Mechanical Engineering Commons^™

Llnl Raft Flash Pole Redesign, Jack Stangel, Evan Wolfson, Jake Borden, Alexander Meeter

Mechanical Engineering

During research exercises in the ocean, Lawrence Livermore deploys a fleet of rafts outfitted with flash modules affixed to tall poles (in tandem called flash poles) that flash while a photo is taken to act as datums for data collection. The current flash pole design that the LIDSS (Lawrence Livermore Independent Diagnostic Scoring System) team uses is too short to be visible in high seas, not mechanically suited to be made taller, too susceptible to the elements and blunt impact and too difficult to service. We aim to solve these issues.

Torsional Vibration Kit Simulator (Tks), Joseph Thachet, Luca Lawson, Ryan Ota, Otis Mcloughlin

Mechanical Engineering

The goal of this project was to create torsional vibration on a shaft while limiting axial and radial vibration. To do this an eddy current brake was used to slow down a rotating shaft. The electromagnets used to create the eddy currents are able to be turned on and off at a frequency produced by a function generator. This power cycling of the electromagnets creates an alternating braking force thereby inducing torsional vibration while limiting the other two vibration types

Uv Vessel Hoist Scope Of Work, Quinn J. Horak, Harvey Perkins, Andrew A. Osborn, Mikayla H. Nieman

Mechanical Engineering

The San Luis Obispo Wastewater Treatment Plant uses ultraviolet (UV) tubes to purify water. These tubes are cleaned by an internal wiping mechanism that must be removed for servicing and replacing damaged tubes. Currently, this is accomplished by using an engine hoist, but this method requires a large amount of effort and is not safe. Technicians have requested a new method of lifting wiper mechanisms that is safer, faster, and easier to use than their current method.

To solve this problem, we have developed a design that consists of a custom gantry crane with a hoist on a trolley. The …

Trailer Transport System For Multi-Ton Bins, Joanna Lizbeth Bendy, Kevin Matthew Creel, Annelise Vaara Cuneo, Hugo Alonso Valdez

Mechanical Engineering

This project aimed to improve the process of transporting 10,000-pound industrial waste bins. The current method for relocating these bins poses safety risks and requires significant manual effort. This project presents a conceptual solution that enables a single operator to efficiently and safely move roll-off bins using a custom-designed trailer system. The design incorporates three main subsystems: a trailer frame, an integrated winch system, and an off-the-market puller device to guide and secure the bin during transport. Two scaled proof-of-concept prototypes were fabricated to evaluate key aspects of the system's functionality. Testing and analysis suggested that the system is viable …

Brush Seal Cycling Test Rig, Angelo J. Reis, Neil M. Bedagkar, Max A. Soury, Eoin K. Lenham

Mechanical Engineering

To prevent backflow from the high pressure compressor stages of their gas turbines to lower pressure regions, Solar Turbines utilizes brush seals along their driveshafts. Due to manufacturing limitations, no shaft is perfectly symmetric about its rotating axis, leading to orbiting that creates asymmetric friction on the shaft through rubbing. With this biased application of friction comes a hotspot on one side of the shaft, causing bowing of the shaft and cascading into an amplified vibrational response. Our goal is to gather data on this phenomenon and offer a potential solution.

Heart Valve Leaflet Cutting Automation, Gabriella Aclan, Josh Deweese, Lizzie Dilao, Jason Wong

Mechanical Engineering

The content contained in this report is confidential and proprietary information of Edwards Lifesciences.

Poly Mars Mini-Rover, Dane Carroll, Aaron Lubinsky, Henry Bouma, Gerardo Tapia-Onate, Scott Frizzel

Mechanical Engineering

The Cal Poly Mars Rover project is creating a fleet of near-identical rovers operating collaboratively to research the surface of Mars. Over the last six years, teams at Cal Poly have been developing vehicles to be launched upon the commercialization of interplanetary travel. Two of these vehicles are to take the roles of ‘Scout’ and ‘Relay’ with the most significant difference being their respective ‘arms.’ The ‘Scout’ will have a robotic arm that interacts with objects on the surface while the ‘Relay’ will have a fixed arm, equipped with a StarLink antenna to communicate with orbiting satellites as seen in …

Air To Water Capture In Support Of Un Sustainable Development Goals, Jordan Macconnell, Michael Tiscareño, Ari Dennis, Baxter Mercy

Mechanical Engineering

This senior project explored the use of thermoelectric cooling for atmospheric water capture. The system was designed to cool aluminum condensing surfaces below the dew point using Peltier modules, with forced convection heat sinks on the hot side. The purpose of this system was to gather reliable amounts of water for various water-scarce areas around the world to help meet the UN's sixth Sustainable Development Goal.

