Mechanical Engineering Commons^™

Rover Chassis & Suspension, Nikki Zainer, Aung Bhone Zaw, Joelle Romero, Colin Thompson

Mechanical Engineering

The Mars rover project is part of the University Rover Challenge (URC), a robotics competition organized by the Mars Society that tasks student teams with designing and building the next generation of Mars rovers. Cal Poly Human Space Technology and Research (CP-HSTAR) has inherited a rover developed by a previous senior design team.

This report documents the progress made in refining the rover’s structure, highlighting key specifications, and detailing design improvements aimed at enhancing the suspension’s structural integrity, improving wheel traction, increasing modularity, and developing an enclosed chassis for electronic components.

This report includes a detailed breakdown of the rover’s …

Hitch Cart “Landing Gear”, Rebekah White, Jose Raygoza, Randy Hernandez, Brandon Leon

Mechanical Engineering

This report aims to allow our sponsor, to review our design process of the Hitch Cart Landing Gear Prototype. In the design overview section of this report, we discuss the primary design modifications we made to the wheel mechanism of the existing hitch cart prototype, including the addition of the ACME screws and the folding brackets. This allows our sponsor to see the intended improvements made to the past prototype and understand the primary goal of our project. Then, in the implementation section, we cover the entire manufacturing process to allow our sponsor to understand what manufacturing steps must be …

Pseudo Gps For Romi, Emmanuel Baez, Owen Guinane, Gabriel Coria, Conor Schott

Mechanical Engineering

The Pseudo-GPS system for Romi robots addresses the need for precise real-time location tracking in Cal Poly's Mechatronics lab. This project, developed by Emmanuel Baez, Gabriel Coria, Owen Guinane, and Conor Schott, under the guidance of instructor Charlie Refvem, provides a proof-of-concept system to enhance the Romi robots' geolocation capabilities for advanced robotic algorithms.

The proposed system uses a Raspberry Pi 4 equipped with a Pi camera module and ArUco markers to track the position and orientation of Romi robots within a lab environment. Custom 3D-printed stands secure markers on the robots, and a designated origin marker defines the coordinate …

Expandable And Retractable Wheel Design, Ethan Fortenberry, Emily Cottrell, Keegan Martin, Benjamin Mcconnell

Mechanical Engineering

Our sponsor, Jeremy Goren, wants to see his patented expandable wheel design come to life. He requires a functional final product actuated by linear actuators and with a continuous, circular outer shell. The overall design can be broken up into 2 parts: the inner hub and outer shell. The wheel's shell will consist of a 12-piece outer shell that guides the 6 inner shell pieces. The outer shell pieces will be connected via a UBracket. The hub will consist of 3 identical parts that will hold 2 linear actuators each. The pieces will be bolted together to create 1 singular …

The Waterbug: Adaptive Paddle Board Frame, Remy James Elio Lacchia, Katie Kellum, Madeline Evenson, Shelbi Sullaway

Mechanical Engineering

People with disabilities, particularly wheelchair users, face limitations in participating in outdoor activities like paddleboarding. Central Cal Adaptive, a nonprofit organization, aims to bridge this gap by offering adapted paddleboarding experiences. However, their current paddleboard presents challenges such as portability, range of motion, stability, and safety. Our team, comprising Madeline Evenson, Remy Lacchia, Katie Kellum, and Shelbi Sullaway, has collaborated with Central Cal Adaptive to refine the existing paddleboard design. The team’s goal is to enhance the paddleboard's functionality to better cater to wheelchair users' needs, ensuring lightweight, portable, and safe features for an improved outdoor experience.

Our paddleboard concept …

Piston Crown Design, Kurt L. Lippmann, Liam T. Janssen, Alex Rangel, Larry J. Davis

Mechanical Engineering

This project investigates the effects of dimpling a piston crown, and its impact on engine combustion dynamics. Through computational methods, the effects of piston crown dimpling on flow characteristics were evaluated. Theoretical results were verified with experimental methods. Experimental methods included characterization of exhaust gas content, engine horsepower and torque, and exhaust opacity.

