Manufacturing Commons^™

Semi-Automated Glass Mat Splice Operation For Asphalt Shingle Line, Justin Bracci, Harry Zhao, Chad Linafelter

Mechanical Engineering

The following report details the senior project sponsored by GAF Materials Corporation, Shafter, CA in regards to semi-automating a glass-mat splicing table for asphalt roofing shingle production. Herein includes details, research, design, and analysis regarding the semi-automation of the gluing processes for the splicing table. A working prototype was manufactured and tested for the future implementation onto GAF’s production line or further senior project involvement.

Team Nathan Suspension, Frankie J. Wiggins, Alex D. Seitz, Justin P. Bautista

Mechanical Engineering

Nathan Cooper is an 8-year old boy with Spinal Muscular Atrophy (SMA). SMA has affected Nathan’s muscle development and requires him to use the Standing Dani™ mobility device. The Standing Dani is a motorized standing wheelchair, or Wheelstand. Nathan controls and uses it to get around. Though the Standing Dani performs well for most functions, it has some distinct issues. The primary issue that this project addresses is its lack of suspension and the discomfort that Nathan feels as a result. After talking with our client, we developed several specifications generally related to geometry, safety, vehicle dynamics, and reliability. Many …

Final Design Report Bull Outdoor Products Tailgating/Backyard Barbecue, Kyle Van Allen, David Mei, Nicholas James Marquez

Mechanical Engineering

Bull Outdoor Products, Inc. is a specialty company whose main products are high end barbecues for use in outdoor kitchens. They desire a more portable barbecue stand(s) that can be used for tailgating. This is to be achieved by creating a dual-purpose stand/frame that allows for the barbecue head to be used on a trailer hitch or as rolling stand that can be used without a trailer hitch.

Formula Sae Hybrid Carbon Fiber Monocoque / Steel Tube Frame Chassis, Matthew Hagan, John Rappolt, John Waldrop

Mechanical Engineering

The Cal Poly Formula SAE Team created this project in order to design and fabricate a high-performance chassis which would be competitive at 2013 FSAE Lincoln, and to document the process so that future teams could more easily create a chassis. One of the main goals was to reduce weight from the 143- lb 2012 chassis subsystem. A weight of 95 lb was achieved, with 82 lb in the chassis structure itself and a predicted torsional stiffness of 1700 lb*ft/deg. Composite materials design and manufacturing techniques were developed during the project. Design, testing, and manufacturing processes are detailed, and results …

2d Wireform Process Improvement, Katy Conlin, Carlo Ebora, Jordan Gamble

Mechanical Engineering

The body of this work has been created for Edwards Lifesciences in conjunction with senior project requirements. As such, the information produced and contained within is under a non‐disclosure agreement. As per request by sponsor, the body of the work will not be submitted to any outside parties, and the title page will serve as proof of completion.

Semi-Automated Method Of Assembly For Physio Ii Ring, Cameron Anderson Deines, Kelsey Jean Engel, Christopher Kiuyen Wong

Mechanical Engineering

No abstract provided.

Bellevue-Santa Fe Charter School Solar Panel Project, Dulce Arroyo Martinez, Henrik Lee, Moises Quiroz, Timothy Iafrate

Mechanical Engineering

This project covers the design, manufacture, and installation of solar panel frames on a charter school in Avila Beach, CA. Through preliminary research regarding important factors (such as solar movement, ideal panel angle, and site-specific factors), a frame that meets the standards set forth in the California Building Codes was designed. After approval by presiding authorities, parts specified in the design were ordered, inspected upon arrival, and manufactured to the design as necessary. Much of the challenge was related to the installation aspect of the project—coordination with the proper authorities and correct submission of applications was integral to the success …

Team Poly Cup, John Adkins, Scott W. Hart, Elise Kiland

Mechanical Engineering

This project involves the use of mechanical engineering expertise to develop, design, and create a functioning prototype of a collapsible coffee cup. The prototype is to be designed to the specifications given by Jason Blum, the project sponsor. Allowances may be given for design freedom as specified by Jason Blum. The goal of this project is to create a product which may replace the both the disposable coffee cups distributed at coffee shops as well as to create a product which may replace the traditional travel mug due to its increased portability.