The final design of this project consisted of a 1.5 x 1.5 x 2 foot frame made of acrylic panels and insulation. Within the frame, the thermoelectric system was constructed using Peltier modules with …

One-Handed Wheelchair, Brian Azevedo, Cade Veljovich, Carlos Perez, Jakob Zuckermandel, Alexander Harper

Mechanical Engineering

A person who uses a wheelchair for mobility needs a way to operate it with only one hand. This may be necessary if they lack functionality in one hand or prefer to use only one hand while operating the wheelchair. Even for users with two available hands, it is difficult to operate As of now, such wheelchairs are not widely available or easily accessible, yet these devices are crucial for improving the quality of life and mobility of many people. The goal of this project is to design a more viable and ergonomic solution for people who operate a wheelchair …

Micro Mobile Home R3, Roha Y. Ali, Yuka M. Iwashita, Luke C. Douglas, Joshua Q. Le

Mechanical Engineering

Homelessness is an ever-growing issue all around the world. In 2023, over 250,000 or ~40% of all people experiencing homelessness did not have access to shelter spaces in the U.S. [1]. All people have the right to a place where they are safe from violence, crime, and the constant fear that they will be forced out.

Both homeless people and outdoor enthusiasts need a new way to keep themselves and their belongings safe when living outdoors, since existing products do not offer adequate security, portability, or versatility.

2024-2025 Cal Poly Fluid Power Vehicle Competition Team, Jaskaran Singh Hothi, Justin Menzie Lesko, Tristan Kai Crawford, Lucas Rupert Erickson, Diego Velazquez

Mechanical Engineering

The Fluid Power Vehicle Challenge (FPVC) provides an avenue for the exploration of fluid-powered transportation, adhering to regulations set by the National Fluid Power Association (NFPA). This document serves as a roadmap for our team’s research, design, and manufacturing of a vehicle for participation in the FPVC. The team’s journey began with extensive background research, encompassing stakeholder engagement, analysis of existing solutions, and education on fluid power fundamentals. From this information, we decided to focus on enhancing mechatronics systems, improving the transmission, optimizing the mounting, adding a pneumatic element, and improving the efficiency of the hydraulic system of the vehicle …

Large Backflow Check Valve Life Cycle Test Stand, Colin Bentley, Christopher Carloni, Ethan Gray, Luke Romanini

Mechanical Engineering

Backflow preventers are plumbing devices containing internal check valves used to prevent cross-contamination between downstream contaminants and potable water supply. Zurn Wilkins needs a life cycle test stand to mechanically force open check valves submerged in contaminated water and verify check performance. The stand needs to be modular to work with a range of check types and sizes.

Zurn Wilkins is the primary stakeholder for this project. Secondary stakeholders include commercial and residential building owners, contractors, and water utility companies, who rely on their products for safe and efficient water management. The team for this project consists of four Cal …

Hi-Trac Camera Jig, Gabriel Frank Junge, Josh Sherreitt, Jake Weiser, Luke Silver

Mechanical Engineering

Uranium fuel assemblies are stored upright in an underwater container inside the spent nuclear energy fuel pool at Diablo Canyon. The engineers and in-service-inspection team all work together to safely locate this container inside the pool on pins so it is guaranteed safe before they begin loading it with spent uranium fuel rods. The Operators currently employ the use of a zip-tied camera jig that is lowered into the pool along with the tank (called a HI-TRAC) to ensure it is oriented correctly in the pool. This camera jig is in desperate need of re-vamping and re-designing to optimize efficiency …

Expeditionary Ocean Power Generator, Otto Jacob Van Willigen, David Scott Nyberg, Logan Christopher Schilling, Kyle James Hohman, Travis Michael Eccher

Mechanical Engineering

The Expeditionary Ocean Power Generator (ExOPG) project is a point absorber wave energy converter developed by a team of five mechanical engineering seniors at California Polytechnic State University in partnership with NAVFAC EXWC. Designed to support U.S. Marine Corps operations, the device aims to reduce the reliance on diesel generators by generating and storing up to 100 watts of power from ocean waves in a sturdy and self-sufficient device.

