Handout 050107

From A Global Perspective

UNDERGRADUATE RESEARCH AND SENIOR DESIGN DAY

FRIDAY, MAY 4, 2007

Time Room Title Page

Industrial and Systems Engineering

8:30 - 9:00 354 Opening / Welcome – Dr. Vohra10:00 - 10:20 241 Inventory Management System for Elgin Industries ……………… 110:25 - 10:45 241 Analysis and Time Study of Assembly Operation ……………... 210:50 - 11:10 241 Ideal Industries Kanban System …………………………………… 311:15 - 11:35 241 Process Improvement for Motorola’s CCSI Sector ……………….. 311:40 - 12:00 241 Plant Layout Analysis and Redesign …………………………….... 412:00 - 1:00 354 Lunch 3:30 - 4:00 101 Awards Ceremony

Electrical Engineering

9:05 - 9:25 221 Aqualizer ……………………………………………………... ……. 5 9:30 - 9:50 221 Grill Monitor ……………………………………………...... ……… 6 9:55 - 10:15 221 IEEE Micro Mouse …………………………………………………. 710:20 - 10:40 221 Ion Beam Sputtering System Reconstruction………………………… 810:45 - 11:05 221 ARKS: Advanced Remote Keyless System ………………………… 912:00 - 1:00 354 Lunch 1:05 - 1:25 221 3-D Rotating LED Display ………………………………………… 10 1:30 - 1:50 221 Wireless Multi-Device Controller ………………………………….. 10 1:55 - 2:05 221 The Electronic Tip Up …………………………………………….. 11 3:30 - 4:00 101 Awards Ceremony

Mechanical Engineering

9:05 - 9:20 101 TTX Torque Measuring Bolster ………………. . ……………….. 129:25 - 9:40 101 SAE Mini Baja Drive-Train ……………………… ……………... 139:45 -10:00 101 Automatic Locking Knee …………………………… …………… 1310:05 - 10:20 101 Hamilton Sunstrand Deaerater Project ………………………….. 1410:25 - 10:40 101 Freecoaster Redesign ……………………………………………. . 1510:45 - 11:00 101 Crutch Design ……………………………………………………. 1511:05 - 11:20 101 Vactor Hose Reel Cover ………………………………………… 1611:25 - 11:40 101 Ethanol Still …………………………………. …………………. 1611:45 - 12:00 101 Universal snap-back aircraft towbar ……. ……………………… 1712:00 - 1:00 354 Lunch1:05 - 1:20 101 Stroller with detachable car seat ………………………………… 181:25 - 1:40 101 Antarctic Winch Deployment System …………………………… 11:45 - 2:00 101 Vactor Door Prop ………………………………………………… 192:05 - 2:20 101 Design of Formula SAE Engine Components ………………… 192:25 - 2:40 101 Jet Engine from Turbocharger …………………………………… 202:45 - 3:00 101 Brookfield Zoo Bear Enrichment Project ………………………... 203:30 - 4:00 101 Awards Ceremony

Engineering Technology

9:30 - 9:50 311 Steel Drum ……………………………………………………… 219:55 - 10:15 311 Compound Parabolic Concentrator for Crop Drying …………… 2210:20 - 10:40 311 Basic Utility Vehicle …………………………………………… 2310:45 - 11:05 311 Caterpillar Tire Assist Mechanism …………………………….. 2412:00 - 1:00 354 Lunch 3:30 - 4:00 101 Awards Ceremony

Industrial and Systems EngineeringSenior Design Projects

Project 1: Inventory Management System for Elgin IndustriesCompany: Elgin Industries

