Senior Design Book 2018 · Technology Spectrometer (Sponsored by LEDIL) Jason Kors, Christian...

Fall 2018

Senior Design Book

Fall 2018

Building the Functional Engineer

When engineers and technologists graduate from NIU, they are ready to walk into their new jobs and get

right to work. That’s because we are committed to giving students the tools and experience to be functional

engineers. From the start, they are exposed to real-world, everyday problems they must solve by putting

theory into practice.

Senior Design is the culmination of this experience. This is senior students’ chance to prove they have

learned; more formulas and theories, to identify a problem and innovate a solution, to build a prototype, and

to communicate their ideas. This book describes the Senior Design projects of the Fall 2018 senior class.

Congratulations to our seniors. Whether you are continuing your studies in graduate school or stepping into

the workforce, you are a proud representative of NIU and your future success is a testament to

#WhyEngineering.

#WhyEngineering #SeniorDesign

Bridging Theory with Practice

Electrical Engineering

Automatic Resistor Sorter Nathaniel Ambler, Joshua Kitterman, Zhaobang Xue, Robert Widick Project Advisor: Mr. Edward Miguel

URI-DOC Dominick Glatz, Nelson Pena Rodriguea, Kurt Widhalm Project Advisor: Dr. Venumadhav Korampally

Big Data Weather System Nicholas Marc, Michael Niewinski, Ellen Schwarzwalder Project Advisor: Dr. Wei Li

Free Flow Fahad Balateef, Muhammed Diallo, Nasiruddin Jamali, Rashed Alghayadh Project Advisor: Dr. Donald Zinger

Design A Solar Panel for the Glidden Museum Salman Alzobidy, Alexander Savitt, Majed Alanazi, Joshua Nilles Project Advisor: Dr. Donald Zinger

3D EM Tracking (3D Stylus) Donald Krambeck, David Dobrzynski, Daniel Graunke, James Shulgan Project Advisor: Dr. Veysel Dimir

Leap Motion Sign-language Translator Murray Fordyce, Andrew Murphy, Marianne Gueieb, Peter Cole, Stephen Binderup Project Advisor: Dr. Donald Peterson

NIU CEET Antenna Measurement Set-up Mary ChristelleAnn Calacal, Brandon Palfalvi Project Advisor: Dr. Veysel Dimir

Projects By Department

Mechanical Engineering

Arc Jet Malachi Vachon Fischer-Porter, Daniel Bruce Trygstad, Michael Joseph Zawadzki Project Advisor: Dr. Donald Peterson

Perfusion Bioreactor Giovanni Garcia, Dominique Cecile Greeno, Fabian Carlos Gutierrez, Giovanni Pacheco, Ryan Paggao Project Advisor: Dr. Sahar Vahabzadeh

Haptic VR Anna Raoling Green, Nicholas A. Napolitano, Joseph Vincent Sarna, Robert William Steiner Project Advisor: Dr. Sachit Butail

Custom Brake Cooling System Daniel Adam Freigo, Adam Matthew McNally Project Advisor: Dr. F. Sciammarella

CAT 836K cleaner finger optimization (Sponsored by Caterpillar Inc.) Solomon James Sawlaw, Justin Thomas Clausen, Dakota Krokosz, Nicholas Dean Weaver Project Advisor: Dr. Iman Salehinia and Dr. F. Sciammarella

SBICM Flavio Jonuzaj Sr., Matthew James Lueck, Brandon Matthew McTaggart, Harsh M. Patel Project Advisor: Dr. Bobby Sinko

Oxygen assitance device for SCUBA Hamad Yousef Alghayadh, Khalid Abed S. Almehmadi, Mustafa Altermathy, Nathan James Zellak Project Advisor: Dr. Kyu Taek Cho

Semi-Autonomous Lake Monitor (Sponsored by IDEAL) Ian Jeffrey Kidd, Mhariel Valmadrid Pastrana, Ian Daniel Schabel, Benjamin Joseph Ziegler Project Advisor: Dr. Ji-Chul Ryu

Freedom Project Catherine Ann Canciamille, Jennifer Robles, David Andrew Williams Project Advisor: Dr. Sachit Butail

Projects By Department (continued)

SRCV - Sewer line cleaning vehicle Mark Daniel Alvord, Eric Angel Garcia, John Mateusz Nowobilski, Miguel Rodriguez Jr., Ryan Darryl Smith Project Advisor: Dr. Ji-Chul Ryu

