Mechanical Engineering Commons^™

Electric Charging Arm Mechanism - Echarm, Jacob A. Lewis, Gabriel A. Greer

Mechanical Engineering Student Research

As demand for electric and hybrid vehicles continues to rise, many EV owners rely on home charging in their garages. Gabriel Greer and I’s Senior Design Project, the Electric Charging Arm Mechanism (ECHARM), addresses this by creating a robotic system that autonomously detects a vehicle’s charging port, connects to it, and returns to a rest position when charging is complete. ECHARM is designed as a six-axis robotic arm with wrist and shoulder joints driven by stepper motors through custom cycloidal drive gearboxes. A closed-loop control system using rotary potentiometers ensures precise motion control. At the end of the arm is …

Deep Learning For Predicting Impact Energy And Compression After Impact Strength Of Composite Materials Using C-Scan Images, K. T. Tan, Jason P. Mack, Faizan Mirza, Zhong-Hui Duan

University Research

Traditional assessment of post-impact performance in carbon fiber reinforced polymer (CFRP) composites often relies on simplified scalar metrics that fail to capture the complex spatial interactions driving failure. This study addresses this limitation by developing an automated, end-to-end deep learning framework that shifts from manual feature extraction to the direct interpretation of raw damage morphology from ultrasonic C-scans. Using a ResNet18-based convolutional neural network (CNN) trained on 1,428 augmented images, the model achieved coefficients of determination (R2) of 0.7948 ± 0.0847 for compression after impact (CAI) strength and 0.9436 ± 0.0098 for impact energy. Beyond prediction, this dual-purpose methodology serves …

Teleoperated Robotic Arm With Vision-Based Imitation Learning, Favour E. Emmanuel, Hunter J. Donahue

Williams Honors College, Honors Research Projects

This report presents the design, development, and deployment of a teleoperated robotic arm system capable of vision-based imitation learning. The system uses a leader-follower architecture with myArm C650 and myArm M750 robots manufactured by Elephant Robotics. The leader arm movement is controlled by the operator, whereas the follower performs actions acquired from demonstrations. Data collection included synchronized joint-angle recording and multi- camera video streams capturing human demonstrations.

These demonstrations were processed with a deep learning imitation algorithm called Action Chunking with Transformers (ACT). The main capability of this algorithm is its ability to make future action predictions based solely on …

Areosense, Josephine Turney

Williams Honors College, Honors Research Projects

The AeroSense growing system is designed to make indoor aeroponic gardening easy and accessible for everyone. By combining sensors, automation, and AI, the system can monitor and adjust humidity, lighting, and nutrient levels to help plants thrive without requiring expert knowledge. The goal is to create a self-regulating garden that takes the guesswork out of growing fresh herbs and vegetables at home. The project involves building a working aeroponic prototype equipped with misters, pumps, and environmental sensors, all managed by a Raspberry Pi. Using computer vision and machine learning, AeroSense will be able to assess plant health and respond automatically …

High-Speed Non-Pneumatic Tire (Npt) Design For Speeds Above 60 Mph, Jacob Grams, Brady Maurer, Jake Groewa

Williams Honors College, Honors Research Projects

This project focuses on developing a high-speed non-pneumatic tire (NPT) capable of safely operating at speeds greater than 60 mph, a performance range where most existing airless tire designs fail due to structural instability and performance limitations. The objective of this work is to design, analyze, and prototype a structurally optimized honeycomb-based tire structure with improved load distribution, deformation control, and durability. Multiple geometries were evaluated using finite element analysis (FEA) to assess stress and maximum resultant (total) displacement behavior under loading conditions, and a material selection study was performed to identify a suitable material for the design. The final …

