Mechanical Engineering Commons^™

Flexible Custom Electric Skateboard, Caleb Adam Kelsay

Electrical Engineering

At Cal Poly traveling long distances only accessible by foot such as across campus or from the car park to class can be tiring and time-consuming. While not physically demanding, the trek consumes time in our tight college life schedule. To improve our time efficiency this project provides a relatively lightweight, powered solution to quickly and effectively travel long distances while maintaining full control and safety even on hills, a current limitation of traditional skateboards.

This electric skateboard includes the battery capacity to travel all around campus on a single charge with a compact and flexible skateboard design that provides …

Museum Wave Tank Design, David James Streng, Lisa Michelle Dischinger, John Frederick Niemoller

Mechanical Engineering

The Santa Maria Discovery Museum would like to add a tsunami wave tank to be one of their demonstrations. The wave tank needs to draw the attention of their young crowd and be educationally informative about the shapes and effects of waves. As this is a museum demonstration for children, the structure, user interface, and wave making mechanism must be durable.

We are a senior project team from California Polytechnic State University that worked on this project with Allan Hancock College and Stanford University. We created waves by rapidly moving a plunger vertically in the water column. This project allows …

Thermal-Fluid Dynamic Model Of Luge Steels, Brandon Stell

Master's Theses

Luge is an Olympic sport in which athletes ride feet-first on sleds down an ice-covered track. Competitors spring from the starting position and accelerate their sled by paddling with spiked gloves against the ice surface. Once the Luger leaves the starting section, their downhill motion is solely propelled by the effects of gravity. Athletes compete, one after the other, for the fastest time. Runs can differ by as little as a thousandth of a second, meaning that every minor sled adjustment, change of line choice, and shift of body position is critical. In the past, the sport of Luge has …

Development Of An Insulated Solar Electric Cooker (Isec) With Thermal Storage For Use In Developing World Countries, Amanda Gyokery, Spencer W. Davis, Kyle Henry Smit

Mechanical Engineering

According to the World Health Organization, about half of the world’s population uses biomass stoves to cook their meals. However, biomass fires can be dangerous. Unattended biomass fires and indoor air pollution are responsible for an estimated 600,000 deaths annually and the creation of approximately 4 million instances of chronic disease. They also release CO2 and other pollutants into the air, and require the families to gather enough material to keep it burning (WHO 2017). Although cleaner cooking technology seems like a clear solution, often families are either unwilling to change how they cook food or are unable to afford …

Deep Well Pump Seal, Peter M. Gordon, Matt C. Johnson, Dylan A. Smith

Mechanical Engineering

Lifewater International, a Christian non-profit, trains locals to repair water well hand pumps in various third world countries. It would be beneficial to retrofit difficult-to-repair hand pumps with a locally-made pump cylinder such as HydroMission's "SlapShot". The majority of the components in the "SlapShot" can be easily obtained in rural third world villages. However, the thick leather gaskets required to seal the water cylinder during the pumping operation are imported. These thick leather gaskets are expensive, and when they fail, this results in pumps being out of commission for extended periods of time. Lifewater has presented this problem to a …

Dyno-Mite Redesign, Brandon Joseph Miller, Daniel Robert Hoffman, Richard Demedici Young

Mechanical Engineering

The Cal Poly Mechanical Control Systems Laboratory currently employs an outdated device, known as the Motomatic, to teach students about various motor characteristics and control methods. These include open-loop vs. closed-loop control, speed vs. position control, and DC motor response curves. The current device does not function properly and produces unreliable data due to overwhelming non-linear effects such as stiction and shaft misalignment. Our team was tasked with designing a replacement device that retains many of the same educational goals as the original lab procedure, while also adding new educational goals pertaining to the device system dynamics. The new apparatus, …

Rogue Rotary - Modular Robotic Rotary Joint Design, Sean Wesley Murphy, Tyler David Riessen, Jacob Mark Triplett

Mechanical Engineering

This paper describes the design process from ideation to test validation for a singular robotic joint to be configured into a myriad of system level of robots.

