Manufacturing Commons^™

Mechatronics: Fundamentals, Design, Integration, And Validation, Guoming Zhu

Mechatronics

This textbook is a product of Co-DREAM OER (Collaborative Development of Robotics, Mechatronics, and Advanced Manufacturing Open Educational Resources), an initiative funded by the U.S. Department of Education to develop open educational resource textbooks on robotics, mechatronics, and advanced manufacturing processes. The texts are written for students enrolled in 2-year associate’s, 4-year bachelor’s, and graduate-level courses. This specific text has been created by a team of scholars, students, support staff, and other professionals from across the country. It is intended for mechatronics courses for 4-year bachelor’s and graduate-level programs.

A Feedback Loop Control To Automate Cold Atmospheric Pressure Plasma Based Additive Manufacturing, Arineh Shahbazi

Discovery Day - Daytona Beach

Currently, nanoparticle annealing based additive manufacturing process requires high temperatures, making them unsuitable for a broad range of applications. By lowering the temperature and developing a process to use Cold Atmospheric Pressure Plasma (CAPP) for annealing, many more doors are opened to a wide range of materials, films, and environments for space, communication, and microelectronics. CAPP-based additive manufacturing technology is continually evolving, making projects like nanoparticle annealing more feasible. In this work, we designed a CAPP jet printer assembly consisting of a 0.25-inch outer diameter glass tube connected to a 3D printing nozzle. The flow of Argon gas in the …

Trajectory-Based Model Predictive Control For Rotary Crane Sway Suppression With Only Horizontal Boom Actuation, Haryson J. Nyobuya

Tanzania Journal of Engineering and Technology (TJET)

Safety is of biggest importance in construction and industrial activities involving rotary cranes. These cranes are huge and responsible of moving large parts or/and materials from different positions. Now operating these cranes tend to be subdue to pay load oscillations when moving the load for which is extremely dangerous when not suppressed. This study proposes the generation of trajectory using Model predictive control approach with reduced control horizon compared to state horizon. Reduced control horizon design reduces computational time for trajectory generation while maintaining the pay-load sways to a minimum. In this approach the complex dynamic model is reduced to …

Rapid-Prototyping Nanofabrication: Lcd-Based Projection Lithography And Physical Vapor Deposition, Sabeel Saleem Mohammmed

University Honors Theses

The semiconductor industry's continued growth, driven in large part by demand for artificial intelligence hardware, has highlighted the need for greater workforce development in regions adjacent to major fabrication centers like Oregon's Silicon Forest. This capstone project lays the groundwork for a small scale and student led semiconductor fabrication lab at Portland State University by demonstrating two of the core steps in chip manufacturing: photolithography and thin film deposition. Rather than relying on conventional fixed reticles, this work explores a unique, low cost approach to patterning that uses an ultraviolet-compatible liquid crystal display (LCD) as a programmable reticle, allowing arbitrary …

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 …

A Full Polymer Piezoelectric Flextensional Energy Harvester, Nadia Ahbab, Sidra Naz, Bingqi Zhao, Tian-Bing Xu

Mechanical & Aerospace Engineering Faculty Publications

This study presents a full polymer piezoelectric flextensional energy harvester (FPPFEH) comprising a single-layer poly(vinylidene fluoride) (PVDF) film bonded to a 3D-printed polylactic acid (PLA) flextensional frame. For an arm inclination angle of θ=10°, the free-body model gives a theoretical geometric force-amplification factor of M_F=cot θ ≈ 5.67; this value represents an ideal upper bound and was not independently validated by local force or strain measurements. During assembly, the film was tensioned only to remove visible slack and maintain a flat configuration. No intentional pretension was applied, and any residual tension was not measured. Off-resonance force-controlled tests showed …

Robotizing Complex Welding Processes Through Imitation Learning And Generative Models From Human Demonstration, Yue Cao

Theses and Dissertations--Electrical and Computer Engineering

Arc welding processes demand real-time adaptive control that current robotic systems cannot achieve autonomously. This dissertation develops a systematic framework to robotize complex welding by learning from human demonstration, integrating generative modeling, physics-informed reconstruction, and model-based imitation learning. First, human--robot collaboration systems are established for both Gas Tungsten Arc Welding (GTAW) and Double-Electrode Gas Metal Arc Welding, combining robotic teleoperation with virtual reality interfaces to capture high-quality operator demonstrations. Second, a physics-informed neural network framework reconstructs complete molten pool flow fields from high-speed imaging, enriching process understanding beyond direct sensor observation. Third, generative models, including a hybrid latent variational autoencoder …

