Senior Design Projects Spring 2016

Third Place 2016 Design Expo Award Winner
AFRL Rapid Descent System

Team Members

Ashley Pedrotte, Alec Getchel, Jen Hothouse, Jarad Weeks, Arthur Kangas, and Nalani Taniguchi, Mechanical Engineering

Advisors

Paul Van Susante, William Endres, and Kevin Johnson, Mechanical Engineering-Engineering Mechanics

Sponsor

Air Force Research Lab (AFRL)

Project Overview

Our team is working to design an apparatus that will improve the descent of United States Air Force (USAF) Special Operations Force (SOF) personnel from medium and heavy lift helicopters, and tilt rotor aircraft from altitudes in the range of 20–90ft. The design must safely, rapidly, and effectively move personnel to the ground so that they are ready to complete their mission.

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Hand Cycle Frame Design

Honorable Mention 2016 Design Expo Award Winner
Hand Cycle Frame Design

Team Members

Charlie Davis, Jacob Gefroh, Wil Jakeway, Alexander Niemi, and Donald Rogers, Mechanical Engineering

Advisors

Antonio Gauchia, Mechanical Engineering-Engineering Mechanics

Sponsor

General Motors and Achilles International

Project Overview

Our team is designing and prototyping an improved hand cycle frame, focusing on integrating 700c rear wheels into an Invacare Force RX frame. Currently, replacement parts for hand cycles are not readily available, have higher associated costs, and can require custom wheel builds. Existing manufacturers offer only threaded rear axles, similar to those used in wheelchairs, limiting the range of compatible wheel types. A frame re-design is needed on the Top End Force RX model to accommodate a wider use of more readily available parts. Project Achilles Freedom is in need of a more competitive race cycle to enable disabled veterans to pursue racing. As the sport is becoming more competitive, faster and lighter designs of hand cycles are needed.

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Hand Cycle Cockpit Systems Improvement

Hand Cycle Cockpit Systems Improvement

Team Members

Joshua Greib, Ryan Gentner, Nick Saur, Scott Klein, and Travis Graham, Mechanical Engineering

Advisors

Paul van Susante, Mechanical Engineering-Engineering Mechanics

Sponsor

General Motors and Achilles International

Project Overview

Achilles International is a charity that aims to enable people with all types of disabilities to participate in mainstream athletics in order to promote personal achievement, enhance self-esteem, and lower barriers to living a fulfilling life. Achilles, with the support of General Motors, tasked our team to develop improvements for the cockpit of the Invacare Force RX hand cycle. We set our focus on designing systems that enable wounded veterans to compete in racing events with greater ease. The new designs include a clamp-on strapless restraint that will reduce fore/aft motion, an adaptable shifter/braking mounting mechanism, and an easily removable front spray prevention system.

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Automated Bolt Feeder

Automated Bolt Feeder

Team Members

Michael Carroll, Chris Doig, Jonathan Drake, Jerry Tozer, and Lauren Trump, Mechanical Engineering

Advisor

Aneet Narendranath, Mechanical Engineering-Engineering Mechanics

Sponsor

Fiat Chrysler Automobiles (FCA}, Misumi, and ArcelorMittal

Project Overview

Our team has been working on a bolt feeder project for Fiat Chrysler Automobiles. Operators at one section of their assembly line are required to screw bolts to the engine. In the current process, they grab bolts from a container by hand, causing bolts to be dropped. This design will provide a place to drop the bolts off on the other side of the assembly line and then transport them to be sorted and dropped back over the line and into the operator’s hand in a repeatable sequence.

