Mechanical Engineering Commons^™

Human Powered Vehicle Trainer, Nicholas Hung Nguyen, Gregory Reece Bridges, Jacinta Garcia, Mitchell Sidney Smith

Mechanical Engineering

This Final Design Review (FDR) document describes the final design and completed prototype of a Mechanical Engineering senior project team at California Polytechnic State University, San Luis Obispo. The project goal is to create an adjustable human powered vehicle training bike for George Leone that allows a rider to gain confidence with the unique reclined bike geometry ahead of the World Human Powered Speed Challenge at Battle Mountain, Nevada. This document outlines the customer’s needs and technical research performed which together determine the project’s scope and engineering specifications. Next, we present the initial idea generation process and its results, along …

Adaptive Paddle Board, Alexander Holthaus, Alexander Holthaus, Garrett Holmes, Garett Jones

Mechanical Engineering

This Final Design Review (FDR) document outlines the Adaptive Paddle Board senior project, done by four Mechanical Engineering Students at California Polytechnic State University and provides detail on the project and what the team has accomplished. The goal was to create a universally adaptive paddle board that can be used by the Central California Adaptive Sports Center for a wide range of persons with disabilities. This document highlights current research from patents and existing products, details regarding customer specifications, results from concept generation, the manufacturing and testing that went into the final design, and the process taken to get there. …

Uav Catapult, Sean Drew Huxley, Benjamin Richard Lacasse, David Matthew Garcia, Jordan Joseph Cearns

Mechanical Engineering

This document outlines the Senior Design Project proposed by Dr. Aaron Drake that was assigned to a team of Mechanical Engineering students at California Polytechnic State University, San Luis Obispo. The purpose of this project was to design, build, test, and finalize a launching system for two small, fixed wing, unmanned aerial vehicles (UAVs) owned by Dr. Drake and Cal Poly. The goal was to create a system that was both portable and reliable to use, only requiring a two-person team to use effectively in the field. The most important design requirements were determined to be the launch speed, assembly …

Retaining Ring Material Wear Analysis And Testing, Thomas Headland, Barten Hansen, Austin Fisher, Kevin Hurtado

Mechanical Engineering

The chemical mechanical planarization (CMP) of wafers for integrated circuits is an essential – yet expensive – step in their manufacture. CMP machine down-time due to the replacement of process consumables, such as wafer retaining rings, is a significant contributor to the process cost. To reduce the operational cost of their CMP machines, Revasum is interested in exploring new designs and materials for wafer retaining rings to increase their operational lifetime. Background research showed that there is currently no suitable method for testing new retaining ring designs and materials for wear characteristics specific to the CMP process. Available wear testing …

Sand Foot: A Prosthesis For Walking On Sand, Samantha A. Galicinao, John Dewing, Daniel Dugan Dotson, Christopher Urasaki

Biomedical Engineering

This critical design report describes the product development of a prosthesis for use on sand. Quality of Life Plus (QL+), a national non-profit organization aimed to develop prostheses for veterans and people with disabilities, introduced this project and its accompanying challenger, Sgt. Brady, to Cal Poly’s Interdisciplinary Senior Project class in September 2018. After consulting with Sgt. Brady and QL+ and performing extensive research, the Sand Foot team defined customer requirements and engineering specifications to meet these requirements. Comfortability, durability, and sandproof were key customer requirements. Several conceptual models were brainstormed and a final design was selected based on the …

Fracture Control Modeling With The Finite Element Method, Jorge A. Pluma Reyes

Master's Theses

This thesis investigates the feasibility and usability of the finite element method approach in the design of crack arresting devices. Current design and manufacturing practices are improving structures' susceptibility to fracture, in particular brittle fracture; however, cracks in structures are still observed within their lifespans due to severe unexpected service conditions, poor designs, or faulty manufacturing. Crack arrester systems can be added during service to prolong the longevity of structures with sub-critical or critical flaws. Fracture properties of different specific structures under specific services can be obtained experimentally, however, experiments are expensive and of high complexity. Alternatively, the finite element …

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 …

Duocel Metal Foam Display Cases, Kate Goldsworthy, Katherina Prodanov, Benjamin Swanson, Syed Hasan

Mechanical Engineering

This Final Design Review (FDR) report outlines the senior design project that was conducted by a team of four mechanical engineering students at California Polytechnic State University-San Luis Obispo for ERG Materials and Aerospace Corporation. The goal of this project was to design displays that showcase the properties of ERG’s Duocel® foam at tradeshows and client meetings. To better understand the needs of our sponsor, the team researched Duocel®’s capabilities, related technologies, and relevant standards and regulations. With this information, we further defined the problem by creating a problem statement and a set of engineering specifications through a Quality Function …

Insulated Solar Electric Cooker With Phase Change Thermal Storage Medium, Justin Brett Unger, Nathan Robert Christler, Matthew Weeman, Marcus Edward Strutz