Swim Fly Drone, Alia Wolken, Sha'anan Levy, Andrew Jwaideh, Eduardo Santos

Mechanical Engineering

This project addresses the need for a versatile drone that is capable of operation in both air and water environments, with potential applications in infrastructure inspection, defense, search and rescue, and ocean exploration. This project focuses on the design and development of a waterproof aerial drone capable of floating on the water surface and submerging underneath to controlled depths with the integration of a custom detachable buoyancy chamber. The buoyancy chamber design utilizes syringes to compress and decompress air inside of the chamber, changing the volume of the chamber, with an actuation system controlled by a closed-loop control system that …

Zero-G Exercise Equipment, Charisse Biglete, Jake Brajevich, James Monroe, Ethan Siahpush

Mechanical Engineering

In a micro-gravitational environment, the body undergoes less loading than that found on Earth. This leads to muscular atrophy, Osteoporosis, decreases in protein synthesis, and various other undesirable outcomes. To prevent this, astronauts undergo a strict exercise regime to maintain their health. The current exercise equipment available for spacecraft is large, heavy, complicated to use, costly, and unsafe. There is a definite need for the re-engineering of the exercise equipment to be used by astronauts while in microgravity environments to rectify these issues.

Experimental Investigation Of Vertical Axis Wind Turbine Performance Using Bio-Inspired Blades, Ahmed Elbaz

Mechanical Engineering

Vertical Axis Wind Turbines (VAWT) are becoming a key player in small wind power applications. Recent research on turbine performance focused on methods to augment turbine performance to secure a more efficient and reliable wind energy conversion system to electrical power. Most of these research works rely on Computational Fluid Dynamics (CFD) simulations given the excessive cost of wind tunnel testing. Many research papers investigated innovative blade shapes in order to improve turbine performance. In the present paper, a new bioinspired, blade shape is proposed to enhance the power output of VAWT. This shape is based on modifying NACA 0018 …

Slo Children’S Museum Music Education Exhibit, Charles Coffen, Madeline Carleton-Sniff, Yael Castillo, Anthony Ramos

Mechanical Engineering

The Children’s Museum in San Luis Obispo is a non-profit facility providing education to young children through interactive exhibits. The proposed project would address a basic introduction to musical theory through mechanical engineering principles. The target audience for this musical art installation would be young children, aged 5-10, who would be regularly interacting with this exhibit, as well as their parents, and the employees of the museum. The installation will educate children in basic musical understanding through interaction while still being engaging enough to hold their attention. This document describes the final concept design and various methods of verification in …

A Case Study On Optimizing Industrial Air Conditioning With Thermal Solar Energy In Egypt, Tamer Adel Mohamed, Hesham Safwat, Mohammed A. Ebaid

Mechanical Engineering

This study investigates the feasibility of implementing a solar-assisted adsorption chiller in an industrial building at the Oriental Weavers International factory located in 10th of Ramadan City, Cairo, Egypt. The objective is to replace an inefficient split air conditioning system currently used to cool the Jacquard units during carpet manufacturing. The research begins by analyzing the performance of the existing cooling system to establish a baseline. It then explores the potential energy savings achievable by replacing the current system with a solar-assisted adsorption chiller. The existing oversized boiler will serve as an auxiliary heater for the new system. TRNSYS simulation …

Direct Evaporative Cooling For Sustainability And Environmental Conservation, Hesham Safwat, Iman El-Mahallawi

Mechanical Engineering

This work presents the results of experimental work on cellulose cooling pads with honeycomb structure to study their evaporative cooling effect which is one of the partial solutions for achieving the SDG goals 2030. The paper outlines vari ous types of evaporative cooling materials, highlighting their distinctions and potential applications. Furthermore, it offers a comparative analysis of the cooling effects between wide hole and narrow hole cellulose cooling pads, both individually and in combination. The experimental setup results are thoroughly examined to provide insights into the performance of the cooling pads. Results showed up that direct evaporative cooling have a …