Humidifying Incubator Shaker David Michael Kaliniec, Erick Miguel Gonzalez, Collin Blake Seidelman Project Advisor: Dr. Sahar Vahabzadeh

Shadow Track (sponsored by Shadow Track) Benjamin Cuauhtemoc Bentley, Mark Benjamin Lafrentz, Daniel Nevarez, Benjamin James Starcevich Project Advisor: Dr. Ji-Chul Ryu

Hybrid Collector Anthony Greco, Timothy Joseph Jackimek, Johnathan Christian Oberlander, Samuel James Schmalz I, Arsensio Young Sun Aguilera Project Advisor: Dr. F. Sciammarella

Mobile Dynamometer Station for STEM Outreach (sponsored by Genesis Automation) Kyle Thomas Sullan, Ryan Michael Bielman, Jeffrey Thomas Good, Michael Vincent Koeplin Project Advisor: Dr. F. Sciammarella

Project Icarus Amro Abdulmutalib Shanshal, Patrick Daniel Maglaya, Joshua E. Marble, Oscar Barba Project Advisor: Dr. Brianno Coller

Industrial & Systems Engineering Increasing productivity of the Stone Assembly line at SPX FLOW (Sponsored by SPXFLOW) Abdullah Alhajji, Sonja Marquette Project Advisor: Dr. Purush Damodaran and Dr. Christine Nguyen

Designing a cell for LPC Metering (Sponsored by WOODWARD) Gilbert Bwetabure, Joshua Moore, Parth Thakkar Project Advisor: Dr. Purush Damodaran and Dr. Christine Nguyen


Technology

Spectrometer (Sponsored by LEDIL) Jason Kors, Christian Morales, Kamil Polniak Project Advisor: Dr. Mills and Dr. Martin

Weber Grill Annalyssa Bell, John Mayer, Erik Osterby Project Advisor: Dr. Andrew Otieno

Electronic Knee Walker Farhan Alghamdi, Arturo Avila, Isaias Cervantes, Stephen Slager Project Advisor: Dr. Ted Hogan

Auto Water Spray Booth Tim Fisher, Mike O' Malley, Erich Wenzel Project Advisor: Dr. Rao Kilaparti

Interdisciplinary (Mechanical & Electrical)

CIS Mobility Michael Bockwoldt, Michael David Duda, Hnin Eaindray Lin, Matthew Joseph Martone, Jazael Medina, Nathan Alexander Luptak, Fahad Mohammedhussein, Mary Carter, Mark Pacyga, William Dedic Project Advisor: Dr. Donald Peterson

Magnetic Pulse Welding (Sponsored by UTC Aerospace Systems) Eric Walchli, Syed Sabeel Hasan, Lauren Anderson, Jeremiah Rodriguez Project Advisor: Dr. Eric Karlen and Dr. Donald Zinger


Electrical

Engineering

Team Members: Nathaniel Ambler, Joshua Kitterman, Robert Widick, Zhaobang Xue

Project Advisor: Mr. Edward Miguel

Automatic Resistor Sorter

Sorting piles of unknown or misplaced

resistors can be a real mind-numbing

task. Measuring resistor values using a

multi-meter or color codes can be time

consuming and inaccurate. A device that

would allow the user to accurately

measure and sort such values quickly and

efficiently could not only save time, but

money as well.

Problem Statement

• Ability to accurately read resistor

values with <1% error using a

custom designed ohmmeter

• Fast and efficient sorting method (2-

3 second sorting time per resistor

read)

• Create a user interface that is

seamless and user friendly

• Device should be portable in size

and fit on a small table or countertop

Design Tasks

The custom ohmmeter allows for

accurate resistor reading with <1% error.

The user interface allows for profiles to

be created with up to 8 resistor values to

use for sorting. The compact design and

simple interface allows for hobbyists and

lab technicians to setup and operate the

device with ease.

Final Design/Deliverables

With no similar product on the market

currently, the Automatic Resistor Sorter

would be immediately marketable. Cost

of production for the prototype model

slightly exceeded our expected budget

of $150. A final production of the device

could be expected to cost $75 - $125,

allowing for an economic sorting

implementation.