Pin-Plane Electrical Discharge Driven By A Mosfet Dc Current Source, Myles Perry, Sidmar Holoman, Daniel Wozniak, Shirshak Kumar Dhali

Electrical & Computer Engineering Faculty Publications

The generation of atmospheric pressure nonequilibrium plasma using electrical discharges is an active area of research due to its significance in a wide spectrum of applications including medicine, combustion, and manufacturing. In our attempt to create a helium plasma jet in a pin-plane discharge with a constant current source, we observed self-pulsating behavior. We present the results of the electrical, optical, and spectroscopic measurements carried out to characterize the discharge. The duration of the discharge is a few tens of nanoseconds, and the repetition rate is in the few tens of kHz. The effect of the gap distance and gas …

Design And Development Of Evacuated Photovoltaic-Thermal Systems For Efficient Cogeneration Of Heat And Electricity, Behnam Roshanzadeh

Mechanical Engineering ETDs

In conventional PV systems, most of the solar energy is dissipated into the environment as heat. Accordingly, hybrid Photovoltaic-thermal systems have been developed to utilize the waste heat from PV cells for various thermal applications. However, most PVT systems suffer from low thermal performance compared to solar thermal collectors, as the absorber plate in PVT systems is partially or fully covered by PV cells. This dissertation focuses on improving the thermal performance of PVT systems by introducing the evacuated PVT systems.

An evacuated-tube PVT system was designed and simulated for domestic hot water supply. The evacuated-tube PVT system demonstrated 40% …

Human Comfort Modeling, Measurement, And Improvement In Human–Robot Collaboration, Yuchen Yan

All Dissertations

A dissertation is proposed to explore human comfort in human-robot collaboration (HRC) through modeling, prediction, and enhancement methodologies. Human comfort is a crucial yet underexplored factor in HRC, directly influencing task efficiency, trust, and overall collaboration effectiveness. Understanding the influential factors, developing computational models, and refining methods to improve human comfort in HRC are essential steps toward advancing the field of collaborative robotics. To address these challenges, multiple studies have been conducted. A series of experimental studies were performed to investigate how robot motion-based parameters affect human comfort in HRC. These studies examined both analytical comfort modeling approaches and physiological …

Solid Loading Effects On The Assembly Of Alumina Particles In Aqueous Suspensions Due To The Dielectrophoretic Forces, Sivakumar Chithamallu, Rohan Kiran Parai, Dipankar Ghosh

Mechanical & Aerospace Engineering Faculty Publications

Current work in situ investigated the mechanisms of the interparticle interactions that evolve in dilute aqueous alumina suspensions subjected to alternating current (AC) electric field and the effects of solid loading of suspensions. The interactions were investigated for alumina suspension compositions in the 0.005‒0.04 vol.% solid loading range. Field‐induced interactions evolved via particle motion and dynamic assembly, chain formation parallel to the direction of the applied field and chain growth, chain cross‐linking, and chain thickening. The evolution time of each of those events was rapidly accelerated with solid loading. While chain cross‐linking was negligible in low solid loading suspensions, a …

Enhancing Resilience In Complex Energy Systems Through Real-Time Anomaly Detection: A Systematic Literature Review, Ali Aghazadeh Ardebili, Oussama Hasidi, Ahmed Bendaouia, Adem Khalil, Sabri Khalil, Dalila Luceri, El Hassan Abdelwahed, Sara Qassimi, Antonio Ficarella

Manufacturing & Industrial Engineering Faculty Publications

As real-time data sources expand, the need for detecting anomalies in streaming data becomes increasingly critical for cutting edge data-driven applications. Real-time anomaly detection faces various challenges, requiring automated systems that adapt continuously to evolving data patterns due to the impracticality of human intervention. This study focuses on energy systems (ES), critical infrastructures vulnerable to disruptions from natural disasters, cyber attacks, equipment failures, or human errors, leading to power outages, financial losses, and risks to other sectors. Early anomaly detection ensures energy supply continuity, minimizing disruption impacts, an enhancing system resilience against cyber threats. A systematic literature review (SLR) is …