The ExOPG device uses a rack and pinion mechanism driven by vertical wave motion to convert mechanical energy into electrical energy via a generator, which is then processed and stored by …

Floating Wind Turbine Foundation, Clayton Lahodny, Dillon Nelson, Trevor Ortega, Andrew Cervantes

Mechanical Engineering

The 2024 Collegiate Wind Competition (CWC) has introduced a new element to their Turbine Design Competition: a floating foundation. In previous years, foundations have been fixed-bottom in a box of sand and water. The Cal Poly Wind Power Club, who competes in the CWC every year, requires a floating foundation to be designed, manufactured, and tested to assist in winning the competition. The foundation is a large, hollow, cylindrical barge with a hanging spar (heavy mass). The barge will provide a restoring moment using buoyancy, and the heavy spar provides additional restoring moment. Four cables will be attached at the …

Hydropower Collegiate Competition, Aiden D. Foster, Devon Bountry, Joanna Vo, Timothy Rinker, Amanda Rodriguez, Minh Nguyen, Eli Haushalter, Sophie Watkinson, Maiya Holton, Breanne Evans

Mechanical Engineering

The Cal Poly SLO HCC team presents a feasibility study and engineering design review package for retrofitting the non-powered Ritschard Dam in Colorado into a hydroelectric facility as part of the 2025 Hydropower Collegiate Competition. Through a rigorous and multi-staged assessment of plausible dam sites in the western US, the team has chosen the Ritschard Dam in Colorado to implement an electromechanical component designed to accommodate a large range of flowrates stemming from a large variance in upper reservoir capacity due to geographical and climate effects. The team evaluated non-powered dams based on technical feasibility, electric grid proximity, power generation …

Adjustable Dynamometer Motor Mount, Garrett Carson Ng, Elijah Siegel Reuven, Ethan Fong, Daniel Larimer

Mechanical Engineering

The Cal Poly Electrical Engineering Department and sponsor Dr. Dolan needs a manufacturable motor fixture that securely aligns motors of various sizes with dynamometers. Previous lab motor fixtures could not accommodate motors of different sizes, making precise alignment between motors and dynamometers time-consuming and unreliable. Our team developed a modular, manufacturable fixture capable of aligning various motor sizes quickly, accurately, and securely, enhancing lab consistency and usability.

Baja Sae Brakes, Carson Moore, Jaedyn Michael Imhoff, Will Duncan, Matthew Shaffer

Mechanical Engineering

Historically, the Cal Poly Racing Baja SAE has produced a braking system that has proven unreliable and barely passes competition rules and inspections, leading to ill performing and unsafe brakes. The goal of this project is to produce a system and documentation that meets the requirements provided by Cal Poly Racing Baja SAE. The final design includes a transient braking model of the vehicle to set system requirements, universal custom front and rear calipers modified from “Cal Poly BSAE Custom Brake Caliper Senior Project”, and a revamped hydraulic harness. Leaning on the team’s previous work and modifying the custom calipers …

Development Of 6d Electromagnetic Actuation For Micro/Nanorobots In High Viscosity Fluids For Drug Delivery, Mostafa Abdelaziz, Maki Habib

Mechanical Engineering

This research focuses on the development, design, implementation, and testing (with complete hardware and software integration) of a 6D Electromagnetic Actuation (EMA) system for the precise control and navigation of micro/nanorobots (MNRs) in high-viscosity fluids, addressing critical challenges in targeted drug delivery within complex biological environments, such as blood vessels. The primary objective is to overcome limitations in the actuation efficiency, trajectory stability, and accurate path-tracking of MNRs. The EMA system utilizes three controllable orthogonal pairs of Helmholtz coils to generate uniform magnetic fields, which magnetize and steer MNRs in 3D for orientation. Another three controllable orthogonal pairs of Helmholtz …

