Electro-Mechanical Systems Commons^™

Power At Sea Develop Phase, Jake Lauer, Isabella Heinemann, Bailey Gargasz, Zachery Boyer

Mechanical Engineering

This project develops a renewable, wave-powered charging system designed to extend the mission duration of Autonomous Underwater Vehicles by eliminating the need for frequent manual battery replacement. Building upon a prior oscillating water column prototype from the CONCEPT phase, the team redesigned and tested an improved system capable of converting wave-induced air motion into electrical power using a Wells turbine. Key enhancements include doubling the column diameter to increase displaced air volume, integrating a flared inlet and bi-directional nozzle to improve airflow, and selecting corrosion-resistant materials suitable for long-term deployment in marine environments. Multiple prototypes were constructed and evaluated through …

Development And Testing Of A Computer Vision Pose Estimation System For Planar Mobile Robots, Andrew Jones

Master's Theses

This thesis details the development and testing of a computer vision-based real-time pose estimation system for differential drive robots. A single camera with a fisheye lens is used to locate ArUco markers placed at fixed locations and attached to robots. Using the OpenCV library, the Perspective-n-Point (PnP) problem is solved to facilitate the transformation of 2-D robot positions in an image to world-frame coordinates. An analytical solution is presented to estimate robot poses based on a single PnP solution, rather than solving the PnP problem for each pose estimate. Pose information is relayed to individual robots using a multi-microcontroller architecture …

Prompt-Driven Tabletop Robotic Manipulation With A Structured Llm Interface And Visual Verification, Tomas Franco

Master's Theses

Creating a tabletop robotic manipulation system that connects language goals to robot actions is a challenging problem. Large language models can interpret mission objectives and reason through actions, but when placed directly in control of hardware they can produce hallucinated commands that result in unsafe behavior without the proper safeguards.

This thesis presents a constrained LLM-guided manipulation system built around the Quanser Qarm, a four degree of freedom manipulator with a mounted Realsense RGB-D camera and a gripper with readable current. Every decision made by the LLM planner is routed through a gated command interface that restricts the model to …

Formula Sae Planetary Gearbox Characterization Dynamometer, Trevor Marco Toma, Thomas Welden Pierce, Ethan Liu

Mechanical Engineering

This report outlines a custom hub motor dynamometer requested by the Cal Poly Racing FSAE team. The need for this testing platform is to characterize an existing Formula SAE planetary gearbox for a proposed 4WD powertrain. Hub motors, compact electric machines integrated directly into each outboard wheel, offer significant advantages in efficiency, traction, and chassis packaging compared to conventional RWD drivetrains. By mapping torque capacity, efficiency, lubrication method effectiveness, and fatigue life, the team can validate gearbox design and performance.

This senior project group designed and built a dynamometer according to these specifications which will allow for successful testing to …

A Comparative Study Of Model Predictive Control And The Stanley Method For Vehicle Path Tracking Applications, Noah S. Fitzgerald

Master's Theses

This thesis compares a model predictive controller (MPC) and a lateral Stanley controller for vehicle path-tracking applications under simulation-based and perception-driven operating conditions. Both controllers were evaluated in simulation using a nonlinear dynamic bicycle model executing single and double lane change maneuvers. Following simulation-based evaluation, both controllers were implemented on hardware within a perception-driven steering-control pipeline. This pipeline utilized recorded sensor data from the MXcarkit 1/8^th-scale autonomous vehicle platform, incorporating lane instance segmentation and homography-based roadway estimation.

Under idealized simulation conditions, the MPC demonstrated improved trajectory-tracking performance during aggressive maneuvers while requiring greater steering activity and computational effort …

Improving The Reliability And Performance Of A Supersonic Indraft Tube Wind Tunnel, Christian J. Kaml

Master's Theses

Access to supersonic testing is increasing in demand, and wind tunnels remain one of the safest and most cost-effective methods for gathering high-speed flow data. Despite being more economical than alternative options, supersonic wind tunnel facilities often require substantial investment to construct, operate, and maintain.