Formula Integrated Monocoque Development, Hayden Wagner, Aaron Fang, Elijah Schulz, Carson Smith

Mechanical Engineering

Every year the Cal Poly Racing FSAE club set out to create two separate race cars to compete in the upcoming formula combustion and formula electric competitions. Both the combustion and electric formula cars operated on the same vehicle platform with the powertrain systems being the main difference between the two cars. Cal Poly Racing FSAE is the only school in California to run a full carbon fiber monocoque chassis, with each chassis design operating on a roughly four year design cycle. A new FSAE senior project team has set out to improve upon the previous chassis design as the …

On The Correlation Between Pre-Processing Workflow And Dimensional Accuracy Of 3d Printed Parts In High-Precision Material Jetting, Karin Chen, Ahmed Elkaseer, Steffen Scholz, Veit Hagenmeyer

Mechanical Engineering

Material Jetting (MJ) is distinguished in the additive manufacturing field for its ability to create accurate multi-material functional objects with features in the range of few micrometers. Analyzing the impact of each step in MJ from virtual design to 3D printed object on the process response is essential for optimizing the technology’s capabilities. The current state-of-the-art reveals a gap in MJ regarding the fundamental understanding of the correlation between the pre-processing workflow and the geometrical and dimensional accuracy. This study aims to bridge this gap by examining factors such as utilization of different CAD software with diverse working principles, part-based …

Direct Evaporative Cooling For Sustainability And Environmental Conservation, Iman El-Mahallawi, Hesham Safwat, Mahmoud Elsayed, Mahmoud Alghrieb

Mechanical Engineering

This work presents the results of experimental work on cellulose cooling pads with honeycomb structure to study their evaporative cooling effect which is one of the partial solutions for achieving the SDG goals 2030. The paper outlines various types of evaporative cooling materials, highlighting their distinctions and potential applications. Furthermore, it offers a comparative analysis of the cooling effects between wide hole and narrow hole cellulose cooling pads, both individually and in combination. The experimental setup results are thoroughly examined to provide insights into the performance of the cooling pads. Results showed up that direct evaporative cooling have a significant …

Spring Rate Measurement Of A Pneumatic Mountain Bike Tire, Joseph D. Balderama, Alexandre Kachlakev, Duncan Wyke, Luki Rosen

Mechanical Engineering

The Final Design Review (FDR) presents a comprehensive overview of the spring rate measurement project for a pneumatic mountain bike tire. This report details the project's design, its implementation, and how it met all specified requirements. It also includes a discussion of the project's findings and recommendations for future work, assuming continuation of the project. The primary goal is to develop a device that allows professional race teams or experienced mountain bike riders to parameterize tires based on their spring rate in addition to internal pressure.

Since the Critical Design Review (CDR), the design has undergone significant changes due to …

Rapid Composter, Cate Seay, Clarisbet De Jesus, Lesley Milena Estrada, Reese Dennett

Mechanical Engineering

This Final Design Review documents the efforts of a team of mechanical engineering students from California Polytechnic State University, San Luis Obispo as they work towards completing their assigned senior design project. This team was tasked with designing and developing an onsite rapid composter for the Girl Scouts of California’s Central Coast. The selected design concept that will be explained focuses on creating a composter that is child-safe, portable, weatherproof, solar-powered, and requires minimal manual user input. This report will not only provide a detailed description of the chosen design but will also supply an extensive design justification. This mainly …

Cal Poly Bsae Brake Caliper, Carter Henry Foye, Benjamin Leistiko, Nathan Berger, Colin Williams

Mechanical Engineering

In the past, the Cal Poly Racing Baja SAE team has used off-the-shelf brake calipers for their vehicle. Off the-shelf calipers have been either oversized, resulting in a heavy and hard to package system, or undersized, resulting in an unreliable system that does not provide adequate braking power. The goal of this project was to provide a caliper that meets the requirements of Cal Poly’s Baja SAE team. Our final design consisted of a two piece CNC machined caliper that uses the complex piston seal geometry from an existing mountain bike brake caliper. Using an existing caliper as a reference …