Students: Justin KodaJames LezonJason Schafer

Time: 10:00 – 10:20 a.m.Location: Room 241

Faculty Advisor: Dr. Ghrayeb

Abstract: The main goal of this project is to formulate a model designed to reduce the current inventory levels for Elgin Industries. Elgin Industries has been a major producer and distributor of automotive engine and chassis parts for many years. There are several factors which will need to be considered to find the best method. First of all, we need to determine which products are mainly responsible for the excessive stock level. Collectively, the company is responsible for approximately 22,000 SKUs. However, only a small percentage of these SKUs account for the majority of stock. Secondly, the lead time for each of the products is unknown. Lead times for each product will be essential in determining an order level. However, Elgin Industries has a very complex order and receiving system where single orders are received in random quantities at several different times. To add to the lead time complexity, some products are kitted and require extensive analysis to calculate a time. Next, Elgin Industries’ clientele typically makes purchases on an as needed basis. This causes product demand to be very unpredictable. Many of the products are sold in large volumes with considerable variation from month to month. Next, certain conditions must be considered when developing the individual inventory models. Due to the company’s strong devotion to customer service, it is important that the percentage of stock outs is kept to a minimal level. However, this loss of goodwill must be weighed against the cost of storing a product in inventory. Also, there is the storage space factor which must be considered. Finally, due to the high volume of SKUs, the data must be arranged in a presentable and accessible manner so that it can be easily referenced. If the data is scattered, the findings will be difficult to implement. Therefore, the most practical way to present our findings would be a database table using software such as Microsoft Access. Only after all of these factors are considered can a valid inventory model be formulated.

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Project 2: Analysis and Time Study of Assembly OperationCompany: Bergstrom Incorporated

Students: Scott HickeyMarcin KociolekCalvin WongNathan Woodson

Time: 10:25-10:45 a.m.Location: Room 241

Faculty Advisors: Drs. Asoudegi, Moraga and Rahn

Abstract: Bergstrom Incorporated is company that produces cab climate systems for many different types of trucks and off road machines. This project will examine the assembly of two different systems. The two lines will be observed to see what possible improvements can be made, followed by time studies to determine standard assembly times. Upon completion of these time studies, analysis of the throughput and line balancing will be done to increase efficiency. Process maps, value stream maps, and flow charts will all be included to see the process and the cost of each. Finally, a manual of steps taken to complete this project will be included for Bergstrom to continue on to other assembly lines as needed. It is believed that there is much inefficiency within these two lines, so great success is

imminent.

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Project 3: Ideal Industries Kanban SystemCompany: Ideal Industries

Students: Colby CurtisAndrew Ellia

Time: 10:50 – 11:10 a.m.Location: Room 241

Faculty Advisors: Dr. Ghrayeb and Moraga

Abstract: The objective of this project is to design an inventory management system for Ideal Industries’ new Pulsar 60 press at their Sycamore production facility. The Pulsar 60 will be used to produce six brand new products, each of which will be subsequently conveyed “downstream” to Ideal’s DeKalb facility. Using the principles of JIT manufacturing, the project team will design a Kanban inventory management system that will reduce costs by virtually eliminating overproduction, excessive production resources, and excess inventory. The project team will be utilizing computer simulation to optimize the final parameters of the Kanban system.

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Project 4: Process Improvement for Motorola’s CCSI SectorCompany: Motorola

Students: Chris DeFalcoAndy Wyrwal

Time: Room 241Location: 11:15 – 11:35 a.m.

Faculty Advisors: Drs. Ghrayeb and Rahn

Abstract: The objective of this project is to improve the overall process for Motorola’s CCSI sector. The first step would be a define stage implementing process mapping. The CCSI system, including the testing phase, would be the first target. This is crucial to help define the critical parameters and identify any waste that can be eliminated. This information is essential to any improvement that will be suggested. The mapping should then be widened to include the areas both upstream and downstream of CCSI in the supply chain. This will also yield key information for the critical parameters, and will give CCSI a better understanding of the aspects that they can control, as well as those they cannot.

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Project 5: Plant Layout Analysis and RedesignCompany: SPX Fluid Power – Rockford Illinois

Students: Stephen LambCory MeyersShannon Milligan

Time: 11:40 – 12:00 Location: Room 241

Faculty Advisor: Dr. Ghrayeb

Abstract: The SPX facility in Rockford has major layout flaws that require attention to improve operations. The factory is a composite of three other SPX companies that have been crammed together into one building which has led to a disjointed and inefficient layout. The goal of our project is to familiarize ourselves with the plant and perform analysis of material flow in order to create an updated and efficient design. We will achieve this goal through a series of analysis starting with a large amount of data collection. Last years highest sales by volume will determine which finished units will be studied on each of SPX’s 90 or so workstations. These units will be broken down into components whose routes will be tracked and mapped through the facility in order to illustrate material flow. This data will be converted into a layout via from/to analysis and the CORELAP algorithm. We will use this information to develop a new, optimal layout for SPX. Upon completion, we will perform an overall analysis of savings that will be produced by our redesign. The deliverables of the project will be presented to the company, hopefully to be implemented in the near future.