Mechanical Engineering

This final design review document outlines the senior design project carried out by a team of four mechanical engineering students at the California Polytechnic State University – San Luis Obispo under the sponsorship of Dr. Peter Schwartz of the Cal Poly Physics department. The aim of this project was to improve upon the design of previously developed Insulated Solar Electric Cookers (ISECs) by adding a thermal storage system to allow for quicker cook times and the ability to cook food at non-peak solar hours. The team’s goal was to develop a working prototype utilizing a phase change medium as the …

Framed Human Powered Vehicle Frame, Keyanna Brielle Henderson, Brendon Howard Morey, Kyra Noelle Schmidt, Austin Patrick Henry

Mechanical Engineering

The following is the Final Design Review (FDR) Report for Framed, a team tasked with designing and fabricating the frame of the 2018-2019 Cal Poly Human Powered Vehicle (HPV) Club bike. The bike is to be raced at the 2019 World Human Powered Speed Challenge in Battle Mountain, Nevada with the goal of breaking the American collegiate speed record. The purpose of the FDR Report is to introduce the project’s background and objectives, discuss the final design, and present the results of manufacturing and testing. Prior to beginning work on the design of the frame, the group conducted extensive research …

Vaccine Cooler For The Global Poor, Benjamin J. Larson, Cooper E. Gibson, Eilbron Younan, Cody R. Volk

Mechanical Engineering

Cal Poly physics professors Peter Schwartz and Nathan Heston approached the Solar Freeze team with the problem that remote communities in Africa have limited access to modern-day medicine or vaccines. They suggested that we try and design a cooling device that can keep vaccines cold for multiple days at a time while the medicine is transported to remote villages. Currently, there are vaccine cooler products on the market, but most of them are very expensive or lack portability. Peter and Nate have tasked the Solar Freeze team to come up with a less expensive solution that is also portable and …

Autonomous Vehicles Operating Collaboratively To Avoid Debris And Obstructions, Toan T. Le, Cole W. Oppenheim, James H. Gildart, Kyle M. Bybee

Mechanical Engineering

The purpose of this project is to demonstrate the safety and increased fuel efficiency of an automated collision avoidance system in collaborative vehicle platooning. This project was cosponsored by Daimler Trucks North America headquartered in Portland, Oregon, as well as Dr. Birdsong, and Dr. DeBruhl of Cal Poly. The mechanical engineering team consists of Cole Oppenheim, James Gildart, Toan Le, and Kyle Bybee who worked in coordination with a team of computer engineers. Vehicle platooning is a driving technique to increase the fuel efficiency of a group of vehicles by following a lead vehicle closely to reduce the drag experienced …

Adjustable Seating Systems, Grace Timken, Zachary Dworaczyk, Jasper Lewin, Eric Voss

Mechanical Engineering

The Adjustable Seating Systems team designed and prototyped a collapsible and nestable seat for use in transit vehicles to create more free space for more passengers and cargo. Our team is the second senior project group to have worked at solving this problem. The previous team established a unique seat folding method that is currently pending patent approval. Our team’s responsibility was to improve the ease of use and overall hardware design of the entire seating system. This document captures the efforts that our team has performed to organize an approach to completing a full design and working prototype this …

Danny’S Recumbent Bike Accessibility Device Final Design Report, Joseph J. Lee, Huy Nguyen, Jack Mcatee, John Kulick

Mechanical Engineering

The purpose of this document is to fully define our design solution and explain our manufacturing and testing results. Our project’s goal is to find a way to allow Danny Knutson, a retired Navy pilot and incomplete quadriplegic with limited use of his arms and an impaired sense of balance, to enter and exit his recumbent tricycle without any discomfort for him or his aide. We completed multiple interviews with Danny, patent research, existing product research, and other technical literature research in order to fully understand the problem. We synthesized this information to create a concrete list of customer wants …

High Strollers, Braeden Hammond, Morley Perrin, Reid Bartels, Juan Rodriguez

Mechanical Engineering

This report documents the final product of Jonathon’s new lightweight stroller. The Mechanical Engineering team from Cal Poly, High Strollers, began the project to create a lightweight stroller for the project sponsor, Nina Aguayo, and her son, Jonathon Aguayo, in Fall of 2018. Jonathon is diagnosed with Delayed Brain Development and Hypotonia with some characteristics of Cerebral Palsy. He has a 50lb high intensity stroller to go to and from school. Mrs. Aguayo needed a stroller that is easier to transport while still meeting all of Jonathon’s needs. The re-designed stroller will make leisurely outings for Mrs. Aguayo and Jonathon …

