Senior Design Projects Spring 2014

Air Force Research Laboratory Challenge: Heavy Lift System

Air Force Research Laboratory Challenge: Heavy Lift System

Team Members

Timothy Cencer, John Groen, Andrew Janczy,
Corey McKenzie, and Steven Saliga,
Mechanical Engineering

Advisor

James DeClerck and William Endres, Mechanical
Engineering-Engineering Mechanics

Sponsor

Air Force Research Laboratory (AFRL)

Project Overview

The challenge issued by the Air Force Research Laboratory was to create a lift system to rescue entrapped soldiers from damaged vehicles. The system needed to be capable of safely lifting a 55,000-pound vehicle up two feet while being small/light enough to be carried and operated by one person. The solution developed is a hydraulic spreader that optimizes size, weight, and power unlike anything currently on the market.

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Automated Sealant System

Automated Aircraft Sealant System

Team Members

Alison Hilditch, Andrew Reed, Nicole Maggi, and William Yahr, Mechanical Engineering; Matthew Courchaine and Patrick Harris, Electrical
Engineering

Advisor

Aneet Narendranath, Mechanical Engineering-
Engineering Mechanics

Sponsor

HGS Aerospace

Project Overview

Our team is continuing project development on automating the process of applying a mixed two-part sealant onto an aircraft component. The current industry-standard manual sealing process results in increased process time and technician injury, which we are aiming to reduce. The specific goal for this project’s design is to dispense sealant along a complex two-dimensional path with the aid of a vision-capable, 6-axis, robotic arm. We will provide a proof of concept that will be used for future development.

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Center Beam Railcar Repurpose Design

Center Beam Railcar Repurpose Design

Team Members

Jocelyn Tervo, Riley Peterson, Becky Schlak,
William Melcher, Alec Bolthouse, and Nathaniel
Scheetz, Mechanical Engineering

Advisor

Kevin Johnson, Mechanical Engineering-
Engineering Mechanics

Sponsor

NU-Rail and Michigan Tech Rail Transportation
Program

Project Overview

There are currently thousands of idle center beam railcars being stored across the United States. These railcars were once heavily used for carrying dimensional lumber, but after the housing industry crashed they were not fully utilized. Our team has been tasked with the objective to create a conversion design that will enable the use of these idle railcars in a growing industry, specifically the oil industry. We must create a conversion design with multiple constraints and objectives in mind.

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Chrysler Roadside Repair Module

Chrysler Roadside Repair Module

Team Members

Mike Rinke, Jeremy Moseley, Nghia Truong, and
Rachel Smith, Mechanical Engineering

Advisor

William Endres, Mechanical Engineering-
Engineering Mechanics

Sponsor

Chrysler Group LLC

Project Overview

Our team was commissioned by Chrysler Group LLC to design a better method for mounting, raising, and lowering an under-slung spare tire while packaging all of the necessary tools and accessories in a more compact and practical way within a roadside repair module for a 2017 Chrysler SUV with third-row seating. The problem lies in storing a spare tire within the vehicle with a third row of seats. A redesigned under-vehicle storage and raising and lowering system for the spare tire is required to optimize the amount of storage space for the end user in the rear of the vehicle.

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Dust Removal System for ME-EM Sixth Floor Woodshop

Dust Removal System for ME-EM Sixth Floor Woodshop

Team Members

Gregory Hardy, Zachary Schneider, Ritik Singh,
Bradley Johnson, Colin Lay, and Steven Clark,
Mechanical Engineering

Advisor

Kevin Johnson, Mechanical Engineering-
Engineering Mechanics

Sponsor

Department of Mechanical Engineering-Engineering Mechanics

Project Overview

Our team has been tasked to redesign the ventilation system for the sixth floor woodshop in the Department of Mechanical Engineering- Engineering Mechanics (ME-EM) R.L. Smith building. Currently, the system does not effectively capture and remove dust particles. The ventilation system consists of a fan connected to a series of ductwork leading to several stationary power tools. The fan draws air through duct branches while the machines are under operation to capture the wood dust. The system experiences flow losses, is prone to clogging, and is a potential safety hazard. It has not been tested to determine the proper pump size or confirm that the required flow rate for the machinery is met..