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Electrical EngineeringSenior Design Projects

Project 1: AqualizerCompany: Students: Nicholas Garbe

Neil Morrical

Time: 9:05 – 9:25 a.m.Location: 221

Faculty Advisor: Dr. Miller

Description: An Aqualizer produces luminous jets of water patterned in response to an arbitrary audio signal input. This input can come from a device such as a CD player, computer, stereo, microphone, musical instrument, etc.

Project Objective: Successful DSP of an audio signal to actively control a water fountain with variable valve and lighting control. Device to be implemented for use in home entertainment applications.

Project Summary: Through the application of a multiple filter thick film circuit, the incoming signal will be received by a microcontroller through an analog to digital converter. This microcontroller, which utilizes an application-specific algorithm, will provide controls signals to the servo valves and LED configurations in order to provide a water and light display. This water and light display will be synchronized with the audio signal frequency spectrum. In addition to entertainment purposes, this device could be implemented in conjunction with a powerful bass sound system to enable the hearing impaired to enjoy music-based entertainment.

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Project 2: Grill MonitorCompany: Students: Michael Freeman

Ruben MoralesChristopher Williams


Faculty Advisor: Dr. Reza Hashemian

Description: We plan to design a system that will continuously check the temperature of the grill so the user will not have to. Instead, the monitor will alert the users, if the grill requires attention. The chef will have a remote with them that will alert them when the temperature drops below the temperature set on the console.

Project Objective: To design a device that will wirelessly alert a user if the temperature of the grill falls outside of a desired range.Project Summary: The user will adjust a potentiometer to a desired grilling temperature. A temperature sensor will then monitor the temperature of the grill. If the temperature falls outside the range set, then it will trigger an rf transmitter to send out a signal, which will be received by an rf receiver, which the user will keep with them. When the receiver detects a signal, it will set off an alarm, alerting the user to tend to the grill.

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Project 3: IEEE Micro MouseCompany: Students: Matt Bowers

Mitch ButtonRobert MaroldRyan Satterlee

Time: 9:55 – 10:15 a.m.Location: 221

Faculty Advisor: Dr. Zinger

Description: The micro mouse must be self-contained, and no larger than 25 cm in length or width. There is no restriction on height. The micro mouse can not scale or destroy the walls of the maze. The micro mouse competition is an event in which small robotic mice solve a 16 by 16 maze consisting of unit squares that are 18 cm by 18 cm.

Project Objective: The objective of this project is to design a small robot within the above specifications that has sensing and decision making capabilities. We are going to integrate a microcontroller, sensors, and motors into the robot.

Project Summary: Our micro mouse is capable of traversing a mock-up 3/8 size maze. The robot can make all decisions to explore the entire maze. The robot is capable of correcting for all mechanical and electrical errors through feedback from the sensors. This feedback is sent to the microcontroller and this data is used to control motors of the robot.

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Project 4: Ion Beam Sputtering System ReconstructionCompany: Students: Erik Hohenberger

Admad KashaniJohn Vanderford

Time: 10:20 – 10:40 a.m.Location: 221

Faculty Advisor: Dr. Alan Genis

Description: To rebuild and improve the Veeco ion beam sputtering system. The deposition system and it’s power supply were in a fire 2 years ago, and has not been functional since the day of the fire. The main purpose of this project is to rebuild the power supply and deposition system and bring it back to a working order while adding a computer interface for power supply.

Project Objective: To rebuild the deposition system and have it hold a proper vacuum, rebuild the power supply for the argon ion beam, and add a computer user interface for sensing elements of the power supply.

Project Summary: Rebuild the IBS system to operational condition for student use. Develop new sensors and a new user interface to monitor operational parameter (i.e. current density, beam current, filament life.)

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Project 5: ARKS: Advanced Remote Keyless SystemCompany: Students: Raheel Arshed

Dominik DukalaMondi MiminiHassan Shoukry

Time: 10:45 – 11:05 a.m. Location: 221

Faculty Advisor: Dr. Haji-Sheikh

Description: Today’s cars come equipped with an advanced intelligent key system that allows the car to sense the user’s approach and thus unlock the doors. This concept triggered our minds to build our own cost effective system and install it on a 2000 Chevrolet Camaro.