Business/Cost Analysis

Image #2

include labels and explanations of

what we are seeing

Fall 2018

CAD model Circuit schematic

Team Members: Dominick Glatz , Kurt Widhalm, Nelson Rodriguez

Project Advisor: Dr. Korampolly

Uri-DocUrinalysis Diagnosis On-Command

Problem Statement

The goal is to create a device which

takes a noninvasive sample from the

patient and analyze it for signs of

illness. This can be done by assessing

color of the sample, such as in a

spectrometer. As the absorbance band

of our target substance increases, the

need to seek treatment also increases.

Salinity and pH of the sample may be

used as a reference to better diagnose

the cause of illness.

Design Tasks

Final Design/Deliverables Business/Cost Analysis

Fall 2018

Figure 2. Absorbance Circuit

Prototype

How can we quantitatively measure

kidney health? Illnesses of the kidneys

necessitate dialysis to remove toxins.

However, dialysis is a lengthy and

expensive treatment. By measuring

urine pH, salinity, and testing for the

presence of Blood, we can help

physicians schedule dialysis

treatments for patients living far from

a medical facility.

In our final product, we were able to

detect the biomarker Hemoglobin, a

protein present in blood, using specific

light absorbance. In concurrence with

pH and salinity, this data can be used

to determine if a patient’s kidneys are

damaged, or if they require dialysis.

The goal was to create a device which

could diagnose kidney damage for less

than the cost of a physical exam. Data

obtained by our device will serve

physicians by suggesting care if the

results are out of a healthy range.

Cost: $153.34

Figure 3. Light absorbance of Hemoglobin, Pure and Doped w/ Yellow #23

Figure 1. 3D Model of Final Device

A97-B101-C103

Team Members: Nicholas Marc, Michael Niewinski, Ellen Schwarzwalder

Project Advisor: Dr. Wei Li

Big Data Weather System

Research grade weather stations are

too costly to be able to place in

concentrated areas. This leaves large

coverage gaps in weather data.

Current alternatives such as

commercial data networks and at

home weather station networks do

not adequately solve this issue.

Problem Statement

Design a low-cost, high accuracy

weather station that can be placed in

concentrated and coordinated areas

to create a network, allowing for

mass data collection. Station must

be able to power itself and must

have access to communications.

Design Tasks

Designed a weather station

consisting of group designed

pyranometer, aspirated radiation

shield, wind speed and direction

sensors, power system with solar

panel, that is controlled by a

microcontroller, and uses WIFI.


Big Data is a growing industry that

in 2016 was a 130-billion-dollar

industry. The data from our weather

station, could be packaged and sold

to researchers, government entities,

and businesses interested in

analytics.


Fall 2018

Level 1 Design of BDWS. This shows how all the major components of the BDWS interact.

Shows how BDWS network can fill in large uncovered areas from systems like the ASOS.

Team Members: Fahad Balateef, Muhammed Diallo, Nasiruddin Jamali, Rashed Alghayadh

Project Advisor: Dr. Donald Zinger

Free-Flow

Frozen pipes can cause sever damage

to homes accompanied by costly

repairs. Current market solutions are

expensive and not always reliable.

With our project Free-Flow we hope

to provide a reliable and cost-

effective solution to give home

owners a peace of mind.

Problem Statement

• Prevent pipes from freezing

• Monitor the temperature of

pipes within the home

• Simple setup and operation

• Reliable solution

• Cost and Energy efficient

Design Tasks

• Radio frequency system that is

integrated with temperature

sensors and flushing actuator

• Power reliability through multiple

device powering options

• Operates in different homes


• Cost around $25 to make (per set

of 3)

• Sell for $50

• Save on energy bill

• Save hundreds of dollars in

repairs


Fall 2018

Middle RF

communication

(Node MC)

Temperature

Sensor

(Node TS)

Flushing Actuator

(Node FA)

Node(s) TS senses the temperature and RF

communicates with Node MC. When temp nears

freezing, then Node MC communicates with Node

FA to flush the toilet. Causing the water in the

pipes to circulate and not freeze.

An example representation where the different

nodes will be placed within a home.

Team Members: Salman Alzobidy, Alexander Savitt, Majed Alanazi, Joshua Nills

Project Advisor: Dr. Donald Zinger

DESIGN A SOLAR PANEL MICROGRID FOR THE GLIDDEN MUSEUM

The Glidden family has reached out to

NIU requesting assistance into a

renewable energy source for their newly

renovated museum. Also, Dr. Zinger has

requested a low voltage inverter that he

can use in his lab.