Nissan Leaf Disassembly Tool And Test Stand Design, Mariah Z. Hodge

Williams Honors College, Honors Research Projects

The Akron Engineering Tribology Laboratory has developed a water-based lubricant and aims to test and observe if the water-based lubricant could work in an electric vehicle environment. As parameters for creating a test stand to mimic an electric motor environment are not readily available online, the goal of this senior design project is to take apart a used Nissan Leaf engine to define the parameters a test stand must meet to accurately recreate an electric motor environment. Knowing these parameters, a test stand will then be designed for testing the water-based lubricants. The purpose of building a test stand to …

Eletric Charging Arm Mechanism - E-Charm, Jacob A. Lewis, Gabriel A. Greer

Williams Honors College, Honors Research Projects

As demand for electric and hybrid vehicles continues to rise, many EV owners rely on home charging in their garages. Gabriel Greer and I’s Senior Design Project, the Electric Charging Arm Mechanism (ECHARM), addresses this by creating a robotic system that autonomously detects a vehicle’s charging port, connects to it, and returns to a rest position when charging is complete. ECHARM is designed as a six-axis robotic arm with wrist and shoulder joints driven by stepper motors through custom cycloidal drive gearboxes. A closed-loop control system using rotary potentiometers ensures precise motion control. At the end of the arm is …

Using A Record Player Inspired Probe System To Investigate Adhesion And Friction Of Tire Rubber At Micrometer Length Scales, Kyle J. Galigher, Brendan Schmitt

Williams Honors College, Honors Research Projects

We will be using the principles behind how a record player turns physical grooves into electrical signals to develop a device that can be used to measure the surface of tires. The device will be capable of measuring the surface roughness of rubber samples from both new and worn tires, in order to compare the differences between them. It will be operable at varying speeds, and will produce electrical signals that correspond to the bumps along the surface of the rubber. The design will be carried out and optimized with the use of SolidWorks modeling, finite element analysis, motion analysis, …

Hvac Design And Calculations, Sarah Walters, Sarah Beyea

Williams Honors College, Honors Research Projects

This project studies Heating, Ventilation, and Air Conditioning (HVAC) systems for a car dealership located in Seguin, Texas. The building construction and architectural drawings were provided by EPIC Engineering Group. Comprehensive load calculations were done on the building in order to calculate necessary airflows throughout the building. Three possible HVAC design solutions were compared: Rooftop Units (RTUs), rooftop units paired with Variable Air Volume (VAV) Terminals with electric reheat, and Variable Refrigerant Flow (VRF) paired with a Dedicated Outdoor Air Unit (DOAS). Energy modeling was completed to compare the utility costs and energy consumption of each system. A comprehensive weighted …

Ai-Based Porosity Detection In Babbitt Bore Turning, Kaylee Leggett, Hannah Adams Gemmell, Kaisa Shingleton

Williams Honors College, Honors Research Projects

For this project, an external company reached out to the University of Akron requesting assistance with defect detection during their vertical turning operations. As babbitt is removed in a vertical turning process, it occasionally reveals defects, mainly porosity, which can lead to costly downstream failures of the part. Current inspection techniques involve use of dye penetrant, which is time consuming, labor intensive, unergonomic, and a source of human error. The goal of the project is to create an alternative inspection method using an AI-based machine-learning model. After the turning operation, a camera is deployed to perform an in-place inspection, taking …

Design New Stage For Vacuum Pin On Disk, Miranda Boyd

Williams Honors College, Honors Research Projects

For my senior design project, I am redesigning the moving stage for the vacuum pin-on-disk test used in the Akron Engineering Tribology Lab. This system is used to evaluate bearings and lubricants for aerospace applications under controlled vacuum conditions. The current stage design limits flexibility when adjusting for different testing parameters, so my goal is to develop a new movable stage that allows for varying weights and loads to be applied accurately and safely. The redesigned stage will improve test efficiency, adaptability, and precision, ensuring the system can accommodate a wider range of experimental conditions and materials while maintaining compatibility …

Lumacurve Control System Update, Jacob Kustra, Caleb Wengerd

Williams Honors College, Honors Research Projects

The existing track heater control system used by Lumacurve has become outdated and requires frequent maintenance due to inconsistent operation and component failures. This project aims to modernize the system through the implementation of a programmable logic controller (PLC), infrared non-contact temperature sensing, and an automated pneumatic ejection mechanism.