Poly Spotlight Control, Ryan P. O'Neill, C. Oleg Frandle, Anthony T. Lombardi

Mechanical Engineering

When this project began, The Cambria Center for the Arts Theater used a manually-operated spotlight. The sound created by the fans, along with the sheer size of the spotlight, required that it be housed in an attic room above the theater and shined through a closed window. This trapped a lot of heat in the room and involved some risk with climbing into and out of the attic room. This project sought to remedy those issues by mounting a pair of newer LED spotlights inside the theater. Doing this required a method for remotely controlling and actuating the angular position …

Development Of A Rotordynamic Signal Processing Matlab Interface And A Two-Disk Rotor Model, David L. Baker

Master's Theses

Using MATLAB and a National Instruments data acquisition card, a signal processing program meant to monitor the behavior of rotordynamic systems in real-time was developed and tested. By using traditional analysis methods in this field of engineering, commonly desired data representations such as bode, polar, orbit, full spectrum plots were able to be produced to a very high accuracy. Additional capabilities offered by this application are slow roll compensation, synchronous and sub-synchronous filtering, and true three dimensional plotting. The verification of this program was done by comparing the results to the ones acquired with Bently Nevada’s “Automated Diagnostics for Rotating …

Medium Duty Gas-Turbine Engine Blade Removal Tool, Elliott James Greb, Jacob Thomas Syage, Kellen Thomas Field

Mechanical Engineering

Solar Turbines Incorporated sponsored a team of three Cal Poly Undergraduate Mechanical Engineering students to design, manufacture, prototype, and test a tool for the removal of turbine blades from their respective disk assembly without damaging the disk itself. The tool was developed for Solar’s industrial gas turbine engines. The tool complies with all OSHA and Solar Turbines safety and engineering constraints, and was designed for use in a shop facility. The tool was made adaptable for geometric variances in multiple turbine rotor disk stages, and requires no more than one technician to operate using a maximum of two shop resources. …

Animated Otto-Langen Atmospheric Engine, Keiran M. Hansen, Lance Hodgson, Rachel A. Jakob, Chris J. Splees

Mechanical Engineering

Based on an existing relationship between Dr. Owen and the Deutsches Museum, Otto-Mated was given the opportunity to collaborate with the two in a year-long senior design project. Otto-Mated was tasked with modeling and simulating the Otto-Langen Atmospheric Engine as a form of preservation and education. The model was created in SolidWorks and animated in Blender, effectively providing the museum with accurate and educational videos demonstrating the engine’s function. Within this document are the plans, decisions, and processes used to create our final product for Deutsches Museum.

Process Management And Design Layout Of High Throughput Screening, Anthony Vasquez, Kyle Dupuy

Industrial and Manufacturing Engineering

Calibr is a pharmaceutical company in San Diego and growing very quickly rate and need help redesigning their lab layout and in doing so reducing their cycle times and down times in machines. In addition to this, they do not currently have an accurate measurement of how long their processes take in an overall cycle. The objective of this project is to provide Calibr with a redesigned layout to accommodate new equipment as well as a software tool that can output Gantt charts for their planning of their testing. Our approach to this project first included mapping out the facilities …

Effects Of Support Structure Geometry On Slm Induced Residual Stresses In Overhanging Features, Ryan Baskett

Master's Theses

Selective laser melting (SLM) is a new and rapidly developing manufacturing method for producing full-density, geometrically complex metal parts. The SLM process is time and cost effective for small-scale production; however, wide-spread adoption of this technique is severely limited by residual stresses that can cause large deformations and in-process build failures. The issues associated with residual stress accumulation are most apparent in parts with overhanging features. Due to the complexity of the SLM process, the accumulation of residual stresses is difficult to assess a priori. The deformations and in-process failures caused by residual stress accumulation often lead to an expensive …

Cal Poly Table Top, Kelsey M. Ishimatsu Jacobson, Andrew J. Whitney

Mechanical Engineering

Since many tables currently used at Cal Poly are not ideal for active design situations, we have designed, built and tested to be used in design classrooms with an emphasis on using the tables to quickly prototype ideas. This table is a standing height table in a trapezoidal shape which can comfortably seat four people. The modular design of the table allows multiple tables to be use to create different shapes so that the tables can be used in multiple ways.