Problem Statement

• Design solar panel microgrid that

capable of running the museum

• Provide alternative options for the

energy storage

• Build prototype for our microgrid

• Design control system for the

prototype

• Design a low voltage DC/AC

inverter with input 12Vdc and output

120Vac

• Build the low voltage inverter

Design Tasks

For the final design, there are three

energy sources: solar panels, battery

storage and the A/C power grid. The

main source of energy is the solar panels.

The design of the solar panels is to

provide the museum with enough power

to properly function for the entire year.

In the event the solar panels do not

produce the needed power, the museum

will be powered by the battery storage.

The microgrid will also be connected to

the A/C power gird as an additional

power source. With the project in hand,

the DC to AC low voltage inverter is the

combination of the doublar voltage

design and H-bridge design given the

input of 12V D/C and an output of 120V

A/C.



System, component and load design DC/AC low voltage inverter design

Fall 2018

The cost for DC/AC low voltage inverter

approximately was 171.75.

Component Price

Solar Panels $98910

Battery Storage $52867.7

MPPT $725.84

DC/AC Inverter $2250

2 DC/DC Buck Converter $1000

DC/DC Boost Converter $500

Total $ 156254

Team Members: David Dobryznski, Daniel Graunke, Donald Krambeck,

James Shulgan

Project Advisor: Dr. Veysel Demir

3D Electromagnetic Tracking

The majority of modern 3D graphic

design is done by either manipulating

2D drawings to create 3D models or

using digital sculpting software. We

aimed to fill the current market gap for

an affordable and intuitive tool that

would create digital free form 3D

sketches drawn directly in physical 3D

space.

Problem Statement

● Must be able to detect stylus within

a 6 x 6 x 4 in. volume.

● Accuracy of digital stylus position

must be within 3 mm.

● 3D tracking must be within 15-20

ms between actual and digital

stylus position.

● Stylus incorporates two buttons for

an easy to use and intuitive

experience.

Design Tasks

3D stylus uses a 125kHz voltage

signal to induce a voltage across an

array of 36 sensor coils through EM

induction. These voltages are

measured by the Arduino and used

by Processing to determine the

position and movement of the pen.


Cost for production can remain

under $100.00. Our project utilized

educational benefits for enclosures

and stylus which would vary end

cost. This proof of concept can

extend to multiple facets of tracking

technology as well as provide an

intuitive tool for Graphic Designers

and 3D modeling.


Fall 2018

Figure 1. Envisioned Product Figure 2. Signal Transmission and Detection

Team Members: Stephen Binderup, Peter Cole, Murray Fordyce,

Marianne Guieb, Andrew Murphy

Project Advisor: Dr. Donald Peterson

Leap Sign Language Translator

People living with disabilities require

consistent and intuitive means to

communicate. Our client is a high

school student in Paw Paw living

with dystonia. We have been tasked

with creating a communication

solution to enable her to participate

in class, and socially with her peers.

Problem Statement

Our client’s preferred method of

communication is the American

Sign Language (ASL) alphabet. To

make our solution most natural for

her, we wanted to design around

this. The main goal of our project is

to create an interface that translates

hand gestures into letters, macros,

or commands

Design Tasks


Using a Leap Motion Controller, our

system takes in spatial data about the

user’s hands. This is then processed

with an AI model that determines

which gesture was probably made,

based on previously trained examples.

Our device functions standalone or as

a peripheral to a computer.

The importance of communication

to people with disabilities allows

companies to charge thousands of

dollars for systems like ours. Our

system costs only $600, which

offers a comparatively cheap and

effective alternative for individuals

who sign.


Fall 2018

Frame capture from Leap Motion Controller

visualizer software. This is how the Leap

“sees” the user’s hands.

In memory of Paul Strohman

Neural networks are arrays of nodes separated into layers:

an input layer, a hidden layer and an output layer. Through

linear algebra techniques, connections are made through the

hidden layer to make a decision at the output

Team Members: Brandon Palfalvi, Mary Calacal

Project Advisor: Dr. Veysel Demir

NIU CEET Antenna Measurement Setup

NIU CEET has an antenna

measurement setup within an

anechoic chamber for educational and

research purposes. This setup is

complex, outdated and is suspected to

be defective.

This project aims to build a new

antenna measurement setup It shall be

user friendly and cost effective.