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Ford Transmission Efficiency Team

Ford Transmission Efficiency Team

Team Members

Zach Lemke, Trever Denstaedt, Mitchell Coder, Matt Peltier, and Mikhail Putintsev, Mechanical Engineering

Advisor

Kevin Johnson, Mechanical Engineering-Engineering Mechanics

Sponsor

Ford and ArcelorMittal

Project Overview

The Environmental Protection Agency (EPA) is raising the current standard for fleet-wide fuel efficiency to 34.5 miles per gallon for 2016, and to 54.5 miles per gallon by 2025. To meet these requirements, manufacturers will have to reduce losses in various drivetrain systems. Our team, working with Ford, was tasked with designing a transmission testing setup to be used for testing Ford’s 6f-35 front-wheel-drive transmission. It has been designed for a no-load spin test to measure the torque that is required to spin the transmission in different gears and speed ranges. This testing apparatus will help in measuring the effectiveness of changes made with the design of the transmission to improve efficiency.

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Jeep Wrangler JK: Smart Direct Air Exhauster

Jeep Wrangler JK: Smart Direct Air Exhauster

Team Members

Neil Feliksa, Derek Grogg, Kayla Branton, Victoria Kovach, and Andrew Ross, Mechanical Engineering

Advisor

Antonio Gauchia Babe, Mechanical Engineering-Engineering Mechanics

Sponsor

Fiat Chrysler Automobiles (FCA)

Project Overview

Fiat Chrysler Automobiles has tasked our team with providing a fresh design and prototype of a new, automotive smart direct air exhauster (SDAE) for mitigating the effects of air bind in door closing effort (DCE). This device is designed for the JK Jeep Wrangler, two-door hardtop model. The Jeep Wrangler JK (2007–present, as well as past models), have classically suffered from high DCE. The successful implementation of an effective SDAE on the two-door JK Wrangler hardtop will help boost sales, improve customer satisfaction, and maintain the high quality reputation of the Jeep brand.

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Stryker High Speed Drill Collet

Stryker High Speed Drill Collet

Team Members

Shane Blystone, Austin Ross, Phillip Romback, and Tessa Jagger, Mechanical Engineering and Sarah Skelton, Biomedical Engineering

Advisor

William Endres, Mechanical Engineering-Engineering Mechanics

Sponsor

Stryker Instruments

Project Overview

Our team is designing a new collet that will be able to securely grip Stryker’s new geometry on the company’s cutting accessory while being able to fit within the constraints of the S2 drill attachments. The goal would allow Stryker’s customers to continue using their current S2 drill without having to spend the capital to upgrade to the latest drill models. The collet uses ceramic balls to secure the geometry on the cutting accessory. The collet will be operating in a cutting attachment connected to Stryker’s high speed drills, used for neurosurgeries, spinal surgeries and E.N.T (ear, nose, and throat) surgeries to cut and remove bone.

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Split Hopkinson Pressure Bar Launch Mechanism

Split Hopkinson Pressure Bar Launch Mechanism

Team Members

Korey Erickson, Chet Daavettila, Timothy Daavettila, Joel Larson, and Steven Helminen, Mechanical
Engineering

Advisor

Kevin Johnson, Mechanical Engineering-Engineering Mechanics

Sponsor

REL, Inc.

Project Overview

Our goal is to design, build, and test a new launching mechanism to be used for Split Hopkinson Pressure Bar (SHPB) testing. The current striker bar launching method used by REL Inc. for SHPB testing has safety limitations, is inefficient, and does not provide the desired levels of test repeatability. This project is important for REL, Inc. as an industry leader in SHPB testing and manufacturing to design the safest, most efficient, and accurate striker bar launching mechanism for their customers.

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Oil Chip Separator

Oil Chip Separator

Team Members

Hunter Hamlin, Jacob Schoff, Stefano Michaud, Jacob Grobbel, and Ryan Werner, Mechanical Engineering

Advisor

William Endres, Mechanical Engineering-Engineering Mechanics

Sponsor

MacLean-Fogg and ArcelorMittal

Project Overview

MacLean-Fogg requires a device to process and separate metal shavings from the oil used as a lubricant in the cutting process. The current process requires a grinder that is often damaged by errant parts in the waste stream. Our team developed a trommel-based system that no longer requires a grinder and is not affected by errant parts. Oily chips are fed into a four-foot diameter, eight-foot long rotating drum. The chips are agitated by the rotation while being sprayed with hot water. The oil and water is collected in a tank so that it can be separated and the oil can be reused.