Investigation Of Surface Quality And Productivity In Precision Hard Turning Of Aisi 4340 Steel Using Integrated Approach Of Ml-Moora-Pso, Adel T. Abbas, Neeraj Sharma, Khalid Alqusaibi, Mohamed Abbas, Rakesh Sharma, Ahmed Elkaseer

Mechanical Engineering

AISI 4340 steel has applications in gun barrels, where the surface quality of the barrel is the prime factor. This study explores the application of a machine learning (ML) approach to optimize the precision turning of an AISI 4340 steel alloy using both conventional and wiper tool nose inserts under varying cutting parameters, such as cutting speed, depth of cut, and feed rate. The analytical framework integrates experimental machining data with computational algorithms to predict key output parameters: surface roughness (Ra) and material removal rate (MRR). A Multi-Objective Optimization based on Ratio Analysis (MOORA) method is used for data normalization. …

Helical Products Parts Display Stand, Binh Nguyen, Emily Yuan Mendyke, Zoe Porter

Mechanical Engineering

Helical Products needs a new product display stand that will demonstrate their custom springs, couplings, and u-joints. Their current display stand, a marble run contraption, is large, loud, and difficult to transport, so they would like the new stand to remedy these issues. The goal of this senior project is to create a display stand that captures the attention of their customers with dynamic product demonstrations while addressing the issues outlined above.

The new display stand is also a marble run contraption, but instead of being almost 4 feet tall and 3 feet long, it is 23” tall, 26.25” long, …

Emg-Based Intraoperative Neuromonitoring Using Advanced Machine Learning Approaches, Abdalla Nabil Elsharkawy, Nourhan Zayed

Mechanical Engineering

Intraoperative neuromonitoring (IONM) plays a critical role in minimizing nerve damage during surgeries by providing real-time feedback on neural integrity. This study evaluated models associated with deep learning and machine learning models for electromyography classification of signal during intraoperative neuromonitoring (IONM). The CNNLSTM model achieved the highest accuracy (85.2%), outperforming traditional models like KNN (53%), RF (62%), and CNN (76%). This demonstrates the degree to which the CNN-LSTM model can gain insight into temporal and spatial dependencies throughout the EMG signals, which makes it optimal for real-time classification in IONM applications. This implies that deep learning techniques can improve surgical …

Vanlife Desalination, Emily Rhee, Tomas Franco, Marco Jimenez

Mechanical Engineering

Van life can be defined as the unconventional lifestyle of living in a car, van, or motor vehicle. Living in a motor vehicle allows for you to effectively live in whatever location you deem fit, and with that comes certain standards that need to be met; one being fresh potable water used for drinking, hygiene, and basic living. The scope of this project is to design a system that can effectively remove salt from seawater (desalinate) and can be integrated into a van that can be used for off-grid living.

In this project we worked to create a design that …

Development Of Planetary Drive System For Formula Sae Electric Race Car, Brian Wong, Bradley Maruoka, Joshua Charles Fine, Madison Kai

Mechanical Engineering

Hub motors are compact electric motors mounted directly on each outboard wheel hub. Utilized in Formula SAE and Formula Student vehicles, this configuration offers several advantages over traditional drivetrains, including packaging optimization within the chassis, vehicle traction, and improved efficiency. Although hub motors are not yet common in 4WD vehicles, they are being explored for use in EVs and may become more common in the future. Every year, Cal Poly Racing FSAE designs and builds a formula-style race car. To improve drivetrain performance, the team is investigating the achievability of a hub motor 4WD drivetrain, requiring extensive research, development, and …

Wind Turbine Rotor Test Stand, Ashlen Brooke Sperry, Cayley Mckee, Kristofer Lee Pascua, Francisco Medina

Mechanical Engineering

Dr. Lemieux and the mechanical engineering department at Cal Poly are renowned for the countless projects that allow students to be a part of hands-on learning and the “Learn by Doing” experience. One such experience is the wind energy class that requires students to design, build, and test wind turbine rotors; however, a test stand for these rotors is needed. Dr. Lemieux and the senior project team will design and build a test stand that will enable the simultaneous testing of two student-designed rotors at the existing wind turbine site. In addition to energy measurement, Lemieux emphasizes the importance of …