Project Objective: To design, build and implement an Advanced Remote Keyless System (ARKS) that allows the user a proximity door lock/unlock at a cost effective price.

Project Summary: The ARKS consists of two main systems. A transmitter attached to the car keys, and receiver installed in the car. The transmitter sends at a certain range an AM signal to be picked up by the receiver. As a result, the car will lock/unlock.

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Project 6: 3-D Rotating LED DisplayCompany: Students: Michael Dziewonski

Jason Manning

Time: 1:05 – 1:25 p.m.Location: 221

Faculty Advisor: Dr. Miller

Description: It is basically a spinning platform with multiple light bars controlled by a PIC microcontroller. We hope this will produce a 3-D image.

Project Objective: Our objective is to apply the knowledge we have accumulated within the classroom to design and construct a working 3-D Rotating LED Display.Project Summary: The Project contains a Matrix of LED’s which are implemented on a rotating platform used to display 3-D images.

Project 7: Wireless Multi-Device ControllerCompany: Students: Charles Hannah

Scott Weiss


Faculty Advisor: Dr. Hashemian

Project Objective: To wirelessly control on, off, or dim functions on multiple devices such as lights and other home devices. With cost at a minimum we plan to set up an alternative to expensive home automation systems.

Project Summary: Using a microcontroller and a transmitter in the remote we will be able to send multiple unique signals to numerous modules. The modules will be able to receive, decode, and perform the appropriate function on the device simply plugged into it.

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Project 8: The Electronic Tip UpCompany: Students: Matt Sassenrath

Steve Vaccaro


Faculty Advisor: Dr. Tahernezhadi

Description: The scope of this project is to design a tip up that is resistant to impact and notifies the fisherman immediately when there is a fish on the line, through a transmitter and receiver. The exterior will be painted with a bright color, and a light will be attached on top of the tip-up flag, each is done to be visible at night.

Project Objective: To build an ice fishing tip-up with a solid exterior and a transmitter.

Project Summary: An ice fishing tip-up with transmitter on it to immediately inform the fishermen of a fish on the line. Everything will be enclosed by a sturdy exterior that is built out of wood which will be visible at nigh, by means of a light and a fluorescent color.

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Mechanical EngineeringSenior Design Projects

Project 1: TTX Torque Measuring BolsterCompany: TTX Students: Gleb Maksimov

Corine McNamara


Faculty Advisor: Dr. Fallahi

Project Objective: To modify an existing bolster so it will be able to measure the torque, lateral and vertical loads on bow-liners.

Project Summary: The main goal of this project is to model and design a bolster that is capable of measuring torque, lateral, and vertical loads. Currently bolsters are used on all TTX freight trains and it connects the two side frames of the car that hold the wheels and add support. On the car type of interest, a 125-ton articulated double stack care there is one truck, containing a bolster, two side frames, and a set of wheels in between a set of two cars. A bow-liner is inserted in the center bowl of the bolster. The articulated cares currently use plastic bow-liners that wear out quickly. In order to switch to metal bow-liners, which are used on various other trucks, the forces in the uncoated metal the coated metal and the plastic liners must be compared. In order to do this, an existing bolster was modified to hold a strain-gauged cylinder that is able to measure all the forces going throw the center bowl and the liners. A box was then signed and built to put the strength back into the cutout bolster. This design was drawn in AutoCAD and modeled in SolidWorks. Then extensive studies in Cosmos were performed to measure the bolsters ability to carry the necessary loads. The device will be tested in Pueblo Colorado at TTCI. The truck containing the modified bolster will also be equipped with existing instrument wheel sets to measure the forces in the wheels. The car will go through several tracks empty and loaded and the results form the three liners will be compared. In order to switch to the uncoated metal liners they prove to be safe by the railroad criteria.