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Unassembled Wheelnut Detection System

Unassembled Wheelnut Detection System

Team Members

Corey Bakker, Ryan Connor, Ian Hufford, Kevin Miller, and Nicole Wright, Mechanical Engineering

Advisor

Kevin Johnson, Mechanical engineering-Engineering Mechanics

Sponsor

MacLean-Fogg and ArcelorMittal

Project Overview

Metform, a division of MacLean-Fogg, produces over 24 million, 2-piece wheelnuts each year. The manufacturing process includes various coating and tumbling operations during which a small percentage of the wheel nuts become unassembled. With offline sorting unavailable, the unassembled parts continue to packaging and end up in the customer’s hands. The goal of our project is to develop an in-line sorting system that meets current production requirements. These requirements include maintaining a non-continuous operating speed, handling oily parts, meeting workplace safety standards, correctly identifying and rejecting non-conforming parts, and having the ability to bypass other part numbers.

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Driveline NVH Improvement

Driveline NVH Improvement

Team Members

Alexandria Bonner, Nathan Campbell, Joshua Esch, Neal Magnuson, and Sylvie Rokosh

Advisor

James DeClerck, Mechanical Engineering-Engineering Mechanics

Sponsor

Ford Motor Company

Project Overview

Driveline vibration has been a source of customer dissatisfaction combined with a perceived loss of quality in automobiles. Methods and techniques to reduce driveline vibration have lacked innovation over the past few decades, creating the urgency for new technologies to be developed. To improve customer satisfaction, our team has designed a new method of damping that is compatible with Ford Motor Company’s automobiles. Our method gives Ford an opportunity to innovate a concept and stay ahead of the competition in similar markets.

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Titanium Tow Hook

Titanium Tow Hook

Team Members

Evan Halloran, Jordan McInnis, Donald Keller, Korey Keipe, and Zachary Mauerman, Mechanical Engineering

Advisor

Antonio Gauchia Babe, Mechanical Engineering-Engineering Mechanics

Sponsor

Fiat Chrysler Automobiles (FCA}

Project Overview

Our team is working with FCA to design a titanium tow hook that can be fitted into the current Jeep Grand Cherokee. Our project consists of designing a tow hook that is compatible with the current mounting system that can be used instead of the current forged steel tow hook. Once our design was submitted and approved, FCA procured prototypes, which will be tested at Michigan Tech. Our team is also in charge of designing and manufacturing a fixture that will support the new design that can also be tested on campus.

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Three-Point Hitch Load Measurement System

Team Members

Zachary Chenier, Travis Claus, Jordan LaCombe, Bethany Schaefer, and Patrick Ylitalo, Mechanical Engineering

Advisor

Eddy Trinklein, Mechanical Engineering-Engineering Mechanics

Sponsor

John Deere

Project Overview

Our team is working with John Deere to design and build a three-point quick hitch that will measure the dynamic load fluctuations between a tractor and its implement during use. The current methods include the use of strain gauges and pin load cells which require complex calibration and custom manufacture. Our new design offers the ability to use off-the-shelf load cells that offer easy calibration and are readily available.

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Surgical Power Tool Hub Interface Redesign

Surgical Power Tool Hub Interface Redesign

Team Members

Dean Halonen, Paul St. Louis, Dave Hancock, Zach Andres, and Bradon Kampstra, Mechanical Engineering

Advisor

William Endres, Mechanical Engineering-Engineering Mechanics

Sponsor

Stryker Instruments

Project Overview

Our team is redesigning the ESSx Microdebrider for Stryker Instruments to eliminate leakage from the tool hub interface, improve tool tip rigidity, and make the tool interchange process more user friendly

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Mercury Marine Flywheel Imbalance Measurement System

Mercury Marine Flywheel Imbalance Measurement System

Team Members

Aaron Schneider, Ann Silski, Jenna Seaser, Matthew Palo, and Owen Marttila, Mechanical Engineering

Advisor

James DeClerck, Mechanical Engineering-Engineering Mechanics

Sponsor

Mercury Marine

Project Overview

Current industry techniques relating to measuring the balance of a spinning mass, in this case a flywheel, are not adequate because of the lack of repeatability and inconsistent data. Our team was asked not to balance a flywheel, but rather to provide an operator with a tool to measure the imbalance value and a radial vector on which the imbalance is located. Our project arose when it appeared that flywheels being received by Mercury Marine did not actually meet the specifications set forward in their technical drawings. One of our goals is to approach this problem from a different standpoint through fresh eyes.