Development And Processing Of Shape Memory Polymer Composites (Smpcs) For Application In Structural Robotics And Robotic Sensors., Kavish Sudan

Electronic Theses and Dissertations

Shape Memory Polymers (SMPs) have attracted significant attention since their introduction in the 1980s due to their remarkable ability to regain their original shape from a temporarily deformed state when exposed to an external stimulus, typically heat. This shape memory effect, driven by thermal transitions such as the glass transition temperature (T_g) or melting temperature (T_m), has made SMPs highly attractive for applications in soft robotics, aerospace, and biomedical devices. However, SMPs face challenges such as limited mechanical strength, thermal stability, and electrical conductivity, which hinder their broader adoption in advanced applications. To address these challenges, …

Large-Scale Research Infrastructure Empowers High-Quality Development Of Private Enterprises: Current Situation, Challenges, And Policy Recommendations, Lingling Zhang, Fuqiang Wang, Mingze Zhang, Zexia Li

Bulletin of Chinese Academy of Sciences (Chinese Version)

Private enterprises have become an important source of innovation in China’s economic development. Large-scale research infrastructure, as a crucial strategic support and innovation element for breaking through key technologies, provides a platform for the innovative development of private enterprises. At present, some large-scale research infrastructures in China, such as the China Spallation Neutron Source and the Shanghai Synchrotron Radiation Facility, have begun actively exploring mechanisms to serve private enterprises. These efforts have helped a number of private companies overcome critical technological bottlenecks and achieve original innovations. Nevertheless, in the current process of opening up large-scale research infrastructures to private enterprises …

Cognitive Manufacturing: Definition And Current Trends, Fadi El Kalach, Ibrahim Yousif, Thorsten Wuest, Amit Sheth, Ramy Harik

Publications

Manufacturing systems have recently witnessed a shift from the widely adopted automated systems seen throughout industry. The evolution of Industry 4.0 or Smart Manufacturing has led to the introduction of more autonomous systems focused on fault tolerant and customized production. These systems are required to utilize multimodal data such as machine status, sensory data, and domain knowledge for complex decision making processes. This level of intelligence can allow manufacturing systems to keep up with the ever-changing markets and intricate supply chain. Current manufacturing lines lack these capabilities and fall short of utilizing all generated data. This paper delves into the …

Shape Memory Alloy Capsule Micropump For Drug Delivery Applications, Youssef Mohamed Kotb

Theses and Dissertations

Implantable drug delivery devices have many benefits over traditional drug administration techniques and have attracted a lot of attention in recent years. By delivering the medication directly to the tissue, they enable the use of larger localized concentrations, enhancing the efficacy of the treatment. Passive-release drug delivery systems, one of the various ways to provide medication, are great inventions. However, they cannot dispense the medication on demand since they are nonprogrammable. Therefore, active actuators are more advantageous in delivery applications. Smart material actuators, however, have greatly increased in popularity for manufacturing wearable and implantable micropumps due to their high energy …

Exploring The Impact Of Artificial Intelligence On Project Management Across The Manufacturing, Technology, And Construction Industries, Susie Diaz Ferrera

Harrisburg University Dissertations and Theses

This study explores the impact of Artificial Intelligence (AI) on project management across the manufacturing, technology, and construction industries. The research focuses on understanding the benefits, challenges, and long-term implications of AI utilization in these sectors. Key findings indicate that 46% of participants use AI mainly for task automation and enhancing functions like brainstorming and communication, which significantly boosts efficiency and team productivity. Despite these benefits, the research identifies several obstacles, including high initial costs, inadequate training, technical issues, and unclear regulatory guidelines. The study addresses four main questions, revealing that AI not only enhances project management processes but also …

Impact Force Helmet Device For Concussion Monitoring, Patrice Mulligan, Karina Mealey, Zack Borthwick, Benjamin Fick