The novel indraft tube tunnel architecture was conceived as a high-speed flow testbed that incorporates features of both Ludwieg tubes and indraft wind tunnels to maintain costs low enough to be accessible even to small universities. This design was first developed and tested in 2018 at California Polytechnic State University, featuring a cost per test …

Bowl-O-Matic, Nathan Lin, Luis Torres, Jill Worthington, Aiden Foote

Mechanical Engineering

Adaptive physical education presents the unique challenge of accommodating individuals with diverse physical and cognitive abilities. Instructors and program designers must often integrate specialized equipment, fixtures, or features to ensure activities remain safe, inclusive, and user-friendly. Beyond accessibility, adaptive physical education highlights the importance of empowerment— enabling every participant to experience personal growth, confidence, and connection through movement. Friday Club, a local San Luis Obispo program supported by Cal Poly’s Kinesiology Department, embodies these values by providing adaptive physical activities that promote health and well-being for individuals with varying abilities. One of the most popular and regularly held activities is …

Me3329 Modular Phonograph Gearbox, Garrett Andrik Leighton, Preston Robert Hupe, Gavin Carter Ebner, Andrew Renato Reyes

Mechanical Engineering

The Mechanical Engineering Department at California Polytechnic State University, San Luis Obispo (Cal Poly), seeks to develop a laboratory tool allowing students to reinforce concepts of gears for Mechanical Systems Design (ME329). Some current laboratories do not provide students with hands-on interaction, and the department lacks equipment and documentation to support a standardized lab. With ME329 expanding from ten to fifteen weeks, there is an opportunity to create a physical gearbox design lab allowing students to reinforce lecture material in engaging ways, while standardizing student learning. This senior project is presented and sponsored by Professor Alan Zhang. It will be …

Custom Animatronic Puppet, Jake Schuman, Fredy Herrarte, Madison Reedy, Jackson Reynolds

Mechanical Engineering

This project involved the design, fabrication, and implementation of a custom audio-animatronic puppet modeled after Dr. Brian Davis for the California Polytechnic State University Mechanical Engineering Department. The objective was to create an expressive, lifelike character capable of synchronized speech, head movement, arm gestures, and seated-to-standing motion while demonstrating the integration of mechanical design, controls, manufacturing, and artistic fabrication.

The final system consists of an 18-degree-of-freedom animatronic platform utilizing servo-driven facial and upper-body actuation combined with a pneumatic standing mechanism. A modular aluminum and 3D-printed structural framework was developed using SolidWorks and validated through engineering analysis. Character shells were digitally …

Peltier-Based Hydration Accumulation Terminal (P.H.A.T.), Jenner Mucher, Ethan Pace, Renee Robolledo, Sabrina Luo, Taehoon Lee, Tarsem Pal

Mechanical Engineering

The objective of this project is to design an innovative potable water dispenser capable of safely delivering hot, ambient, and chilled water on demand for human lander missions. The system will support astronauts’ hydration and food rehydration needs while minimizing mass, power, maintenance, and contamination risks in microgravity and partial-gravity environments. Current spacecraft dispensers, such as the International Space Station (ISS) system, provide only heated water and have limited temperature control, cleaning accessibility, and microbial resilience. Building on NASA heritage designs and lessons learned from the ISS Potable Water Dispenser, this project advances a lighter, simpler, and more energy-efficient concept …

Me3328 Buckling Lab, Willem Bitterolf, Samantha Flores, Jacy Gonsalves, Brooke Thompson

Mechanical Engineering

The objective of this senior design project is to design and develop an instructional buckling apparatus (hereafter referred to as a “buckling tester”) to enhance student comprehension of column buckling behavior through direct experimental investigation. The apparatus is specifically intended to bridge the gap between theoretical predictions and observed physical response of structural column members subjected to axial compressive loading. In particular, the system will allow students to examine how column behavior transitions between Euler’s elastic buckling theory, which governs long, slender columns, and the Johnson parabolic formula, which more accurately describes intermediate and shorter columns influenced by material yielding. …

