheat temperatures above the liquidus can result in large grains identical to those observed, limiting the …

A Numerical Simulation Optimizing Droplet Motion Driven By Electrowetting, Jake M. Lesinski

Master's Theses

A numerical simulation of electrowetting on a dielectric was performed in COMSOL to grant insight on various parameters that play a critical role in system performance. The specific system being simulated was the Open Drop experiment and the parameters being investigated were the applied voltage, contact angle at the advancing triple point, and droplet overlap onto neighboring actuated electrodes. These parameters were investigated with respect to their effect on droplet locomotion performance. This performance was quantified by the droplets velocity and the dielectrophortic (DEP) force’s magnitude; the DEP force was calculated from integration of the Maxwell Stress Tensor, however, the …

Redesign Of Cubesat For Beam Charging, Kuba Preis

Industrial and Manufacturing Engineering

This paper is intended to be a study in the applications of the design freedom granted by additive manufacture in the design of a 1U CubeSat frame. The main loads experienced by a CubeSat are structural (during launch) and thermal (solar radiation). Beam charging is an emerging technology which involves charging a CubeSat using a laser beam. In this paper, a CubeSat frame was redesigned to account for the structural loads induced during launch and the thermal loads induced when beam charging. The thermal, weight, design, and structural requirements for a new CubeSat design were derived. The 1U CubeSat frame …

Commercial Vehicle Research Buggy For Active Driver Assistance Systems, Fernando Mondragon-Cardenas, Nathaniel Mccutcheon Furbeyre, Ricardo Steven Lickiss Tan Iv

Mechanical Engineering

This is the Final Design Report for Daimtronics, a senior project team sponsored by Professor Charles Birdsong of Cal Poly and by Daimler Trucks North America. This team integrated mechatronic systems into a scale semi-truck chassis using existing mechanical and software systems from three separate Cal Poly senior projects over the recent years: Daimscale, MicroLaren, and ProgreSSIV. The goal was to have a user-friendly platform capable of executing autonomous driving algorithms that are programmable at a high level in Simulink and Robotic Operating System (ROS). Advanced driver assistance and autonomous vehicle algorithms were not within the scope of this project, …