Team Poly Cup has worked throughout the year …

Design Of An Automatic Wood Trimming Machine, Van Ho, Nicholas Maskal, Andrew Rutland

Mechanical Engineering

This final design report, prepared for Sunrise Arts by the Cal Poly design team Mahogany Automation, details the year-long process in which the team of three engineering students designed and built an automated wooden -plank edge trimming machine that incorporates anti-jamming and continuous loading features. The team has examined current woodworking machines and features available on the industrial and commercial market, and used these as guides along with device requirements set by the project sponsor, Bruce Palmer. The focus has been on designing the simplest and most cost effective device that allows operators to make production runs of wooden slats …

Edwards Lifesciences - Skirt To Frame Attachment Manufacturing Aid, Samuel Joda, Cesar Grimaldo, Patrick Hutchinson

Mechanical Engineering

No abstract provided.

Drape Forming Machine, Adam Johnson, Will Schlosser, Brian Miller

Mechanical Engineering

The goal of this project was to build a prototype machine that formed multiple sheets of debulked pre-preg OOA carbon fiber into a 2-foot long trapezoidal shape. The machine was required to do this process semi-automatically.

Rapid Decompression Containment System, Evan Domingue, Michelle Rudney, Daniel Trees

Mechanical Engineering

Cal Poly students; Evan Domingue, Michelle Rudney and Daniel Trees; are working with General Atomics Aeronautical Systems, Inc. (GA, ASI) and engineer John Wilcox to complete a senior project. The senior project is focused on finding a solution to meet the requirement set forth in MIL-HDBK 1791 4.2.5.2 for rapid decompression which requires cargo items to be designed with pressure relief devices or to be configured for air shipment as to prevent any part from becoming a projectile in the event of catastrophic loss of aircraft cabin pressure. The goal of this project is to design a safe, cost-effective, and …

Titan 130 Engine Aft-Mount, Woody Newell, Michael Haworth, Dylan Perry

Mechanical Engineering

No abstract provided.

Exploration Station Kidshake Table, Jeremy Duhe, Philip Hopkins, Matt Ostiguy, Samantha Weiner

Mechanical Engineering

The KIDShake Table is an all mechanical earthquake shake table sponsored by the Exploration Station Children's Museum of Grover Beach. This interactive exhibit has two working mechanisms, a hand crank and pull rope, that provide two axis movement for knocking down block structures. This table was built and designed for a target age of 10 years.

Beach Wheelchair Project, Rory Aronson, Joshua Marcum, Samuel Coyne, Alex Hayes, Alexa Colburn, Max Hessel, Benedikt Strauss, Marvin Rimmele, Marco Pietsch

Mechanical Engineering

The Beach Wheelchair, Sandcrawler, is a machine intended to help give people with disabilities the full beach experience. The non-profit organization Bridge II Sports sponsored this project, and tasked us with developing the design and fabricating a prototype. This chair has several features including a linkage mechanism that raises and lowers a chair relative to an external frame, hand crank drive with Gates Carbondrive belt and sprockets, buoyant Wheeleez balloon tires, and much more.

Rebounder Fatigue Test Machine, Caroline Reeves, Will Robertson, Ethan Flory

Mechanical Engineering

JumpSport, a company that designs and sells trampolines and trampoline accessories, has sponsored this senior project team to design, build, and test a trampoline fatigue test machine. The machine must simulate a person jumping on the trampoline to test the life of JumpSport’s fitness trampolines and kids’ trampolines. Partway through the design process, the objectives were altered and this senior project team was tasked with merging with another Cal Poly senior project group to create an all-inclusive test machine to accommodate both full-trampoline testing and individual bungee cord testing.

The final design is centered on a slider crank linkage driven …

Loaded Shift Tester Sram, Nick Cox, Sam Shaffer, Michael Polka

Mechanical Engineering

This report details the design, manufacturing, and testing of a loaded shift tester for the SRAM Bicycle Corporation. The machine is used to perform developmental and qualification tests on various bicycle drivetrain components. Using SolidWorks, the design team created a solid model of the machine on the computer, then ordered and manufactured the parts required to build it. The machine was tested to ensure that all the parts worked together, and was finally delivered to SRAM when it was deemed ready.

Bicycle Wheel Test Machine, Dylan Harper, Kevin Hom, Ross Williams

Mechanical Engineering

In recent years, the cycling industry has witnessed huge advancements in bicycle components and materials. The age old goals of speed and low weight are still present today, but the pursuit of these goals may be reducing the structural stability of various components integral to wheel performance, including the wheel hub bearings. These bearings are invaluable to bicycles but little is known about how the forces and loads applied to a bicycle affect the performance of these bearings. Broken axles and hubs are indicators of significant stresses within the hub, but little is known about how the resulting deformation affects …

Hoist To Transfer Athletes From Wheelchair Into A Kayak, Jennifer Batryn, Javier Mendez, Kyle Mooney

Mechanical Engineering

No abstract provided.