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Project 2: SAE Mini Baja Drive-TrainCompany: Students: Antonio Cabezas

Jason CasperVince ChurchillRyan Pasturczak


Faculty Advisor: Dr. Payvir

Project Objective: To design, build and assemble the various drive-train components for the NIU SAE Mini Baja vehicle

Project Summary: Acquire a Motor, CVT, Gearbox, Differential, Drive-shafts and other necessary components from vendors. Modify purchased equipment to suit application. Perform DOE analysis to tune CVT components as well as drive-train sprockets in order to maximize vehicle efficiency. Perform FEA analysis on all modified/created parts. Assemble drive-train as part of entire SAE Mini Baja vehicle, perform vehicle testing and attend competition in May.

Project 3: Automatic Locking KneeCompany: Students: Brian Biskie

Matt McWhirterPurvesh PanchalKarly Perry

Time: 9:55 – 10:15 a.m.Location: 101

Faculty Advisor: Dr. Song

Project Objective: To design a reliable dynamic automatic locking knee mechanism for substitution into existing KAFOs, as well as to redesign the Fillauer Swing Phase Lock

Project Summary: We will research gait and orthoses for the development of a new automatic locking knee mechanism, with the primary goal of guaranteed locking at all instances of foot contact. A parallel objective will be to reverse engineer the current Fillauer Swing Phase Lock (SPL) and to understand the principles governing joint movement. Design recommendations for improved cost effectiveness and reliability will then be applied.

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Project 4: Hamilton Sunstrand Deaerator ProjectCompany: Rockford Hamilton Sunstrand Students: Park Seong Cheol

Jon DavisMohamed KandilArika Swanson

Time: 10:20 – 10:40 a.m.Location: 101

Faculty Advisor: Dr. Majumdar

Project Objective: To devise a method for controlling the oil level in the dynamic tank while further learning about the deaerator concept.

Project Summary: The concept of a deaerator is to separate two distinct fluids. In our case, we want to separate oil and air from each other. The obstacle we are facing in our test setup is that the oil level in the dynamic tank where the deaerator resides, often times rises above safety levels, causing the oil to eject in a hazardous manner. We want to control this oil level such that testing will continue without safety being compromised.

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Project 5: Freecoaster RedesignCompany: Students: Marcus Guethle

Adam Julkowski

Time: 10:45 – 11:05 a.m.Location: 101


Project Objective: To build a bicycle freecoaster hub that is more adjustable and reliable than current models.

Project Summary: The basic operating mechanisms for the freecoasting function were analyzed and ideas were assembled to improve the functionally in a new design. The spring geometry and the adjustable slack function were found to be the key components of the redesign. The hub was designed and built and then the design was evaluated.

Project 6: Crutch DesignCompany: Students: Carolyn Martin

Julia NittiAny RzewnickiKo Chang Soo

Time: 11:10 – 11:30 a.m.Location: 101


Project Objective: To design a crutch that creates straight-line motion.

Project Summary: To redesign an under the knee crutch utilizing Robert’s four-bar linkage. The straight line motion of the design will eliminate the arching motion, and provide a more energy efficient crutch. This design will try to incorporate a hands-free mechanism allowing the user to be more active and productive.

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Project 7: Vactor Hose Reel CoverCompany: Students: Chris Cuva

Nicholas GregersonJeff Kennedy

Time: 11:35 – 11:55 a.m.Location: 101


Project Objective: To design the hose reel cover on Vactor’s 2100 series trucks.

Project Summary: Completely redesigning the current four piece covering system. The new design will be made of a different material, and be more aesthetically pleasing and cost effective. Some of the separate pieces will be combined and the fastening system might also be redesigned.

Project 8: Ethanol StillCompany: Students: Lusi Demers

Benjamin GriggBruno OlimeneBrandon Wallace

Time: 1:05 – 1:25 p.m.Location:

Faculty Advisor: Dr. Handelsman

Project Objective: Produce five low maintenance ethanol stills for the village of Ruwa, Zimbabwe. Project Summary: Ethanol is a clear, colorless alcohol fuel made form sugars found in grains, such as corn. The project objective is to produce 5 or more ethanol stills for the people of Ruwa, Zimbabwe. The production of ethanol on-site in the village will help the people of Ruwa cut down on the amount of fuel lost to thieves and political leaders. Corn is an abundant crop in rural Ruwa, Zimbabwe, as is wood, which will be used as a fuel source in the production of ethanol.