The redesigned system improves temperature monitoring accuracy and reduces operator intervention by automatically ejecting heated plastic tracks from the heater once the desired temperature is reached. An emergency ejection subsystem is also incorporated to safely clear tracks from the heater in the event of improper operation or system faults. Additional emphasis …

Length Modulatin Hip Implant, Ethan Smith

Williams Honors College, Honors Research Projects

Leg length discrepancy is a well-documented complication of total hip arthroplasty, commonly known as hip replacement surgery. Even small differences in leg length can lead to an altered gait, increased joint stress, and long-term postural issues that may affect a patient’s overall mobility and comfort. The current method for correcting this discrepancy often involves a follow-up surgical procedure, which extends recovery time and increases the physical and financial burden on the patient. To address these shortcomings, we developed a concept for an adjustable hip implant that can be lengthened noninvasively after surgery. The design incorporates an internally housed battery and …

Breaking The Vapor Barrier And Scale: Revolutionizing Steel Quenching With Ultrasound Technology, Anthony O. Santos

Williams Honors College, Honors Research Projects

The quenching process is a fundamental heat treatment used to enhance material properties by heating steel to its austenitizing temperature and rapidly cooling it to form high-strength martensite. However, this process is often hindered by two surface barriers: the Leidenfrost effect (vapor blanket) and oxide scale. These cooling limitations restrict the use of steel in high-performance aerospace applications due to inconsistent material properties and unpredictable engineering properties. This research investigates the use of fully submersible, 50-watt 40 kHz ultrasound technology to improve cooling rates in a Jominy test [4]. Through numerical simulations and experimental validation, the study demonstrates that acoustic …

Optimized Returning Floating System (Orfs/Orfeus), Jordan A. Mcclelland, Adam J. Belluardo

Williams Honors College, Honors Research Projects

We are developing a proof-of-concept modified guitar tremolo system for an electric guitar that can automatically optimize tuning adjustments when a player transitions between tuning schemes using a cam system. Currently, changing tunings takes about 10–15 minutes because adjusting the tension on one string affects the tension of the others. Our design aims to compensate for these interactions and significantly reduce the time required to switch tunings.

Large Telescope Mount For Long Exposure Photos, Payne M. Landis, Anna J. Gray

Williams Honors College, Honors Research Projects

When viewing the stars through a telescope, it is common that the object you are viewing drifts out of view. Many amateur astronomers seek to capture long exposure images of the stars, planets, and galaxies with commercially available sky tracking telescope mounts. The complication is that these telescope mounts are both incredibly expensive and have low weight limits. These issues limit accessibility to these products based on the telescope. For each person, telescope parameters determine the amount of light and magnification that can be viewed, which then determines exposures time for adequate photo results. The options on the market for …

Optimization Of Post-Processing Methods For Additively Manufactured Metals, Julia R. Carano

Williams Honors College, Honors Research Projects

Ultrasonic Nanocrystal Surface Modification (UNSM) is a process used to change the surface hardness of flat-faced materials. It is a machining process using a high-powered laser and a blunt-tipped tool at high speeds which aims to improve the uniformity of the surface on most metals. By heating and pressing the surface of the workpiece, the grains of the material become less rounded and more cohesive on a microscopic level. This, ideally, results in a workpiece with improved material properties. The changes were previously observed through hardness testing.

