Senior Design Project

April 2004 Senior Project Presentations

Rotating Campus Board

Team ME1: Brian Frank, Lisa Holmes, Adam Scichitano
Advisor: Dr. Gupta
Sponsor: Exelon Corporation

Objective: Our objective is to take the concept of a static campus board and create a safer, more versatile piece of equipment.

Description: The rotating campus board will allow a person to exercise indefinitely. It helps build and endurance. The rate of rotation can be changed depending on the weight of the person. Our main goal is to reduce the risk of injury and increase availability to all who are interested in this sport.

Turbocharged Dual-Stage Fuel injection

Team ME2: Drake DeVore, David Fowler, Adam Rienke
Advisor: Dr. Gupta

Objective: To design, test, and tune a fuel injection system (Intake & Exhaust) for a Suzuki motorcycle engine to be used in the 2004 NIU Formula SAE race car.

Description: The function of the Turbocharged Dual-Stage Fuel Injection system is to optimize the amount of air, fuel, and ignition spark the engine receives during operation to maximize the power, torque, and fuel efficiency of the motor.The design will feature an intake and exhaust system first tuned with the Ricardo Wave computer software. Each parameter of the system is designed with the above goals in mind. The intake will be machined of aluminum tube, with custom fuel injector mounts built in, to achieve the best mounting of the fuel injectors. It will be tuned to match the performance of a small Borg-Warner turbocharger, selected to its properties matching closest to the desired output. The exhaust, leading into the turbocharger, will be created from mandrel-bent steel tubing and wrapped with insulating header wrap, to minimize heat loss and flow. The dual-stage fuel injection will allow for precise fuel timing and control, thereby improving fuel economy and power of the engine.An air restrictor and throttle body will be added to the front of the intake system, to control the air entering the engine. Engine sensors will send feedback to the Engine Management Computer where direct changes in fuel, spark timing, and many other parameters can be made. The end result will be a well designed, high performance engine for use in the 2004 NIU Formula SAE racing vehicle.

SAE Aero Design

Team ME3: Paul Gush
Advisor: Dr. Gupta

Objective: To design and build a radio controlled airplane for SAE's Aero Design competition, in which the goal is to maximize the payload.

Description: Using an engine specified by SAE, the airplane must be able to take off within 200 feet. The payload will be maximized by optimizing aerodynamic efficiency while maintaining stability and using weight-saving composite materials.

Trike-Able

Team ME4: Paul Berlin, Jr., Dave Haurroun, Benjamin Jansky, Shawn Wilson
Advisor: Dr. Vohra

Objective: Design and fabricate a three-wheeled, pedaled vehicle for the disabled that is capable of being adjusted to meet both rider size and physical capability.Description: The idea of the Trike-Able originally begun as something much less complex. Paul Bruchman came to MEE 481 and proposed an ides to make restraints that would go over the pedals of his son Nathan's tricycle. Nathan has spina bifida, and because of this has limited use of his legs. Nathan does not have the muscular control that would allow him to keep his feet securely on the pedals of his bike. While the idea of simply making foot restraints for an existing vehicle was not complex enough for a senior design project, this brought to light for this design team a broader problem worth tackling . After researching the markets for tricycles for the disabled, it was found that while there were designs that catered to the disabled, they were either too ability/disability specific, or they had so many unhidden restraints and bracings on them that they failed to look like anything a child would want to ride. Seeing that there was a need for something new in the marketplace, we decided to undertake the project of designing and fabricating an entire tricycle that would not only cater to many different people with different disabilities, but also to Physical Therapists, who use such vehicles for treating their patients. It is also a very important concept to our design group to keep the bike from looking like a bike made for the disabled. While it is impossible to completely avoid the appearance of bracings and restraints, it is possible so that the rider can enjoy the time they spend on the vehicle, and not feel as if they are so different from everyone else.

Deaerator Evaluation And Design

Team ME5: Nicolas Delgado, Emmanuel Mbende, Nalini Reddy, Sheryl Thomas
Advisor: Dr. Majumdar
Sponsor: Hamilton Sundstrand

Objective: To evaluate, determine the key parameters and to design the deaerator for Hamilton Sundstrand's Integrated Drive Generator that separates air from the oil stream.