Measurement And Analysis Of The Physical And Climatic Distribution Environment For Air Package Shipment, David Guadagnini

Master's Theses

The modern air parcel distribution industry has significantly grown to become one of the most commonly employed methods to quickly transport goods throughout the world. Although it comes with many benefits, including higher speed, greater reliability, and tighter security, the multimodal transport system within it can expose packages to a wide variety of climatic and physical distribution hazards. In a single route of transportation, packages could be included in different types of small delivery vans, large commercial semi trucks, cargo dollies, feeder aircraft, and high altitude commercial jetliners. The varying hazard level presented during distribution could directly weaken the packaging …

Multi-Criteria Flow-Shop Scheduling Optimization, Raviteja Arikati

Industrial and Manufacturing Engineering

A flow-shop is a type of manufacturing job shop where similar jobs follow a similar, linear sequence through the shop. Every day, flow-shops receive several different orders and it is up to the scheduler to plan the daily schedule. This schedule should be designed to prevent bottlenecks in the shop, to have on-time delivery of products, and satisfy several other requirements. Often, schedulers perform subjective scheduling and utilize simple heuristics or just intuition to schedule the jobs. With computer-based scheduling, schedulers can now create schedules and determine quantitatively what sorts of schedules work best. Currently, much of the computer-based schedules …

Yeager Multi-Function Tool Ql+, Osiel Flores-Hernandez, Carter Wilson, David Wright, Mitchell Jackson

Industrial and Manufacturing Engineering

No abstract provided.

Polar Coordinate Farm Bot Final Project Report, John Brown, Kasenia Colombo, Lucas Salem, Ning Jeng, Rory Stothers, Sam Lees

Industrial and Manufacturing Engineering

FarmBot Inc. is a local startup that is advancing precision agriculture through automation and open source technology. The original FarmBot model, FarmBot Genesis, operates over a rectangular area of 3 x 1.5 meters. It plants, waters, weeds and grows produce autonomously using CNC technology. Our project sponsor and inventor of FarmBot, Rory Aronson, tasked our team with developing and testing a polar coordinate farmbot capable of performing on par with the Cartesian farmbot in growing a circular vegetable garden in a user’s backyard. A successful project was defined by meeting specific customer requirements and engineering specifications predetermined and discussed with …

Design Of An Automated Welding Process For Synergy Mfg., Parsa Bakhtiari

Industrial and Manufacturing Engineering

This senior project involves a partnership with a local off-road parts manufacturer called Synergy Mfg. Synergy is experiencing a rapid increase in demand that is difficult to meet with their current processes. Because of this issue, Synergy is exploring automation in order to decrease their cycle times and increase their production output. More specifically, this report concentrates on automating a manual welding process that has a lengthy cycle time which causes Synergy’s difficulties with meeting demand. Due to time constraints, this project focused on the automation of a welding process for only one part that Synergy produces. This part contains …

Predictive Analytics In Forecasting, Matthew Suarez

Industrial and Manufacturing Engineering

Predicting future demand can be of tremendous help to businesses in scheduling and allocating appropriate amounts of material and labor. The more accurate these predictions are, the more the business will save money by matching supply with demand as closely as possible. The approach for an accurate forecast, and the goal of this project, involves using data analytics techniques on past historical sales data. Working with Campus Dining, a year's worth of their daily sales data will be analyzed and ultimately used for the end result of both an accurate forecasting technique and a way to display the results in …

Design Of A Finger Lime Loading System, Joel Jameson Hitchen

Industrial and Manufacturing Engineering

Automation for post harvest processing of finger limes is required to meet demand for the new citrus fruit being introduced to United States of America food and agriculture market. As labor wages rise, and demand climbs for finger lime product a creative solution is needed to eliminate human labor and reduce the manual input needed to process finger limes. Building on an already successful processing tool, a semi-­automated loading system was designed and implemented to overcome the problem.

Effect Of Composition And Build Direction On Additively Manufactured Hastelloy X Alloys, Justin A. Spitzer, Jeffrey T. Schloetter, Sarah Zerga

Materials Engineering

Microcracking has caused premature failure and reduction in properties in additively manufactured (AM) Hastelloy X. The purpose of this research is to meet or exceed the mechanical properties of wrought Hastelloy X by modifying the composition and build direction of Hastelloy X manufactured using Direct Metal Deposition (DMD). Tensile testing, scanning electron microscopy (SEM), and metallography were performed on the samples. ANOVA was used to analyze the dependence that the properties had on build direction and composition. The nominal composition wrought samples had a yield strength of 310.1 MPa and a 60.79% Elongation. Alloy P60-X18 in a horizontal build had …

Jfs Turbine Engine For Cal Poly Mechanical Engineering Department, Dorian Capps, Zoe Kai Tuggle