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Project 9: Universal snap-back aircraft towbarCompany: Students: Paritosh Patel

Fabrice Tefoung



Project Objective: To build an ice fishing tip-up with a solid exterior and a transmitter.

Project Summary: The objective is to design a universal aircraft towbar with a snap back feature, which will prevent costly damage to the nose wheel assembly. The snap back feature is a safety mechanism that will allow the towbar to bend once the torque limit has been reached. The towbar will also include a universal head, which allows the towbar to be connected to different types of nose wheel assemblies on a variety of airplanes. Requiring the towbar to be able to be connected to different types of airplanes, the snap back feature will have to be adjustable to accommodate different breaking strengths of the nose wheels.

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Project 10: Stroller with detachable car seatCompany: Students: Scott Daniel

Jeremy Garrett Ki-Sik KimPat Moran



Project Objective: To create a folding baby stroller frame that can hold any car seat.

Project Summary: An easy way to use a baby stroller, that can hold any car seat to make transporting of children easier from the car to the stroller. Without having to take a child out of a car seat and place into a stroller. This convenient combination will make it far less time consuming to make the transition complete .

Project 11: Antarctic Winch Deployment SystemCompany: Students: Brian Chandler

Mike Herzog George Lawson



Project Objective: Design a Winch and deployment system for the Antarctic Research Team.

Project Summary: Design a hydraulic winch system for the Antarctic research team to use in their experiments. Winch system must support 20,000 lbs., be able to lift 15 m high, 12 feet out, and fit in an ISO container for easy shipping. Deployment must be simple and able to be done by 3-4 researchers. Design must not be excessively complicated in case repairs are needed to be made in the field.

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Project 12: Vactor Door PropCompany: Vactor ManufacturingStudents: William Dunn

Jong-Sung ParkJacob Schultz



Project Objective: To redesign rear door prop due to safety concerns.

Project Summary: Redesign of the rear door prop on Vactor’s Manufacturing’s trucks. Currently the prop is in an unsafe place causing the user to get between the door and the truck to deploy the prop. Vactor has asked that a new design be created that eliminates this threat of injury but retains functionality.

Project 13: Design of Formula SAE Engine ComponentsCompany: Students: Kevin Benoit

Erik Gotlund



Project Objective: Design of intake manifold, fuel injection system, fuel and ignition programming, exhaust system, and structural oil pan for Formula SAE racecar.

Project Summary: This project will focus on designing an intake manifold, and fuel injection system for a 600cc 4-stroke engine used in the Formula SAE competition. Simultaneous design of the exhaust primaries and fuel and ignition map programming will allow for finite and physical testing of the entire system. In addition, a baffled and structural oil pan will be designed to prevent oil starvation issues under hard cornering. Final assembly will include integration with Formula SAE drivetrain and chassis.

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Project 14: Jet Engine from TurbochargerCompany: Students: Nicholas Augustyniak

Adam DoerrKyle Hurstik


Faculty Advisor: Dr. Payvar

Project Objective: Our objective is to develop a working jet engine using a vehicle turbocharger.

Project Summary: The project will consist of using a standard vehicle turbocharger as the compressor and turbine section of a jet engine. The main components that need to be designed are the fuel, oil, and control system, and the combustion chamber and the nozzle. The engine will be used to create a usable thrust.

Project 15: Brookfield Zoo Bear Enrichment ProjectCompany: Students: Dong Cha

Eric KreutzerNate Sroka


Faculty Advisor: Abe Singh, Tim Sullivan

Project Objective: To stimulate real wildlife conditions via lair crashing in an enclosed exhibit.

Project Summary: Develop a lair crashing system that can mimic real life conditions for the bears. Primary concerns will be: implementation, ease of use, how the bears will react to this system, safety for the keeper and the animals.

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Engineering TechnologySenior Design Projects

Project 1: Steel DrumCompany: NIU Students: Daniel J Brey

Kyle F ShanleyAdam R Theis


Faculty Advisors: Dr. Mirman, Dr. Azad,

Project Objective: - To create an electronic replica and/or substitute for a steel drum. - To be more affordable than current steel drums

Project Summary: The technological sprawl of the 21st century demands availability of ethnic instruments to studio musicians and the public. Few islanders presently construct steel drums; making it a rare and expensive instrument to procure. Our project helps by providing one possible alternative.