Thermal Radiation Effects On Particles From Plasma Arc Radiation, Reece Davis, Joseph Mcgee

Williams Honors College, Honors Research Projects

Understanding the radiation heating and transport of both microparticles and nanoparticles is a phenomenon that is critical for both space and Earth sciences. In space, these particles are heated by plasma arcs within ionized space clouds or solar flares and can be present the path of deep space missions and orbital satellites. While on Earth, processes such as forest fires, nuclear fusion, and microchip manufacturing include the plasma arc heating of particles. These particles lay within the Mie Scattering Regime and Rayleigh Scattering Regime and emit radiation differently based on their diameter. New mathematical and computational modeling has been conducted …

Akron Soap Box Derby Super Kids Car, Alexis Schultz, Cooper Sites, Sean Stevenson

Williams Honors College, Honors Research Projects

This project aims to redesign the All-American Soap Box Derby Super Kids vehicle to enhance safety, accessibility, and performance while maintaining full compliance with official regulations. The Super Kids program enables children with physical and cognitive disabilities to race alongside a co-pilot, but the current vehicle design presents challenges in stability, entry/exit accessibility, and control—especially following recent regulation changes that increased vehicle speed. The redesigned car will focus on improved ergonomics, lightweight construction, and structural integrity within a $1,000 budget and a 165 lb weight limit.

An iterative engineering design process will guide the project through research, CAD modeling, FEA …

Kruss Modifications, Anderson W. Howard

Williams Honors College, Honors Research Projects

My project focuses on modifying a test device in the AETL to allow for high temperature test to be performed. I am also adding modifications to make it safer to perform tests using the high-pressure system.

Automated Soil Resetting System For Extraterrestrial Regolith Simulation, Parker W. Brennan, Anthony C. Daniels

Williams Honors College, Honors Research Projects

This project focuses on designing an automated soil resetting system for extraterrestrial regolith simulation. The system will prepare a regolith simulant testbed to a desired, repeatable density, enabling reliable wheel–terrain testing for planetary rover research. Manual soil preparation currently exposes testers to hazardous particulates and produces inconsistent results.

The proposed system will integrate mechanical and control elements to reset the soil bed safely and efficiently. A combination of raking and vibrational methods will be explored, with feedback sensors and automation to achieve target density control. The research will proceed through literature review, benchtop experimentation, prototype design, and full-scale testing over …

Adjustable Car-Camping Bed Frame, Zachary Lamonica, Mitchell Mcgrath

Williams Honors College, Honors Research Projects

This project explores an innovative camping solution designed to enhance mobility, comfort, and accessibility for outdoor enthusiasts. The first is the Adjustable Car-Camping Bed Frame, engineered to be lightweight, collapsible, and adjustable to various vehicle interiors. It prioritizes ease of setup, compact storage, reliability, and affordability, enabling convenient travel without sacrificing comfort. The design aims to simplify camping while maintaining durability. As an aerospace systems engineering student, I will apply systems engineering to the Bed Frame, using aerospace software and principles. The scope includes research, design, prototyping, and testing, with a focus on real-world usability and environmental adaptability. Additionally, my …

Evaluation Of Health Monitoring Parameters For Automotive Pneumatic Elastomeric System Using Soft Pressure Sensors For Enhanced Vehicle Performance., Md Jarir Hossain, Sarah Suresh Kamath, Jong Min Park, Heung-Seok Oh

University Research

In the rapidly evolving automotive industry, the need for reliable and efficient pneumatic elastomeric components necessitates cutting-edge health monitoring methods, given that the pneumatic components are directly connected to dampening properties, ride comfort, vehicle safety, and stability. A novel approach for pneumatic elastomeric component health monitoring utilizing ionic liquid (IL)-based soft sensor technology has been proposed, which has the promise to enable real-time health monitoring and prognostics of vehicle systems. The proposed polymer sensor leverages the distinctive characteristics of flexibility, stretchability, and high sensitivity. These properties are critical for precisely measuring load, vertical displacement, air pressure, force locations, and load …

Automatic Hole Saw Testing For Mk Morse, Jason Watson, Justin Zapotoczny

Williams Honors College, Honors Research Projects

M.K. Morse has a hole saw tester they use for their hole saw product line. The tester currently requires constant operator attention for a process that could be automated. The goal of this project is to create a new hole saw tester that can run without the need for an operator's complete attention and give reliable data for the hole saws.