Guitar Pickup Testing Fixture, Koen Graue, Ethan Rezentes, Max Schecter, Timothy Webb

Mechanical Engineering

Small guitar pickup manufacturers and hobbyists have an interest in developing guitar pickups with unique tonal characteristics and responses, but currently lack a reliable way to test these pickups and characterize their sound. I.M. Bohannon Mechanical Design approached the team to develop a solution to this problem. In response, the team researched current technologies, customer needs, and existing products on the market to define the scope and requirements for a guitar pickup testing fixture. This report documents the work completed during the project scope and definition phase of Cal Poly's senior project process. It discusses researched topics and existing solutions, …

Semi-Automated Wine Barrel Filler, Elliot Jason Dejong, Carlo Caesare Deianni, Brady Emerson J. Leib

Mechanical Engineering

The proposed project is a semi-automated wine barrel filler. Currently, there is no streamlined and affordable method for smaller wineries to fill wine barrels without dedicating complete focus to the task. The primary use is controlled filling for white wine fermentation, during which an air gap must be left in the barrel to allow for expansion of the wine during fermentation. Tom Greenough, Saucelito Canyon’s head winemaker, and associate winemaker Bodie Ringhofer are the primary stakeholders in our project and want to consistently fill barrels at their winery to a fluid volume of approximately 50 gallons each. This project serves …

Desktop Dynamometer, Ryan Boister, Zachary Chung, Molly Koretz, Tyler Lum

Mechanical Engineering

This senior project presents the design and development of a desktop dynamometer for measuring the performance of small electric motors. The system integrates torque and speed measurement with data acquisition hardware to calculate power output and evaluate motor performance. The compact and cost-effective design provides a practical platform for engineering education, testing, and performance characterization of small-scale power systems.

Smart Sleeve, Evan Abalos, Bright Jung, Owen Bowling, Wyatt Eberhart

Mechanical Engineering

Quantifying human arm muscle activity is essential for understanding human movements and helping individuals who suffer from motor or neurological impairments such as stroke or traumatic brain injuries. Today, these individuals, as well as clinicians, researchers, and athletes, face many challenges when using the traditional surface electromyography (sEMG) systems to monitor muscle activities, including complex setup, restricted mobility, discomfort, inconsistent placement of electrodes, and lack of accuracy. Therefore, a comfortable EMG sleeve device that accurately measures arm movement without interfering with daily tasks is needed, which the team will be designing, manufacturing, and testing as their senior project. In addition, …

Me3328 Combined Loading Beam Bending Lab, Alejandro Islas, Viswesh Vancheeswaran, Owen Spencer, Henry Andrews

Mechanical Engineering

Serving as a new laboratory experiment for ME 3328 (Design for Strength & Stiffness), strain gauges were adhered, wired, and calibrated on a cantilever beam lab apparatus capable of undergoing pure bending, pure torsion, and combined bending.

Implementation Of A Line-Scan Camera Triangulation Sensor For A Ball Balancer, Jackson R. Mclaughlin

Master's Theses

Ball Balancer or Ball on Plate systems are used for education and research in control theory. These consist of a plate which can be actively tilted, with a ball rolling on the surface. Students are challenged to model the dynamics of the system and implement a control loop which is capable of stabilizing the ball by actuating the plate.  The mechatronics group at Cal Poly is developing hardware for one of these ball-balancer systems, for future use in the Mechanical Engineering curriculum.

The position of the ball relative to the plate must be measured in order to control and stabilize …

Off-Grid Cabin Hydroelectric Generator, Keller Feltman, Lance Savatgy, River Perino, Jesse Valencia

Mechanical Engineering

This project developed a portable hydroelectric generator intended to provide low-power electricity generation for an off-grid cabin in Alpine County, California. The system was designed to utilize naturally occurring creek flow to generate electrical power while remaining portable, durable, and environmentally conscious.

The final system consists of an axial-flow turbine, belt-driven generator subsystem, waterproof electronics enclosure, aluminum support frame, and integrated wildlife protection screening. Engineering analysis was performed to estimate hydraulic power availability, turbine performance, drivetrain requirements, and component lifespan. These analyses guided the selection and development of the final design.