Problem Statement

• Design the Transmission Module

• Design the Receiving Module

• Design the Antenna Rotator

• Design the Graphical User

Interface

• Write the Automation Software

• Testing and Validation

Design Tasks

An automated antenna

measurement setup is built. The

system is easy to understand and use.

The setup is also able to send the

radiation patterns to the user’s email

address for collection of

measurements.


This is a much less expensive

method of antenna measurement

compared to traditional methods. It

can easily be adopted by other

universities for their own purposes.

The total cost of the project is under

$2000.


Fall 2018

Fig. 1. The GUI used for the antenna measurement setup.

Fig. 2. An example of a radiation pattern generated by the measurement setup.

Mechanical

Engineering

Team Members: Michael Zawadzki, Daniel Trygstad, Malachi Fischer-Porter


Arcjet Electrothermal Rocket Thruster

Satellites have limited mission durations,

largely due to finite fuel. Fuel is critical to

maneuver and maintain correct orbit. Current

satellites often use chemical fuels, which are

inefficient. Arcjet engines use an electric arc to

heat propellant, which is more efficient than

other engine types but can be prohibitively

expensive.

The Arcjet team seeks to make an inexpensive

Arcjet thruster that is accessible to

manufacturers of low-cost microsatellites.

Problem Statement • Should yield at least 5% improvement

in specific impulse (fuel efficiency)

• Design of power management system

should be simple and reliable

• Cost of engine fabrication should not

exceed $1,000, with total prototype

system cost not exceeding $2000

• Engine should generate thrust in excess

of 100 mN, with an input of under

2KW of power

Design Tasks

An engine composed of AS-TJ isostatic

graphite, tungsten, PTFE (Teflon), stainless

steel, and MACOR ceramic was designed,

built, and tested. A TIG welder and automotive

ignition coil were modified to power the demo

engine. Test was run with argon propellant,

which yielded a specific impulse of 360

seconds. A specific impulse of 850 seconds is

possible if the Argon is replaced with

hydrogen, which yields a 283% improvement

over typical NTO/MMH chemical thruster

efficiency of 300 s.


This product targets the low-cost satellite

market. At a price of under $1,000 per unit,

it would allow small companies and

universities to use a more efficient engine

type. Significant improvements in mission

longevity and capability make this engine

very attractive relative to existing options.

This engine is sold at a 40% margin and

expected annual volume of 1500 units.


Fall 2018

CFD analysis (top) and physical test of engine (bottom) Production cost per unit (top) and diagram of engine layout (bottom)

Cold gas Chemical Arcjet

(Typical)

Arcjet

(Ours)

Ion engine

Engine $10,000 $30,000 $40,000 $1,000 $60,000

Launch

Cost fraction

$30,000 $25,000 $15,000 $15,000 $10,000

Total $45,000 $55,000 $55,000 $16,000 $75,000

Approximate Cubesat propulsion system cost (per engine, typical impulse and size)

Team Members: Giovanni Pacheco, Giovanni Garcia, Dominique Greeno,

Fabian Gutierrez, Ryan Paggao

Project Advisor: Dr. Sahar Vahabzadeh

Perfusion Bioreactor

Current perfusion bioreactors are

costly and many can only culture

cells on one sample at a time. Our

focus is to create a bioreactor that

can culture cells on multiple samples

to reduce cultivation time and cost.

By doing so, it will help advance the

tissue engineering industry to make

bone grafts more reliable and

obtainable.

Problem Statement

• Shear stress and pressure are

similar to the human body

conditions

• Multiple sample holders in the

chamber

• Sterilizable product

• Easily accessible sample holders

Design Tasks

• Multiple samples

• Properly emulates human body

environment

• No leakage in the system

• Optimal conditions on each

sample

Final Design/Deliverables Our perfusion bioreactor has a low

cost compared to other bioreactors.

Additionally, the ability to culture

multiple samples simultaneously

lowers the cost of cultivation. This

creates a new sector of the market

for cost effective perfusion

bioreactors.


Fall 2018

Perfusion Bioreactor System Single Sample Chamber vs Multiple Sample Chamber

Team Members: Anna Green, Joseph Sarna, Nicholas Napolitano,

Robert Steiner

Project Advisor: Dr. Sachit Butail

VR Haptics Glove

VR, Virtual Reality, is a rapidly

growing market. It currently only

employs the senses of sight & sound,

and the few technologies that

incorporate haptic feedback are

considered clunky and expensive to

develop with little knowledge if the

technology actually adds immersion

or benefit to the user.