Description: The deaerator is a component in the Integrated Drive Generator. The Integrated Drive Generator generates power from an oil charge pump and is the main power supply for the jet airplane. Air is added to the oil to simulate the conditions that a high suction oil pump creates in trapping air bubbles in the oil stream. The deaerator removes the air from the oil stream. Hamilton Sundstrand was unable to evaluate the deaerator designs and encountered problems in collecting quality data and due to personnel time constraints. Our goal is to evaluate the performance of various deaerator designs by determining the key parameters in which the future deaerators can be optimized for oil-air separation performance.

FALEX Dual Drive Rolling Fatigue Test System

Team ME6: Brian Benemerito, Michael Bernardi, Kinjin Patel, Clint Summers
Advisor: Michael Anderson
Sponsor: Falex Corporation

Objective: To design a machine that will test rolling fatigue stresses between two rollers in contact.

Description: We plan to design a system that can be used to test rolling fatigue stresses and different lubricants under various rolling conditions. This test system includes dual, direct, bi-directional drives, with a loading system providing normal forces to contact between the two specimens. This tester will also provide an oil recirculation/lubricant delivery system to the surfaces of contact. A heating system will be incorporated in the lubrication system to preheat the test fluid. A computer control and data acquisition system will be incorporated to provide control of the key test functions of speed, load, time, temperature, and cyclic combinations of all controlled variables for flexibility in gear studies. A vibration sensor will be identifying surface conditions that have changed during the test.

Caterpillar 994D Tilt Lever Position Sensor

Team ME7: Michael Bright, Brian Ulrich
Advisor: Kent Foster
Sponsor: Caterpillar, Inc.

Objective: The objective of this project is to place a sensor that sends electronic readouts of angular displacement of the bucket to an onboard computer on the 994D wheel loader and to design robust guarding for that sensor.

Description: Our goal of this project is to determine the position of the sensor that provide the most accurate angular readout to the computer. This will be determined by using kinematic diagrams within Pro/E. The other portion of this project is to design guarding to protect the sensor from the harsh environment in which the wheel loader is working. We will use FEA to analyze this guard and also do impact loading calculations to determine the life of this design.

Kinematic Stage Design

Team ME8: Daniel Black, Jerome Parker, John Taveirne
Advisor: Jame Santucci
Sponsor: Fermi National Accelerator Laboratory

Objective: To design a larger and improved version of the Fermi Lab laser pump chamber stage, Model 9081

Description: A kinematic stage that properly fits the laser pump chamber needs to be designed in order to correctly align the chamber with the laser beam. The Model 9081 stage offers a two-inch distance between the pivot points, and Fermi needs a kinematic stage with six inches between pivot points. The stage we design will need to be as precise as the Model 9081, and will be designed specifically for the laser pump chamber dimensions. The new design will have low beam height and minimal wobble and slop to maintain a set angle while experiments are performed. Safety is also a factor, as the laser being used is a Class IV laser.

Jetter Nozzle Test Stand

Team ME9: Josh Bedyk, Steve Williams, David Worth
Advisor: Bernie Bossom
Sponsor: Vactor Manufacturing

Objective: To design and build a portable nozzle test stand and nozzle holding fixtures to measure and record the performance of various jetter nozzles.

Description: Vactor currently does not have a permanent test stand for its jetter nozzles. However, there is a growing need to have accurate on-site testing to determine the flow rates, pressure, and thrust capabilities of the various nozzles that it sells and uses. This project is concerned primarily with the complete design of a test stand that has proven accuracy because of a built-in calibration system. Presentation is an important aspect of the test stand, so nozzles will be fired within a clear plastic tube for full visibility during operation. Also, results will be displayed on a graph in real time and recorded for full analysis. The test stand will be completely safe for up-close viewing. Overall ease of use is being designed into all aspects of the test stand to reduce errors and set-up time.