General Engineering

To track head trauma in football, our device is placed inside a football helmet to measure both linear and gyroscopic (rotational) accelerations. These measurements are taken using an ADXL375 linear accelerometer and an LSM6DSOX accelerometer and gyroscope. The data from these sensors is processed and transmitted wirelessly by a SparkFun Thing Plus microcontroller to another SparkFun Thing Plus microcontroller connected to a laptop on the sidelines. Our program on the laptop stores the acceleration impact data into a .csv file for each player. If a likely concussive impact is detected, the program displays a popup warning. Testing results were promising …

Keratin-Based Film: Waste To Bioplastic, Emma Bond

University Honors College

The solution to plastic lies in alternative materials, like bioplastics. One such possibility is keratin-based films. They are made from sources that are already deemed to be waste and that all regions of the world are abundant in. Manufacturing values a one-size-fits-all solution and keratin being plentiful worldwide fulfills that set standard. The films’ properties, which are important to the basic needs of a package, vary with different additives and the type of keratin used. α-keratin and β-keratin have different strengths and are found in nature in different sources. The resource focused on was chicken feathers, which produce more β-keratin …

Bottling Automation System, Dylanie Tippit

Honors College Theses

This report details the complete design of an automated bottling system. Each bottle is 5.97 centimeters tall and has an outer diameter of 3.81 centimeters. The goal of the project is to successfully fill and cap twelve bottles in under three and a half minutes. The system will have two conveyors in series, a water dispenser, an electrolyte dispenser, capping station, Human Machine Interface (HMI) and Allen Bradley programmable logic controller (PLC). The water and electrolyte dispenser will have two ball valves in series, with the desired amount of volume to dispense the designated liquid. The capping station will be …

Energy Efficiency In Additive Manufacturing: Condensed Review, Ismail Fidan, Vivekanand Naikwadi, Suhas Alkunte, Roshan Mishra, Khalid Tantawi

Engineering Technology Faculty Publications

Today, it is significant that the use of additive manufacturing (AM) has growing in almost every aspect of the daily life. A high number of sectors are adapting and implementing this revolutionary production technology in their domain to increase production volumes, reduce the cost of production, fabricate light weight and complex parts in a short period of time, and respond to the manufacturing needs of customers. It is clear that the AM technologies consume energy to complete the production tasks of each part. Therefore, it is imperative to know the impact of energy efficiency in order to economically and properly …

Artificial Intelligence Enabled Machinery Fault Detection And Diagnosis Using Vibro-Acoustic Signals, Srinivasa Rao Ippili

Theses and Dissertations--Mechanical and Aerospace Engineering

In various industries, the early detection of faults in rotating machinery is crucial to prevent system failures and ensure customer satisfaction. Typically, vibration measurement and diagnosis are employed for fault detection, but this process faces challenges in automation due to the complexity of installing and maintaining accelerometers, particularly in end-of-line quality control or pre-installed machinery health assessments. Acoustic signals, as a form of mechanical wave, offer an alternative for monitoring machinery while in operation. Unlike accelerometers, acoustic transducers are non-contact and easy to set up, enabling real-time data collection without interrupting equipment operation. However, utilizing acoustic signals in manufacturing poses …

Extending Trailer, Alex Grove

Williams Honors College, Honors Research Projects

The goal of this research project is to revolutionize the convenience in towable transportation. This innovative design aims to enhance the versatility of pull-behind trailers by incorporating an extendable feature, allowing users to effortlessly adjust the length according to their specific needs. Whether navigating tight spaces or accommodating extra cargo, our trailer adapts to diverse situations, providing unmatched flexibility. In addition to its adjustable length, the trailer is engineered to be compactable, addressing the storage constraints often faced by users with limited space. The collapsible design ensures easy storage without compromising on functionality, making it an ideal solution for individuals …

Functional Verification Of Additively Manufactured Metallopolymer Structures For Structural Electronics Design, Nathan D. Singhal

Honors Undergraduate Theses

As an attempt to improve the overall cost-effectiveness and ease of structural electronics manufacturing, this study characterizes the mechanical and electrical responses of structures which are fabricated from a novel metallopolymer composite material by fused deposition modeling as they are subjected to quasi-static, uniaxial mechanical tension. Baseline values of tensile properties and electrical resistivity were first obtained via ASTM D638-22 standard testing procedures and linear sweep voltammetry (LSV), respectively. A hybrid procedure to measure in-situ mechanically dependent electrical behavior was subsequently developed and implemented. The mechanical and electromechanical testing was followed by the derivation of stochastic values for several mechanical …