Quarter Car Suspension Model, Jack Miller, Alexander Eckhardt, Jonathan Lam, Max Gardenswartz

Mechanical Engineering

Dr. Porumamilla, Professor of Mechanical Engineering at Cal Poly, needs a way to demonstrate the concept of base excitation to the mechanical engineering students in the Mechanical Vibrations (ME 318) Lab. A mass-spring-damper model represented by a quarter-car suspension has been selected to represent this concept. A team of four students was assigned to design such a model as a senior design project. This document will explain the testing procedures, how were the results, and if they achieved our requirements. Furthermore, the document will explain how we assemble our product and manufacturing steps. Additionally, Critical Design Report (CDR) design changes …

F56: Rocket Thrust Vector Control, Ethan Douglas Anderson, Yiming Trent Jia, Sahil Sampat

Mechanical Engineering

This Final Design Review (FDR) report compiles relevant information regarding the Rocket Thrust Vector Control senior project as sponsored by Ethan Anderson from Cal Poly Space Systems (CPSS). Documented in this report is our progress from the months following our Critical Design Review (CDR) completion. This consists of a brief overview of the design our thrust vector control (TVC) system and its subassemblies with design changes noted, a thorough walkthrough of our procurement, manufacturing, and assembly process for creating our verification prototype (including software), a breakdown of how we verified each of our specifications through inspection and testing and the …

Cal Poly Battle Bot (F41), Jyotaaver S. Nirula, Andrew D. Peterson, Johnathan W. Waldmire, Nathaniel Ab Davis

Mechanical Engineering

This senior project endeavored to design, construct, and optimize a 120lb robot combatant tailored for the competitive arena of combat robotics. The project is a collaborative effort between mechanical, computer, and electrical engineering students at Cal Poly, combining diverse expertise to achieve a unified goal. Our competition, RoboGames, was in April of this year in Northern California.

The mechanical engineering team assumed primary responsibility for the physical components of the battle bot, focusing on three pivotal components: a robust drivetrain, armor, and a highperformance vertical spinner. These elements constitute the foundation of the battle bot's offensive and defensive capabilities, crucial …

Ross Dam Micro Hydro Project, Marirose Evenden, Tyler Reents, Elena Ryan, Tevan Kim

Mechanical Engineering

The Ross Dam and reservoir in Angels Camp needs a reliable power source for powering its SCADA system which monitors its water level and flow rate. Currently, the existing hydro power supply is very unreliable and needs to be replaced with a micro hydro generator system that can consistently produce power to charge the onsite batteries. This paper details the design and implementation of a micro hydro Pelton wheel replacement system designed by our senior project team.

Outlined in this report is our design overview of the system and how our project will redesign and optimize the use of the …

Automated Expanding Christmas Tree, Ben Mosemann, Zoey Camarillo, Xiomara Medina, Will Tedone

Mechanical Engineering

The Civic Ballet of San Luis Obispo (SLO) needs a new expanding Christmas tree for their 2024 production of The Nutcracker. This Final Design Review Report outlines pertinent information regarding the Cal Poly Mechanical Engineering Senior Project of Team F14 (“D.R.E.I.D.E.L.S.”), who was tasked of designing and building the new expanding Christmas tree frame. Our team’s name, “D.R.E.I.D.E.L.S.,” stands for Design and Research of Expansion Integrated Dramaturgy Ergonomic Leveraging Systems. We thought this would be a fun, creative, and ironic name for our team.