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Inline Polymer Pellet Crystallization System

Inline Polymer Pellet Crystallization System

Team Members

Ethan Archambault, Collin Brown, Mark Nettell,
Zhehao Ren, and Brent Thoune, Mechanical
Engineering

Advisor

Gregory Odegard, Mechanical Engineering-
Engineering Mechanics

Sponsor

Advanced Blending Solutions

Project Overview

Polyethylene terephthalate (PET) is one of the most commonly used materials for food packaging and beverage containers. The demand for PET is steadily growing and as the demand increases, so does the amount of recyclable material to be processed. One step in the recycling process of PET is to crystallize the material before it reaches the drying stage. Current market solutions for crystallizing PET are expensive to operate and are an inefficient use of space. Advanced Blending Solutions tasked our team with designing, prototyping, and testing a PET crystallizer capable of continuous crystallization of PET.

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Lightweight POP Rivet Gun

Lightweight POP Rivet Gun

Team Members

Eric Phillips, Caleb Walk, Justin Osterhout, Daniel
Carpenter, and Anthony Carley, Mechanical Engineering

Advisor

William Endres and Gregory Odegard, Mechanical
Engineering-Engineering Mechanics

Sponsor

Chrysler

Project Overview

The purpose of this project is to take an existing POP ProSet 3400 Rivet Gun and modify some of its components to reduce the weight of the tool. Chrysler is the customer for this project, and rivet guns are increasingly being used by the company on its assembly lines. By reducing the weight of the rivet guns being used by its assembly line workers, the repeatability and accuracy of each rivet installation is increased as a lighter weight gun is easier for the workers to operate and reduces the
likelihood of fatigue.

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Limited Edition RAM TruckTailgate—Structure

Limited Edition RAM Truck Tailgate—Structure

Team Members

Christian Vreeland, Thomas Gruber, Evan
Rosemore, and Taylor Erva, Mechanical Engineering

Advisor

Gregory Odegard, Mechanical Engineering-
Engineering Mechanics

Sponsor

Chrysler Group LLC

Project Overview

Our team worked in collaboration with another Senior Design team to develop a special edition lightweight carbon fiber tailgate for use in the next generation RAM 1500 for Chrysler Group LLC. The prototype tailgate was expected to reduce current production weight by 25 percent while maintaining loading integrity and integrating a custom selling feature.

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ME-EM Lab Mass Air Flow Manifold

ME-EM Lab Mass Air Flow Manifold

Team Members

Mark Johnson, John Bennett, and Zach Denault,
Mechanical Engineering

Advisor

Jeffrey Allen, Mechanical Engineering-Engineering
Mechanics

Sponsor

Department of Mechanical Engineering-Engineering
Mechanics

Project Overview

Our goal is to design, manufacture, and implement a testing apparatus to measure the mass flow rate for new Michigan Tech ME-EM department curriculum lab equipment.

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Pistonphone Adapter Design

Pistonphone Adapter Design

Team Members

John Troost, Jaclyn Burtka, and Dustin Scherr,
Mechanical Engineering; Travis Kuchar, Electrical
Engineering

Advisor

James DeClerck, Mechanical Engineering-
Engineering Mechanics

Sponsor

The Modal Shop Inc.

Project Overview

Our goal is to design and prototype a “pistonphone adapter.” This will include adapter inserts for different-sized microphones that will fit atop the 9110D Portable Vibration Calibrator in a similar fashion to the proximity probe holder—permitting the 9110D to operate as a frequency agile pistonphone calibrator.

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Quincy Mine Tour Vehicle

Quincy Mine Tour Vehicle

Team Members

Anne Jarvey, Andria Nyenhuis, Matthew Kowalkowski, Xin Diao, and Kyle Schmied, Mechanical Engineering

Advisor

Kevin Johnson, Mechanical Engineering-
Engineering Mechanics

Sponsor

Quincy Mine Hoist Association

Project Overview

The Quincy Mine Hoist Association is a nonprofit organization that provides tours of the Quincy Copper Mine located in Hancock, Michigan. During the current tour, visitors travel 2,000 feet into the mine on a hay wagon pulled by a dieselpowered tractor. We were tasked with engineering a new passenger carrier that eliminates the diesel exhaust build-up inside the mine and provides a comfortable ride for passengers. Through concept selection, a center articulated, electric vehicle was chosen. We are responsible for delivering the chassis and passenger cabin designs.