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Mobile Lab

Mobile Lab

Team Members

Dakota Oparka, Kristen Florence, Steven Senczyszyn, Caroline Major, Ryan Engman, Justin Mueller, and Foster Hovey, Mechanical Engineering

Advisor

Aneet Narendranath, Mechanical Engineering-Engineering Mechanics

Sponsor

Department of Biological Sciences

Project Overview

Our goal is to create a mobile gas chromatography lab that can be used by the Department of Biological Sciences to examine nitrogen content in rivers and streams all around the United States. The lab is to be designed inside of a 2015 Ford Transit Van and must include sleeping arrangements. Space, power and safety are all major factors, as the lab needs to store tanks and run lab equipment, as well as allow an individual to work comfortably inside.

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Cummins Fuel Injector NozzlePlunger Automated Match-Fit Process

Cummins Fuel Injector NozzlePlunger Automated Match-Fit Process

Team Members

Tyler Childress, Nathan Karlsrud, Ethan Marshall, Matt Neutkens, Casey Olson, and Zhi Wang, Mechanical Engineering

Advisor

Aneet Narendranath, Mechanical Engineering-Engineering Mechanics

Sponsor

Cummins

Project Overview

Cummins’ current process of manually match-fitting fuel injector plungers and nozzles involves heavy human interaction. Operators are required to test and transport the parts through many steps in the current match-fitting process. Cummins believes that this process could benefit from automation. Our project includes a full CAD package and bill of materials for the design accompanied by a return on investment report. Our team implemented lean manufacturing principles to remove non-valueadded steps from the process. We created a match-fitting simulation to perform design validation and optimize storage design. The simulation is capable of outputting process time, part counts and match dimensions when input with individual part data.

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Fiat Chrysler Automotive Engine Assembly Pallet Cleaner

Fiat Chrysler Automotive Engine Assembly Pallet Cleaner

Team Members

Joshua Olsen, Derek Stone, Kurt Siebenaller, Jacob Bailey, Keith Lewis, and Erik Lemmen, Mechanical Engineering

Advisor

Eddy Trinklein, Mechanical Engineering-Engineering Mechanics

Sponsor

Fiat Chrysler Automobiles (FCA) and ArcelorMittal

Project Overview

Our project involves the design and construction of an engine block assembly line pallet cleaning station for Fiat Chrysler Automotive’s (FCA) Mack Avenue Engine Plant. Most cleaning stations are expensive, and do not add value to the end product, and are therefore cut out from manufacturing lines. FCA wanted an innovative, cost-efficient solution for this problem. Our team developed a design that meets all of FCA’s design requirements and constructed a prototype to demonstrate the functionality of our design.

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Piezo-Actuator Design Phase 2

Piezo-Actuator Design—Phase 2

Team Members

Brad Vinckier, Jeff Halonen, and Luke Heller, Mechanical Engineering and William Weaver, Computer Engineering

Advisor

William Endres, Mechanical Engineering-Engineering Mechanics

Sponsor

Stryker Instruments

Project Overview

The main goal of our project is to create a bone sculpting tool that operates at low frequencies for use in minimally-invasive surgeries and is powered by piezoelectric stacks. The project is a continuation of a previous senior design project sponsored by Stryker Instruments. Our team tested numerous cutting accessory tips along with a test fixture to evaluate the cutting tips. We also created a graphical user interface, improved the circuit board, and incorporated a power supply.

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