In this report, our team will discuss how we procured the materials required and manufactured and …

Focused Led Sintering, Dylan Defazio, Nilav Maulik, Branden Majors, Michael Fontillas

Mechanical Engineering

This report provides a detailed overview of the final design of our light-emitting diode (LED) focusing system. Our system incorporates a converging lens and a specially designed "glass funnel," which acts as a thick fiber optic that narrows the light to a fine point through internal reflection. The glass components of our system are precisely housed in a part made using advanced computer-numeric controlled (CNC) Mill and CNC Lathe manufacturing processes. This ensures high precision and durability of the overall system. Our LED focusing system is designed with a 60-watt stage light. The decision to use a glass funnel as …

Port Adapter For Unported Pressure Sensors, Peter Kristjaan Tomson, Yasser Fahad Aldaoud, Terak Benjamin Hornik

Mechanical Engineering

Boundary layer research is an exciting and ever-changing field in fluid mechanics; thus, the need for high-quality empirical data is ever-growing in importance. Dr. Westphal, a professor at California Polytechnic State University, San Luis Obispo’s (Cal Poly) Mechanical Engineering Department in conjunction with Northrup Grumman is conducting just such research. Dr. Westphal has elected to make the change to pressure sensors that do not come with a built-in port to connect to pitot-static tubes. This necessitates a solution to adapt an unported pressure sensor to his testing apparatus which requires a tubed connection. This document outlines the Final Design Review …

Cal Poly Battle Bot, Jyotaaver S. Nirula, Johnathan W. Waldmire, Andrew D. Peterson, Nathaniel Ab Davis

Mechanical Engineering

This senior project endeavored to design, construct, and optimize a 120lb robot combatant tailored for the competitive arena of combat robotics. The project is a collaborative effort between mechanical, computer, and electrical engineering students at Cal Poly, combining diverse expertise to achieve a unified goal. Our competition, RoboGames, was in April of this year in Northern California.

The mechanical engineering team assumed primary responsibility for the physical components of the battle bot, focusing on three pivotal components: a robust drivetrain, armor, and a highperformance vertical spinner. These elements constitute the foundation of the battle bot's offensive and defensive capabilities, crucial …

Nsf-Eri Evolution Of Liquid Sheet Edges Project: Soap Film Frame Withdrawal And Positioning Apparatus, Samir S. Patel, Sophia Young, Nicole N. Morgan

Mechanical Engineering

The experimental investigation of instabilities along retracting liquid sheet edges seeks to answer a fundamental fluid mechanics question. We’ve successfully delivered an experimental apparatus to conduct research and answer this question. This document chronicles a design overview of our apparatus, our manufacturing process, our design verification, and recommendations for future steps. The final product is a document outlining our final design (i.e., our ‘Final Design Review’ (FDR)).

Liftwalker, Kai A. De La Cruz, Lexie Caterine, Adam Monroe, Jame Whealan

Mechanical Engineering

The LiftWalker’s purpose is to lift users with degenerative diseases from a seated to standing position and support them as they practice the motion of walking as a form of physical therapy. The current LiftWalker is upward of $5,000 so we redesigned the LiftWalker to be more accessible around the world. This meant using affordable and accessible materials and manufacturing processes. To achieve this, we made our design mostly out of bike parts and off-the-shelf components. When it came to the lift system, we found that to maintain a safe and comfortable design it was best to purchase a trailer …

Solar Farm, Parker Folsom, Jon Copeland, Julia Fay, Aiden Taylor

Mechanical Engineering

This senior project focused on creating a portable single-axis solar follower. The purpose of this solar follower is to allow for single-axis tracking of the sun at various points on our sponsor's property to gather information on solar power production. This data will be utilized to locate future sites for a utility-scale solar farm.

The final design of the solar follower comprises four subsystems: two legs, the frame, and the panel assembly. This modular design allows for portability and adjustability on challenging terrain. Following the design stage, our team purchased and manufactured all of the necessary components. All manufacturing work …

Autolacing The Dml, Harrison Hong, Chanh Tu Derek Lam, Candice Espitia, Paolo Navarro

Mechanical Engineering

The design challenge present is the design of a system to efficiently speed up the lacing of the dry mat loop (DML), part of the GAF production line. For this year, the scope of the project focuses on research and creating a proof of concept for the mechanism responsible for moving the mat within the DML. Compiled research focuses on competitor solutions, material properties, and possible mover mechanisms to be integrated into the major design. Competitor solutions provide an idea of raw material manipulation options. Material properties and possible mover mechanisms provide the foundation for ideation and concept prototyping. The …