Towards The Automation Of Post-Processing Of Additive Manufacturing Using Collaborative Robots, Logan Schorr

Theses and Dissertations

Despite the incredible potential that collaborative robots have, they are underutilized in several industries that could benefit greatly. These specialized fields, such as additive manufacturing, face challenges that can be solved with the use of robotics, including advanced computer vision, end-effector tooling, and process refinement. My research aims to utilize collaborative robots in an effort to solve the above stated problems, for the specific fields of additive manufacturing. Specifically within this field is the automation of post-processing; this is normally completely manual, as the tools for automation are not sufficiently developed to handle the flexibility required for additive manufacturing. This …

The Interaction Of The Cotton Piece With The Piles Of The Scrabble Cotton Drum, Fazliddin Egamberdiev, Ilkhom Abbazov, Oybek Kholmuratov, Rashid Kaldybaev

Technical science and innovation

This article presents the results of an analytical study of the process of loosening and cleaning raw cotton from small debris by pileging working bodies of purifiers, on the basis of which directions for further research were chosen to optimize the parameters of the developed pile drum with spherical piles and rubber strips. Cotton entering production contains impurities. The processes of loosening and cleaning the fiber shreds are key in the initial stages of ginning, as they prepare the raw cotton for ginning and directly affect the reliability, productivity of these processes and the quality of the resulting fiber. Weed …

Kwad - Ksu All Weather Autonomous Drone, Nick Farinacci, Sebastian Gomez, Stewart Baker, Ed Sheridan

Symposium of Student Scholars

"KWAD" or "KSU all-Weather Autonomous Drone" project was sponsored by Ultool, LLC to the KSU Research and Service Foundation to create a lightweight drone capable of capturing HD video during all-weather operations. The conditions of all-weather operation include rainfall of one inch per hour and wind speeds of up to twenty miles per hour. In addition, a global minimum structural safety factor of two is required to ensure the system's integrity in extreme weather conditions. Potential mission profiles include autonomous aerial delivery, topological mapping in high moisture areas, security surveillance, search and rescue operations, emergency transportation of medical supplies, and …

Programmable Vibration Table Retrofit With Eagle Medical, Jonathan Ilagan, Madhav Asok, Max Lewter

Biomedical Engineering

This project aimed to repair and upgrade a vibration table used for package testing for the sponsor, Eagle Medical - a medical packaging and sterilization company based in Paso Robles, California. The current vibration table is not programmable and lacks circuit diagrams, making it difficult to repair. In addition, it is not functional due to internal circuitry issues and power requirements. To address these issues, the team will implement several upgrades to improve the product and allow for better random cyclic vibration testing. A full assessment of the existing vibration table will be conducted to ensure the viability of these …

Generalizable And Adaptable Data-Driven Methods For Overcoming Barriers To Practical Industrial Condition Monitoring, Matthew B. Russell

Theses and Dissertations--Electrical and Computer Engineering

The future of smart manufacturing relies on predictive maintenance systems that intelligently minimize expensive downtime through timely assessment of machine condition. Deep Learning (DL) has achieved excellent performance in industrial condition monitoring experiments, but the constraints of the manufacturing environment prevent many algorithms from being practically deployed on the factory floor. Ubiquitous sensing from online machines generates high velocity data streams that require new techniques for efficient transmission and storage. Despite these ever-increasing data lakes, many applications still lack the data needed for training DL fault diagnosis and wear tracking models since most data is unlabeled and only from nominal …

Nidec Automated Winder, Michael Pugh, Ben A. Swartz, Andrew Leonard, Garrett Dostal

Williams Honors College, Honors Research Projects

Nidec Drive Systems is a leading electric motor manufacturing company with several facilities in the US and around the world. However, as of recent, Nidec has started to see some signs of old and outdated production machines affecting their production numbers even though the demand for electric is ever increasing. In an attempt to repair some of these issues, Nidec reached out to the University of Akron to look for senior design groups to help design and standardize better production machines. We were tasked with redesigning a new winder, which is a machine that winds the copper coils to the …