Go With The Flow, Scott Weinhardt, Priscilla Ng, Ben Rydberg, Ritika Makhijani

Mechanical Engineering

This Final Design Review (FDR) report outlines the Fuel System Flow Analysis senior project completed by the presenters listed. Included is research about Solar Turbines’ needs, and objectives for our project, our design decision process and final design, manufacturing, design verification report, final results, and suggestions moving forward with this experiment. The goal of the project is to identify stable pressure fields throughout the Solar Turbines fuel delivery system. Specifically, the optimal placement for taking measurements downstream of the main and pilot fuel control valves. The data is used to validate the accuracy of computational fluid dynamic (CFD) models that …

Universal Bike Suspension Design, Ernesto Huerta, Gregory Ryan Ritter, Chris Michael Fedor, Michael Wu

Mechanical Engineering

Cal Poly Bike Builders (CPBB) is a student club at Cal Poly helping students design and fabricate their own bicycles. Currently, club members build rigid frames and mountain bikes with only front-suspension–commonly referred to as a “hardtail”. As more students join the club, interest grows in building full-suspension mountain bikes (FSMTB). Designing and manufacturing a mountain bike rear-suspension system requires a diverse skillset and a substantial time commitment. As a result, individual efforts building FSMTB have proven unsuccessful. The scope of this project is to develop a defined method and necessary tools such that all CPBB members can efficiently build …

Final Design Report For Human Powered Vehicle Drivetrain Project, Derek Fromm, Luke Opitz, Michael Juri, Olivier Côté

Mechanical Engineering

The Cal Poly Human Powered Vehicle Club is building a bike to surpass 61.3 mph in 2019. The club and their mentor, George Leone, have proposed a senior project to design, build, and test the drivetrain for this year’s human powered vehicle. Research into human powered vehicles and their drivetrains has shown that the power that a rider can output and the efficiency at which the rider can pedal depend extensively on the design of the drivetrain. Despite the existence of standard bicycle drivetrain designs, the senior project team has found that the best design to meet the club’s requirements …

Effects Of Bio-Composites In Corrugated Sandwich Panels Under Edgewise Compression Loading, Jalen Christopher Mano

Master's Theses

Present day composite sandwich panels provide incredible strength. Their largest problem, however, is early bonding failure between the core and the skin. This is due to the low bonding surface area of present cores like honeycomb. Corrugated structures could provide a remedy for this with their much larger bonding surface area. Corrugated structures have extreme mechanical properties deeming them particularly useful in aerospace and automotive applications. However, previous research has shown that the stiffness of carbon fiber causes debonding and drastic failure when used as both a core and a skin. Bio-composites have properties that could strengthen the corrugated sandwich …

Comparison Of Lqr And Lqr-Mrac For Linear Tractor-Trailer Model, Kevin Richard Gasik

Master's Theses

The United States trucking industry is immense. Employing over three million drivers and traveling to every city in the country. Semi-Trucks travel millions of miles each week and encompass roads that civilians travel on. These vehicles should be safe and allow efficient travel for all. Autonomous vehicles have been discussed in controls for many decades. Now fleets of autonomous vehicles are beginning their integration into society. The ability to create an autonomous system requires domain and system specific knowledge. Approaches to implement a fully autonomous vehicle have been developed using different techniques in control systems such as Kalman Filters, Neural …

Advanced Technology Lift Assist Systems - Atlas, Sebastian L. Gnagy, Ismael A. Rangel, Giovani Rodriguez, Tyler J. Hooks

Mechanical Engineering

EMS personal work hard every day to save lives. A big part of the job is helping to lift people who are notinjured but have fallen and can’t get up by themselves. There are currently no procedures or tools that areconsistently used by EMS in this specific situation. This leads to the response often being ad hoc costing more time, resources, and manpower that can be vital if multiple emergencies happen at the same time. Along with this the job of lifting an individual that is overweight is no easy feat and is one of the primary factors that leads …

Final Design Review: Wear Test Machine, Justin Ju-Han Hou, Abraham Jack Mitchell, Alexandra Denae Pavano, Jahyun Kaylla Son

Mechanical Engineering

A California Polytechnic State University Senior Project team has been tasked by Marvin Engineering Co. to design and build a friction wear test fixture; the fixture is to characterize the coefficient of friction and potential friction wear of various industry adopted metal pairings in an oxygen-free environment. This final design review serves to document project research, full design process, method of operation of final product, and a comprehensive testing procedure.