Problem Statement

-Develop a glove that can interact in

a virtual world and offer the user a

physical feedback

-Create a lightweight configuration

for the electrical components

-Develop code to bridge VR

software with arduino

-Incorporate safety features

Design Tasks

-Glove created in order to keep all

components compact and lightweight

-Arm band designed to house larger

electronic components

-User study creates a metric of the

glove’s benefits

Final Design/Deliverables As a new market, the user study will

help determine if the haptic

feedback is worth the cost and effort

to continue further development.

This will give insight of the viability

of entrepreneurship for affordable

VR haptic gear aimed at a consumer

level market.

Business Opportunity Analysis

Fall 2018

Figure 1: Haptic glove and components Figure 2: VR user test environment

Team Members: Adam McNally, Daniel Freigo

Project Advisor: Dr. Federico Sciammarella

Custom Brake Cooling System

• Car overheating brakes past

600°F during heavy track use,

resulting in a near complete loss

of braking ability and reduced

brake component life

• No system available for specific

older model chassis from

automotive aftermarket

Problem Statement • Must allow for full steering and

suspension articulation

• Weigh under 10 pounds

• Must be able to leave system

attached for street use

• Longevity/Durability for life of

vehicle

Design Tasks

Design and create a tubing system

that collects and routes air from the

front of the vehicle to the front brake

rotors. The system lowered braking

temperatures an average of 165°F

while only adding 3 lbs to each side

of the vehicle.


With the estimated volume of

systems sold a year being fairly low,

the feasibility of producing the

systems only makes financial sense

if a shop that already exists takes on

the production.


Image #1

(Please also send the highest

resolution version of your pictures

separately with poster)

Image #2


what we are seeing

Fall 2018

Figure 1: Cooling System installed onto vehicle suspension assembly

Figure 2: IR camera image of heated brake rotor while testing system

Start upMachine

Shop

Tooling $5900 $400

Labor$20 per

system

$20 per

system

Materials $120 $100

Payback (100

systems a year

@ $200 each)

359

Days19 Days

Caterpillar: Confidential Green

Team Members: Justin Clausen, Dakota Krokoz, Solomon Sawlaw, Nick Weaver

Project Advisor: Dr. Iman Salehinia

836K Landfill Compactor Cleaner finger

Optimization

• Landfill compactor cleaner fingers are

critical to maintain traction and

productivity in a landfill application.

• Cleaner fingers act as mechanical fuse

to protect powertrain components.

• Current cleaner fingers are retained

with 3 M24 bolts.

• Cost to replace 836K cleaner finger is

$215 in material and 8 hours labor.

Problem Statement • Design of shear pin to allow cleaner

finger to fuse at 20% of maximum

wheel force.

• Design of supporting structure to

withstand required loading

• Reduce replacement time of fused

cleaner finger by 7 hours

• Retain cleaner finger on machine

until reinstallation can be completed.

Design Tasks

• Completed CAD design

• Complete FEA analysis to predict

component stresses and life

• Shear pin lab testing to validate

theoretical calculations

• 100 hour field trial to validate shear

pin performance and replacement

time

Final Design/Deliverables Total savings based on a failure of a

single cleaner finger per week on a

typical 836K application. Each 836K

has 32 cleaner fingers per machine.


Baseline design Improved shear pin design Non linear ANSYS simulation of shear pin fracture

Fall 2018

Baseline New Design Annual Savings

Material $215 Material $10 $10,660

Labor $960 Labor $120 $43,680

Total $1,175 Total $135 $54,340

Team Members: Flavio Jonuzaj, Harsh Patel, Matt Lueck, Brandon McTaggart

Project Advisor: Dr. Robert Sinko

Simulating Bio-Inspired Composite Materials

The Bio-Inspired Composite Materials project is

about investigating a material design mimicking a

naturally occurring internal structure, one that can

improve material properties through purposeful

design rather than material composition. The

primary experiment of the project is to compare

how laminates internally rotated to 0º, 90º, and 45º

compare in terms of stress, strain and elasticity,

terms which would be calculated from a tensile

stress experiment.

Problem Statement

• Create a purposeful internal structure based

off of a molecular structure design found in

mantis shrimp.

• Examine the changes in tensile properties

created by changing the internal structure.