Ir Imaging Chip Fixturing System, Curtis Wagner, Scott Solomon

Mechanical Engineering

No abstract provided.

Human Powered Hydrofoil Bike Pontoon Floatation, Shelley Dangoor, Tyler Brennent

Mechanical Engineering

This report documents the brainstorming and design development of the hydrofoil bike floatation device. This project is in conjunction with senior project team MobyBike. MobyBike’s focus is in the development of the bike actuation system, as our team’s focus is on designing and developing the floatation device to be incorporated in the final hydrofoil bike design.

Solar Turbines Creep Test Fixture, Rene Maciel, Eric Nelson, Chris Ewald

Mechanical Engineering

No abstract provided.

Handitrike - Recumbent Tricycle, Sean Higginson, Kevin Howie, Vinay Patel

Mechanical Engineering

This report covers the design and construction of the recumbent racing tricycle for Mr. Robert T. Kelly, a disabled veteran. Unfortunately Rob’s right leg is five inches shorter than his left one and therefore is unable to properly operate standard cranks. Our team HandiTrike is composed of Sean Higginson, Kevin Howie, and Vinay Patel and our project requires us to come up with a design that is feasible to complete within the given three quarters, as well as allow Rob to gain full use of his tricycle. Currently Rob ‘s trike uses the standard crank set up found on most …

Formula Sae Turbocharger Engine Development, Eric Griess, Kevin Mccutcheon, Matthew Roberts, William Chan

Mechanical Engineering

This project, Formula SAE Turbocharger System Development, was sponsored by the Cal Poly, San Luis Obispo Formula SAE team. The team proposed this project in order to have a powerful yet lightweight engine so they can be extremely competitive at their competition. The baseline output of the single cylinder 450cc engine (2006 Yamaha WR450F) was 46 horsepower and 27 ft-lb of torque. The goal of this project was to increase the output of that engine to 60 horsepower and 35 ft-lb through the use of a turbocharger.

Wolfpack Gear Inc. Composite Frame Firefighter Backpack, Gabriel Mountjoy, Blair Ridings, Carl Drummond Buchenroth

Mechanical Engineering

No abstract provided.

The Hovering Ball Exhibit, Matthew Bauzon, Will Lennox, Michelle Swan

Mechanical Engineering

No abstract provided.

Formula Hybrid Drivetrain Design, Zachary (Zak) Mcfarland, Alex Pruitt, William Domhart

Mechanical Engineering

The Formula Hybrid senior project group was tasked with designing and building a drivetrain system for the Cal Poly Society of Automotive Engineers (SAE) Formula Hybrid (FHSAE) team. FHSAE gave customer requirements for performance and geometry for the drivetrain and the FHSAE rulebook has guidelines regarding safety requirements. The team chose to compete in the electric category of the 2012 FHSAE competition. After getting feedback from previous car performance and researching different powertrain options, the senior project team arrived at three conceptual ideas. Using a quality function deployment method, the senior project team chose the concept where two motors independently …

Recreational Nordic Sit Ski, Mathew Bissonnette, Johnathon Gorski, Kevin Izumiya

Mechanical Engineering

The purpose of this project was to design, build, and test a recreational Nordic sit ski for use by Disabled Sports Eastern Sierra. The goal was to improve adjustability and reduce weight compared to previous sit ski designs. The project was completed by Cal Poly Mechanical Engineering seniors Mathew Bissonnette, Johnathon Gorski, and Kevin Izumiya. Kinesiology seniors Harpreet Saini and Carl Anderson provided discipline support and disability etiquette training.

The project was sponsored by the National Science Foundation Research to Aid Persons with Disabilities (RAPD) grant. The grant was proposed by and awarded to Dr. Brian Self and Dr. James …

Design Of An Independent Star-Clip Organizer (Iso), Christopher Gonzales, Greg Lovasik, Daniel Silveira

Mechanical Engineering

Discussed below is a new concept to sort and deliver star clips for flight deck safety net manufacturing. Multiple methods were generated, along with the necessary research, and were narrowed down to a single concept: the tray-loading preprocess design, named ISO (Independent Star-Clip Organizer). The overall design has been finalized and designed. Due to budget constraints, an actual prototype was not built. However, the design of such a prototype is described by this report, backed with calculations and experimental testing.

Human Powered Helicopter: Rotor Structure, Joseph Ram, Juan Carlos Olvera

Mechanical Engineering

The following report encompasses the Human Powered Helicopter Rotor Team’s conceptual models and ideas based on research and modeling analysis. The following gives an overview of material researched, concept generation, analyzation, manufacturing, and testing for a rotor structure to be installed in a Human Powered Helicopter.