Throughout prototype testing, several design modifications were required. Initial …

Elastic Actuator For Robotic Leg, Bruce Berg, Allan Pham, Madeline Slater, Sofie Zalatimo

Mechanical Engineering

The Cal Poly Legged Robots Group (CPLRG) is developing a 12 degree of freedom robot with the goal of eventually performing highly dynamic movements such as jumps and flips. During such movements, large impact forces will be experienced by the leg, potentially resulting in damage to physical components such as the motors. The scope of this project is to integrate elastic elements into the quadruped legs to reduce shock loads on the motors and improve the efficiency of the legs through energy storage. The key stakeholders for this project are Professor Charlie Refvem and Dr. Simon Xing. Other stakeholders include …

Water Turbine Dynamometer For Low-Power Turbomachinery Testing, Carmen Alaichamy, Yosef Huynh Torres, Michael Duperly, Michael Thomas Duff

Mechanical Engineering

Students in ME 443: Introduction to Turbomachinery compete to design and build efficient small impulse turbines. The course lacks a standardized method to experimentally calculate turbine power output and mechanical efficiency from accurate measurements of torque and speed, for example. To support the learning goals of ME 443, a dedicated water-turbine dynamometer is needed to provide controlled hydraulic power, accurate mechanical and electrical measurements, and clear data for performance evaluation.

Our proposed system delivers a safe, repeatable, and educational testing environment that can be integrated into the Fluids Lab or used as a standalone instructional tool. Key stakeholders include Professor …

Design And Parametric Study Of A Mems-Based Reservoir Computer For Reinforcement Learning, Andrew P. Carr

Master's Theses

Single-node reservoir computing (RC) is a hardware-efficient approach to machine learning, leveraging the dynamics of physical systems. In this work, two reinforcement learning algorithms, Q-learning and Proximal Policy Optimization (PPO), are applied to a simulated micro-electro-mechanical system (MEMS)-based reservoir computer to solve both discrete and continuous control tasks. MEMS-based reservoirs are low-power, compact, and their natural frequencies (kHz to MHz) pair well with real-time control loops. To explore the relationship between reservoir dynamics and learning performance, a parametric study is conducted on two reservoir hyperparameters, reservoir size and neuron separation, using CartPole-v1 and MountainCar-v0. The RC successfully learns multiple tasks …

Design And Implementation Of An Embedded Control System For The Cal Poly Spacecraft Attitude Dynamics Simulator, Neil Mahesh Bedagkar

Master's Theses

This thesis presents the development of a cascaded reaction wheel control system for Cal Poly's Spacecraft Attitude Dynamics Simulator. This work considers system architecture, empirical modeling, high-fidelity simulation, embedded firmware, hardware integration, and experimental characterization. In discrete-time simulation, it is shown that nonlinear direct model reference adaptive control (NDMRAC) enables a nonlinear, partially known plant with realistic actuator dynamics to track the response of a canonical second-order transfer function, with settling time within 4.67% and percent overshoot within order of magnitude of the second-order response. In hardware, the feasibility of a cascaded reaction wheel control architecture is experimentally demonstrated, achieving …

Cvj Torque Loss Dynamometer, Malaika Sriram, Coleman Brown, Zachary Norris, Logan Mast, Chris Mattis

Mechanical Engineering

This report details the design and results of a dynamometer testing rig built to measure torque losses in constant velocity joints (CVJs) for Cal Poly Racing's Baja SAE team. The rig spins a flywheel connected to articulable CVJs up to 800 RPM using a motor, then decouples it and measures the spin-down rate from 800 to 100 RPM to calculate angular acceleration and torque loss. The data collected from this dyno will be used to inform freewheel packaging for future Baja car development.