Aeg Improved Football Helmet Liner, Matthew Dyson, John Clore, Brady Slates, Nathan Walker

Williams Honors College, Honors Research Projects

The National Football League (NFL) is a leading professional American football organization experiencing rapid growth in popularity. However, the high-contact nature of the sport frequently results in player injuries, with head trauma and concussions being major concerns. This project aims to mitigate these risks by developing an advanced helmet liner designed to reduce the impact of direct collisions and torsional shear forces. In order to do this, we will utilize an impact testing machine with a modified helmet mount. By enhancing the liner's effectiveness, the proposed design seeks to improve player safety without compromising performance. The study focuses on innovative …

High Voltage Junction Box For Demonstrator Vehicle, Benjamin Lubowicki, Ryan Dorste

Williams Honors College, Honors Research Projects

Schaeffler, our industry sponsor for this project, is designing a battery pack for a demonstration vehicle that requires a high voltage junction box to route power to the vehicle. The project type is a unique design of a mechanical component, mechanism, and process. Our objective for this project is to assemble provided electro-mechanical components into an enclosure following a provided electrical diagram. The expected deliverables are the following: 3D CAD assembly of final product, FEA analysis of designed components, 2D print of final product, fabrication and assembly of designed parts, technical report documenting design process and installation. The skills required …

Automatic Scoring Cornhole Board System, Eric Diffendal, Jonah Harsh, Connor Lengel, Brett Sukie

Williams Honors College, Honors Research Projects

The objective is to create a self-scoring cornhole board that can detect and calculate each team's score based on the bags thrown each round and to be created at a low cost/eventually being sold at the current cost of a normal board. When playing cornhole, the game is simple: throw a bag on the board; however, the scores are variable (deduct and add) across each round. The most common issue when playing cornhole is miscalculations of the scores and forgetting the correct scores. Thus, this invention will make gameplay easy for all to play.

Rapid Convective Quench Apparatus Design, Samuel Fenik, Tyler Horvath, Dane Manias, Nicholas Michel

Williams Honors College, Honors Research Projects

In this project, we will research, model, and simulate the heat transfer of a red-hot steel plate undergoing a rapid quenching process by high pressure water jets. Our objective is to quench the steel plate in such a way so that the steam formed from the initial water contact does not inhibit the oncoming water from making proper contact with the plate. After sufficient research has been done, we will design an apparatus which will perform the optimal quenching method and record temperature data with the goal of obtaining the heat transfer coefficient. The purpose of our project is to …

Cochlear Electrode Insertion Training Model, Sarah Powell, Kaelyn E. Kraley, Nathan J. Smith

Williams Honors College, Honors Research Projects

Cochlear implant surgery is a delicate procedure performed by Otolaryngologists (ENTs) to implant an electronic device into the inner ear to provide a sense of sound for people who are profoundly deaf or hard of hearing. The current practices of training involve cadavers and 3D-printed models. Cadavers are commonly used but are expensive, single-use, and do not provide visual and haptic feedback, which are essential for medical students. 3D printed models are less commonly used and are hard to fabricate and not as realistic. If medical students are not properly trained for this delicate procedure, then risks are significantly increased …

Head Mounted Surgical Robot, Mason Currens

Williams Honors College, Honors Research Projects

The purpose of this design project is to utilize a six degree of freedom, robotic system that will be head mounted device that can either assist in, or perform, facial and optical surgery. The six degree of freedom idea came from current systems used in flight simulations. By optimizing the system to fit the figure of a patient’ s head, many of the present errors in surgical robotics can be reduced. One of the major errors when using a facial tracking robot is sudden impulses, such as a cough or a twitch, that the robot can't precisely track. Mounting the …