The R&D department at Marvin Engineering Co. proposed this investigation in order to explore the phenomenon of friction and adhesive wear, specifically the occurrence of galling between stainless steel surfaces. …

Investigation Of Design, Manufacture, Analysis, And Test Of A Composite Connecting Rod Under Compression, Thomas Juhl Rohrbach

Master's Theses

Composite materials hold great potential for the replacement of traditional materials in machines utilized on a daily basis. One such example is within an engine block assembly where massive components inherently reduce the efficiency of the system they constitute. By replacing metal elements such as connecting rods, cylinder caps, or a crank shaft with composite alternatives, a significant increase in performance may be achieved with respect to mechanical strength, thermal stability, and durability, while also reducing mass. Exploration of this technology applied to a connecting rod geometry was investigated through a combination of process development, manufacturing, numerical analysis and testing. …

Torsional Stiffness Of A Race Car, Reiley A. Schraeger, Cameron Kao, Raymond Deng, Omar Roman

Mechanical Engineering

Torsional stiffness plays a major role in any road vehicle. To understand torsional stiffness of a vehicle and make future iterations and improvements, a proper torsional stiffness jig is required to prove accurate and useful data. This report encompasses the new and improved testing jig and potential improvement ideas for more accurate results. With real data result relating to FEA calculations, designers can be confident in the FEA changes to torsional stiffness is accurate and will yield the probably results they desired. This report shows the methodology, manufacturing process and testing procedure to use on any Baja or SAE vehicle …

Cal Poly Supermileage Electric Vehicle Drivetrain And Motor Control Design, Clarisa Joy Howe, Christopher Joseph Mclaughlin, Erik Alvarado, Enyi Liang

Mechanical Engineering

The Cal Poly Supermileage Vehicle team is a multidisciplinary club that designs and builds high efficiency vehicles to compete internationally at Shell Eco-Marathon (SEM). Cal Poly Supermileage Club has been competing in the internal combustion engine (ICE) category of the competition since 2007. The club has decided it is time to expand their competition goals and enter their first battery electric prototype vehicle. To this end, a yearlong senior design project was presented to this team of engineers giving us the opportunity to design an electric powertrain with a custom motor controller. This system has been integrated into Ventus, the …

Design Of A Low-Cost Data Acquisition System For Rotordynamic Data Collection, Gregory S. Pellegrino

Master's Theses

A data acquisition system (DAQ) was designed based on the use of a STM32 microcontroller. Its purpose is to provide a transparent and low-cost alternative to commercially available DAQs, providing educators a means to teach students about the process through which data are collected as well as the uses of collected data. The DAQ was designed to collect data from rotating machinery spinning at a speed up to 10,000 RPM and send this data to a computer through a USB 2.0 full-speed connection. Multitasking code was written for the DAQ to allow for data to be simultaneously collected and transferred …

Ares Cleaning System, Andy Sagers, John Cunningham, Peter Greig, Jack Glynn

Mechanical Engineering

In this Final Design Review, the team outlines the general scope of the ARES Cleaning System project and the final design direction chosen and built. This team consists of a group of four mechanical engineering students who have been tasked with designing and manufacturing an autonomous ARES cleaning system to help their sponsor, Fracsun, better track soiling losses measured at large solar arrays. They designed, conceptualized, manufactured, and tested throughout the project as they looked to create a final, functioning product. In creating this Final Design Review, they have identified how the product will perform the desired functions and what …

Surf Leg, Samantha Campbell, Oyundari Altansukh, Caroline Swanson, Kurtis Barth

Mechanical Engineering

The Surf Leg Prosthetic project team in conjunction with QL+ and Operation Surf designed a transtibial prosthetic to be used for surfing. The senior project team focused on the missions of QL+ and Operation Surf as they went through the design process during the 2018-2019 academic year. The problem solved was that a standard prosthetic for a transtibial amputee does not provide the flexibility in enough degrees of freedom for a user to squat and balance on a surfboard. The goal of this project was to create a device specifically designed to improve the user’s balance and control while surfing. …

Gaf: Mechanical Paint Line Test Stand, Sidney Wong, Taylor Best, Aaron Fisher

Mechanical Engineering

The roofing manufacturer GAF located in Shafter, CA is in pursuit of a mechanism with the ability to improve the quality of paint lining applied on a dynamic roll of roofing shingles. The mechanism must consist of an alignment system along which a paint line applicator can be adjusted in the vertical direction and operate at a certain range of speeds. Other requirements for the mechanism demand that it is feasibly portable, reasonably durable, capable of accurate alignment, mountable to the ground, and within a budget of $15,000. With the customer's design requirements established and understood, a one-year project has …

Portable Thermoelectric Refrigerator, Cassandra Danielle Beck, Ryan Theodore Gelinas, Joshua Michael Dimaggio, Zachary David Wilson

Mechanical Engineering

This project created a versatile thermoelectric refrigerator that can be used via a wall outlet. The product is durable and effective. The refrigerator is functional in any ambient temperature, and uses thermoelectric cooling, and work from a standard 120V power outlet. By understanding existing products’ limitations and strengths, this project produced a product that outperforms what’s currently on the market. Many of the existing products’ operating temperature is dependent on the ambient temperature of the surroundings, which is a large drawback. Additionally, most of them take a long time to reach their lowest temperature, around 3 hours. One team member, …