Design And Development Of A 12-Degree-Of-Freedom Quadruped Robot, Kai De La Cruz

Master's Theses

This thesis presents the design, analysis, and experimental validation of a 12-degree-of-freedom (DOF) quadruped robot developed as a research platform for legged locomotion and control. The system builds upon the Cal Poly Legged Robotics Group’s prior 8-DOF quadruped, addressing key limitations in manipulability, load distribution, and mechanical robustness by introducing a 3-DOF leg architecture.

The mechanical design emphasizes lightweight construction, structural integrity, and modularity to support future research extensions. Static and dynamic loading models were developed to inform component sizing and material selection. A carbon-fiber chassis and redesigned leg assemblies were fabricated and validated through finite element analysis and physical …

Water Bottle Lid Co Detector, Zeke Bukovansky, Jake Siegel, Jack Wisegarver, Cody Rudman

Mechanical Engineering

This project introduces a portable carbon monoxide detector integrated into a water bottle lid to give users a simple way to stay aware of CO exposure in daily life. The design packages an electrochemical sensor, onboard electronics, and clear visual and audible alerts into a compact form that fits standard bottles. By embedding sensing into an object people already carry, the device offers a practical path toward reducing unrecognized CO risks and improving personal safety.

Origami-Inspired Pneumatic Soft Robotic Gripper, Conor J. Schott

Master's Theses

This thesis presents the design and evaluation of a vacuum-actuated, origami-based soft robotic gripper. A custom Sea Urchin crease pattern forms a lightweight folding skeleton that collapses radially under vacuum. The system emphasizes low cost and accessibility through laser cutting, 3D printing, and silicone molding. The Sea Urchin geometry was selected after digital and physical screening of candidate crease patterns for smooth folding, low strain concentration, and uniform inward motion. The folding skeleton is laser cut from 4 mil drafting film and folded into a compliant core. Four membrane configurations were developed: an origami gripper with a 36-inch balloon (Design …

Integration And Testing Of A Quadruped Robot With Ros2, Jeremy S. West

Master's Theses

The Cal Poly Legged Robotics Group has been developing research and teaching platforms for agile legged robotics since 2020. These platforms are expected to provide students with opportunities to develop complete legged-robot systems from low-level control to advanced robotics tasks such as motion planning and decision making. However, the current prototyped quadruped robot lacked the software and sensing capabilities for high-level quadrupedal gaits and advanced robotic research.

To address these challenges, this project developed Switch, a robotic platform that builds upon the previous BRUCE platform with significant hardware and software upgrades. Switch features a modular design that allows individual software …

Aerospace Fastener Installation Tool, Anthony I. Berghout, Matthew K. Eggers, Liam Dunsmore, Jose Pardo

Mechanical Engineering

Contamination, particularly in aerospace manufacturing environments, is a significant concern, especially with fastener designs that incorporate torque-rated breakaway pieces for easier installation. These breakaway pieces are also known as pintails. Howmet has tooling that can collect loose pintails during installation, but they have small capacities and are not ergonomic for aerospace technicians. Their current need is for a light and ergonomic tool capable of installing a wide variety of Ergo-Tech® fasteners while having a large capacity to collect pintails and improve aerospace manufacturing methods. For this Critical Design Stage, we have finalized a design that allows Pintails to pass through …

Edwards Lifesciences: Esheath+ Scoring Automation, Tony Lee Avina, Kirth Hirth, Charith Sunku, Humberto Salazar-Banuelos

Mechanical Engineering

Due to a non-disclosure agreement with our sponsor, Edwards Lifesciences, the contents of the report have been omitted.

Foot Pedal Assistive Device, Julian Rubinstein, Connor Jessen, Isabelle Utsler, Sydney Alexander

Mechanical Engineering

Individuals with lower-limb mobility problems may have trouble accurately locating the pedals of a three-pedal manual transmission car, and some medical conditions cause individuals to fatigue more quickly when driving. This project aimed to create a device that assists in locating the user’s feet, indicates to the user which pedals are currently in use, and provides a visual and physical warning if they are not in the correct place. The project sponsor, Alan Keizer, is the primary stakeholder in this project. This device will be designed specifically for Alan’s Subaru BRZ and will address Alan’s specific lower-limb mobility issues that …