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RAM Tailgate Accessory

RAM Tailgate Accessory

Team Members

Kraig Kadletz, Andrew Pospychala, Chad
Dickenscheid, and Greg Reed, Mechanical
Engineering

Advisor

Gregory Odegard, Mechanical Engineering-
Engineering Mechanics

Sponsor

Chrysler Group LLC

Project Overview

The RAM’s current tailgate opens, closes, and secures cargo. This meets the basic functionality expected from end users and is standard in the industry. Chrysler feels there is an opportunity for their current tailgate on the RAM truck to incorporate a feature that they can highlight and market to a very specific target customer. This feature needs to be unique and is intended for a limited volume (2,000 units) high-performance vehicle or eco-fuel-efficient package. A unique tailgate will add value to the RAM line and add an additional selling point in order to expand their market share and generate revenue.

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Chrysler Roadside Repair Module

Roadside Repair Module

Team Members

Zhe Liu, John Cretens, Kyle Ver Hoef, and Ryan
Hess, Mechanical Engineering

Advisor

William Endres, Mechanical Engineering-
Engineering Mechanics

Sponsor

Chrysler

Project Overview

The purpose of our project is to create a new system to lower and store a spare tire. The designed system needs to take up less space than the current system, therefore maximizing the amount of cargo space available to the customer.

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Center Beam Railcar Repurpose Design

Rotary Cartridge Assembly System

Team Members

Benjamin Abraham, Sarah Daniels, and Kristi Ross,
Mechanical Engineering

Advisor

Eddy Trinklein, Mechanical Engineering-Engineering
Mechanics

Sponsor

Lendrex

Project Overview

Our team is designing a system to expedite the assembly process of rotary cutting tool cartridges. Endres Machining Innovations LLC (EMI) has developed the Gen-II Rotary-Tool System, a specialized cutting tool system for applications where a high thermal load and/or tool wear is a major concern. The current assembly time for the cartridge is over seven minutes. Because EMI engineers assemble these cartridges by hand, the process is costly, and either a semi- or fullyautomated assembly system is desired.

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Single Cylinder Engine Conversion

Single Cylinder Engine Conversion

Team Members

Benjamin Dion, Andrew Komurka, Sondre Sandvik,
Jacob Strack, Reuben Usimaki, and Daniel Van
Alstyne, Mechanical Engineering

Advisor

Aneet Narendranath, Mechanical Engineering-
Engineering Mechanics

Sponsor

John Deere

Project Overview

Our team converted a John Deere 3.9L fourcylinder diesel engine to function with a single active cylinder for combustion and emissions testing. The converted engine incorporates a modified and instrumented cylinder head from a 4.5L sister engine as well as a fuel system and instrumentation from a 2.9L sister engine. These modifications of the 3.9L engine will allow John Deere to expedite engine development by facilitating quick combustion system variation, eliminating cylinder-to-cylinder measurement variability, and providing careful air and fuel control. In addition, single-cylinder testing will reduce both fuel and prototype part costs.

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Variable Height Assist Chair

Variable Height Assist Chair

Team Members

Christian Haiss, Nick Christenson, Shawn Troyer, Te
Yu, and Fanxing Meng, Mechanical Engineering

Advisor

Aneet Narendranath, Mechanical Engineering-
Engineering Mechanics

Sponsor

Department of Mechanical Engineering-Engineering
Mechanics

Project Overview

The purpose of this project is to address the vertical mobility needs of someone who has difficulty standing for long periods of time. The chair has the ability to elevate the user to different levels enabling many common household tasks. The customer for this project is not confined to a wheelchair and did not want a product that resembled one. Existing assist chairs have a feature that lifts the user to a standing position that was also not desired. The goal of this project was to design and build a prototype of a variable height assistive chair.

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