Effects Of Die Type On Mechanical Performance And Failure Behaviors Of Self-Piercing Riveting Joints In Aa5052, Lun Zhao, Amr Monier, Ao Zhang, Liya Li, Ahmed Elkaseer, Zeshan Abbas, Kai Ye

Mechanical Engineering

This study investigates the effects of self-piercing riveting (SPR) die type on the joint quality and failure modes of AA5052 SPR joints. Three die types: flat, pip, and ball-shaped were designed and processed for the SPR process, and 30 riveted specimens were prepared. A 2D axisymmetric finite element (FE) simulation model was established using LS-Dyna to evaluate the impact of each die type. The accuracy of the FE model was validated by comparing simulated joint cross-sections with experimental results. Subsequently, the quality and forming mechanisms of the SPR joints fabricated using each die type were analyzed. Mechanical properties were assessed …

Development Of A Compliant Soft Gripper With Embedded Force Sensors, Ayman Abbas, Abdelrahman Said, Tamer Kahlil, Mahmoud Magdy

Mechanical Engineering

Robotic manipulators have the capability to perform repetitive tasks with a level of efficiency and precision that exceeds the capabilities of human operators. Currently, they are commonly found and extensively utilized across various disciplines. However, robotic manipulators have gradually begun to make inroads into fields beyond manufacturing, such as medicine and agriculture. Due to the diverse range of industries utilizing robotic manipulators, the nature of tasks assigned to these devices can often be more intricate and multifaceted than conventional assignments. Hence, conventional mechanical grippers may not always be suitable, prompting a growing need for grippers capable of adapting to effectively …

Non-Invasive Glucose Monitoring Using Ppg, Ai, And Iot-Driven Mobile Integration For Real-Time Diabetes Management, Mostafa Abdelaziz, Amr Refaie

Mechanical Engineering

Diabetes mellitus patients must regularly monitor their blood glucose levels to manage glycaemia, typically requiring capillary tests at least three times daily and laboratory tests one to two times per month. These conventional methods involve finger pricking, causing significant discomfort and stress. This study introduces an innovative non-invasive glucose monitoring approach by integrating photoplethysmography (PPG) technology with an artificial intelligence (AI) algorithm, complemented by a mobile application using Flutter, IoT systems, and Firebase cloud for real-time data access. Among the AI models tested, polynomial regression demonstrated superior accuracy in glucose prediction, achieving a Mean Squared Error (MSE) of 14.76 and …

Design Of Modular Soft Gripper For Harvesting, Mostafa Abdelaziz, Ahmed Reda, Abdulrhman Atef, Mahmoud Magdy

Mechanical Engineering

Soft robotics presents a transformative approach to agricultural automation, addressing the limitations of traditional mechanical systems in handling delicate crops. This paper introduces a modular soft robotic gripper designed for gentle harvesting applications, with a focus on adaptability, precision, and crop safety. The gripper's performance was evaluated through Finite Element Analysis (FEA) and experimental testing, targeting its ability to conform to objects of varying shapes, sizes, and fragility. The FEA confirmed the gripper's capability to apply a load based on the gripped crop of the range 0.6 – 0.75 N, sufficient for damage-free harvesting of sensitive produce like strawberries and …

Design And Implementation Of Smart Automation For Sustainable Plastic Recycling With Iot Integration, Mostafa Abdelaziz, Mahmoud Khedr, Amr Bakkar, Yossef Zidan, Abdelrahman Youssef, Mahmoud Magdy

Mechanical Engineering

Plastic pollution poses a critical environmental challenge, infiltrating ecosystems and impacting human health. One innovative solution involves repurposing recycled plastics into interlocking blocks as a sustainable alternative to concrete in construction. However, manual production methods hinder scalability, efficiency, and product consistency while generating material waste. This research addresses these limitations by automating the production process using PLC and IoT technologies. The findings demonstrate that automation significantly enhances production rates, ensures consistent quality, and minimizes waste, thereby improving operational efficiency and environmental sustainability. IoT is integrated to enhance the system's capabilities by providing real-time connectivity and data exchange. The IoT dashboard, …