Mechanical Engineering

This project concerns the development of a gas turbine engine laboratory activity for use in one of Cal Poly’s technical elective courses in the Mechanical Engineering Department, ME 444: Combustion Engine Design. The class is taught by Dr. Patrick Lemieux, who is also in charge of the on-campus engines lab where the turbine engine will be installed. The engine itself is a JFS-100-13A turboshaft engine that will be coupled to an electric dynamometer inside of the dyno test cell. Students taking the ME 444 class, likely starting in Winter Quarter of 2018, will be able to perform hands-on experiments using …

Soft Target For Advanced Emergency Braking System Daimler Trucks, Kurt C. Ebert, Kolter Knapp, Esgar Pulido

Mechanical Engineering

This report provides an overview of the AEBS Soft Target project delivered to Daimler Trucks North Amer- ica as part of the 2016-2017 Mechanical Engineering Senior Design class at California Polytechnic State University, San Luis Obispo. The purpose was to build a soft target to test Advanced Emergency Braking Systems, or AEBS, on Daimler 0 s large trucks. Though this design is for Daimler specifically, there may be other interested parties such as highway safety groups and rival auto manufacturers. Currently, there are no suitable alternative products that satisfy every requirement for Daimler to validate their systems. They require a …

Additive Manufacturing For Post-Processing, Nathan D. Goodwin, Andrew Furmidge

Mechanical Engineering

Additive Manufacturing for Post Processing (AMPP) is a team comprised of two Cal Poly Mechanical Engineering students: Nathan Goodwin and Andrew Furmidge. The project is focused in the area of metal additive manufacturing (AM) machines, which are still a developing technology. Improvements have been made to the quality of the machines in the past years, but many limitations still exist. One of these is the inability to print parts that are larger than the build volume. In an effort to solve this problem, whole parts are divided into pieces that are printed individually. This team’s senior project is to create …

Bear Minimum: Ultralight Composite Bear Canister, Rama B. Adajian, Adam C. Eisenbarth

Mechanical Engineering

The ultralight backpacking community needs a strong, easy to use, safe bear canister that is lighter than current market products for trekking in the backcountry. A full design of the lid for the bear canister is to be completed. This includes the locking mechanism to ensure it is bear proof, the interface between the lid and the canister, and the structure of the lid so it passes the strength and weight specifications. The lid, along with the already designed canister body, is to be manufactured with formal documentation. The lid will initially be tested separately and then with the canister …

Self-Powered Ankle Prosthetic, Corina M. Espelien, Kelsey Pietzsch, Anna Sullivan

Mechanical Engineering

Originating from QL+'s customer requirements, the main technical specifications were to have 80% physiological range of motion, elastic energy return, impact absorption, and no external power sources. Based on the background research conducted and the discussions with experts in the field, the project team decided to focus on designing a prosthetic that focused on plantarflexion and dorsiflexion for a more comfortable gait. The main components of the final design are a hydraulic shock absorber, cam, torsion springs, heel, stopper, and separated keel. The heel, front and back keels, and stopper were manufactured out of carbon fiber. The link, lever, attachment …

Prototype Vehicles Laboratory Steering Apparatus, Zachary W. Sharpell, Jorge Lopez, Colby R. Genasci

Mechanical Engineering

The Cal Poly Prototype Vehicles Team (PROVE) is designing a solar powered vehicle to break an international land speed record. The space within the driver’s cockpit allotted for the steering mechanism was too small for a conventional steering wheel. This report describes the process that was followed to design, manufacture, and test a compact and lightweight steering apparatus for the PROVE solar vehicle. A lateral lever steering system, the final design selected for PROVE’s solar car, was designed to withstand the maximum expected loads applied by the driver during the three-minute run of the competition. The lateral lever steering apparatus …

Device To Standardize Leaflet Droop Testing, Mark Butler, Daniel Lussier, Kyle Timm

Mechanical Engineering

No abstract provided.

Characterization Of Flexible Hybrid Electronics Using Stretchable Silver Ink And Ultra-Thin Silicon Die, Joshua A. Ledgerwood

Master's Theses

Flexible Hybrid Electronics (FHEs) offer many advantages to the future of wearable technology. By combining the dynamic performance of conductive inks, and the functionality of ultra-thinned, traditional IC technology, new FHE devices allow for development of applications previously excluded by relying on a specific type of electronics technology.

The characterization and reliability analysis of stretchable conductive inks paired with ultra-thin silicon die in theµm range was conducted. A silver based ink designed to be stretchable was screen printed on a TPU substrate and cured using box oven, conveyor convection oven, and photonic curing processes. Reliability tests were conducted including a …