The goal of this project was to develop an electronic version of a musical steel drum. A system capable of producing MIDI (Musical Instrument Digital Interface) messages was developed to achieve this goal. MIDI is a system used to specify the actions of a synthesizer or other MIDI capable electronic device through digital messages sent to those devices. The synthesizer can be configured to replicate musical notes; for example the notes of a steel drum. The main parts of the electronic system include; 8 force sensing resistors, signal conditioning components, a microcontroller based sensor to MIDI interface, MIDI cables, and synthesizer. The signal conditioning consists of placing the FSR in a voltage divider that feeds a comparator. This allows denouncing and adjustable threshold.

When struck, a force sensing resistor signal is sent through signal conditioning components to produce a logic level high pulse. The sensor signal is then sent to one channel of a controller capable of producing MIDI messages. The MIDI message is then sent to a synthesizer or other capable device to replicate the sound of a steel drum. The note is heard through speakers attached to the synthesizer. The system is equipped with 8 sensors and is thus capable of producing 8 discreet notes. These notes can be programmed but are not user programmable.

Physically the project consists of a circular enclosure 4” high and about foot in diameter with a small tab for connectors. The sensors are mounted on the top like a steel drum is arranged and midi cables to connect to a synthesizer or an interface to a computer are provided. A Led on top indicates proper working condition.

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Project 2: Compound Parabolic Concentrator for Crop Drying (Solar Crop Dryer)

Company: Students: Brandon J Borgman

Justin T Masters Stephen M Toth

Time: 9:55 – 10:15 a.m.Location: 311

Faculty Advisor: Dr. Tatara

Abstract: Our group has begun research on a sustainable crop drying solution. The scope of our research focuses on the feasibility and practicality of using Compound Parabolic Concentrator (CPC) technology to dry crops. We will test the effectiveness of the CPC to dry crops by building a prototype crop dryer with two key parameters. First, the machine will be completely mechanical and sustainable. This means that the CPC crop dryer can not depend on fuel or electricity to run. Second, the moist crop must enter into the machine, advance through the concentrated light, and exit with reduced moisture content. In the event that the prototype is a success, we have created advanced designs for a full scale CPC Crop Dryer based on the initial design of the prototype. This larger machine was designed to be easily assembled right out of the box, and is constructed out of durable, machine-able, affordable materials.

Projective Objective: Determine the feasibility and practicality of using Compound Parabolic Concentrator (CPC) Technology to dry crops.

Project Summary: Determine a prototype CPC Crop Dryer, test with the prototype, collect data, and then, refine the initial design based on collected data.

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Project 3: Basic Utility VehicleCompany: Students: Daniel G. Donovan

Joshua L MalmassariDoug K MeenanJohn Z White

Time: 10:20 – 10:10:40Location: 311

Faculty Advisor: Dr. Otieno

Project Objective: The objective of the Basic Utility Vehicle is to design a low cost yet versatile all-terrain vehicle for third world countries.

Project Summary: Our senior design project consists of the design and fabrication of a Basic Utility Vehicle (BUV). The vehicle cannot exceed 12 horsepower and must have a minimum payload capacity of 1100 pounds. The concept behind the BUV is to design a vehicle that is inexpensive, capable, and reliable for third world countries; our design is specified for Africa. The Institute for Affordable Transportation (IAT) has been sponsoring the Basic Utility Vehicle Competition in order to find better designs to improve transportation in third world countries. This vehicle will be entered in the annual BUV competition in Indianapolis on April 28th.

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Project 4: Caterpillar Tire Assist MechanismCompany: Caterpillar Students: James P Holmstead

Adam J Kearns

Time: 10:45 – 10:05 a.m.Location: 311

Faculty Advisor: Dr. Mirman

Abstract: We are building a tire manipulation mechanism to flip the tires from their sidewalls up onto their treads. The mechanism will utilize an overhead crane within Caterpillars facility. The station attendant will then be able to use the overhead crane to flip the mechanism, which is mounted to the floor with 3 pivot brackets. This will eliminate the need for a specialized forklift operator to be on call when the attendant needs the tires orientated, and this will also eliminate possibility of injury to the station attendant.

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Handout 050107

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