Design Tasks

The results of tensile testing and FE simulation

showed a decrease in tensile strength as the

rotation of the layers increased even though there

was no change to the total infill or the material.

This has implications for tailoring tensile

properties of products to have things like safety

breakpoints. Further study of rotations and

comparison with infill changes could bring

additional design options to manufacturers.


This project shows that altering the internal

geometry, an option that is unique to additive

manufacturing, has the ability to change the

mechanical properties even without changing

materials, something that allows for cost and

time saving during production. While only one

small set of examples were examined here,

further research into these types of purposeful,

bio-mimicking designs could yield significant

advances in manufacturing capabilities.


Image #1




Fall 2018

Fig 1: The 3 designs of dog bones with the

layer orientation.

Fig 2: FE model of maximum deformation to

the 45 degree sample.

Team Members: Khalid Almehmadi, Hamad Alghayadh, Nathan Zellak,

Mustafa Altermathy

Project Advisor: Dr. Kyu Taek Cho

Oxygen Assistance Device for Scuba

(O.A.D.S.)

Scuba divers have limited time and

freedom of movement while underwater,

occasionally suffering fatal injuries due

to Oxygen deprivation. The designed

Oxygen Assistance Device for Scuba

extracts oxygen from water using the

concept of electrolysis, supplying it to

the Scuba diver in critical situations to

avoid injuries

Problem Statement

• Time studies

• Providing more time than spare tank

• Freedom of movement

• Decrease chances of fatal injuries

• Can reach the industry standard

depth for recreational diver limit

(127 ft)

Design Tasks

A diver typically consumes 137.28 grams

of oxygen per hour. By using a 12V

300A lithium ion battery, our device

produces 89.52 grams of oxygen per

hour, hence, the device generates oxygen

for roughly 40 minutes. Finally, the

device is compact and will not be a

hindrance to the movement of the scuba

diver when attached to the tank.


• The battery and Nafion membrane

are the most expensive components


Fall 2018

Internal view of electrolysis chamber 3D model of device

Height of

the tank

is 24

inches,

the

device is

14 inches

Team Members: Benjamin Ziegler, Ian Kidd, Ian Schabel, Mhariel Pastrana

Project Advisor: Dr. Ji-Chul Ryu

Semi-Autonomous Lake Monitor (SALM)

There are a high number of bodies of water

that are contaminated and undrinkable,

even in the US. According to USA Today,

over 10 million Americans are exposed to

contaminated water per year. This could be

prevented by monitoring and

decontamination. The team’s goal was to

create a method to continuously monitor

bodies of water in order to provide

actionable data for environmental

agencies.

Problem Statement

• Semi-autonomous for lakes,

reservoirs and rivers.

• System must be low-cost compared

to others on the market.

• System has interchangeable sensors

to meet customer's needs.

• Continuous monitoring and real-

time data collection and analysis.

Design Tasks

SALM accomplishes the following:

• Semi-autonomous

• Continuous monitoring

• Color mapping

• Real-time data collection

• Positional accuracy within 0.5 meter

• Easy-to-use graphical user interface

• Supports over 15 lbs.

• Cost: $5,000-6,000

The table shows the comparison of

SALM to existing products on the

market.


Fall 2018

Product Inter-

changeable

sensors

DIY Real-time

data

collection

Est. Cost

SALM $6,000

ASV C-Cat-2 $120,000

Otter $50,000


Figure 1: Initial CAD model of the SALM Figure 2: Final prototype of the SALM

Team Members: Catherine Canciamille, Jennifer Robles, David Williams

Project Advisor: Dr. Sachit Butail

Freedom Project

Individuals with Cerebral Palsy are often

wheelchair bound and sometimes have

very limited mobility. These individuals

still want to do things that they enjoy

such as photography and reading despite

their condition. A self leveling table,

phone holder, and storage container that

attaches to the wheelchair will allow

these individuals more freedom to do the

things they enjoy. Current wheelchair

attachments are expensive and the

designs do not consider individuals’

special needs.

Problem Statement

The wheelchair attachments must be

easy to use with only one hand without

putting any muscle strain on the client.

These attachments also must not cause

the client’s wheelchair width to exceed

32 inches so that it can fit through a

standard door frame.

Design Tasks

• Self leveling table that allows the

individuals to lean there chairs

forward and backward without stuff

falling off the table

• Phone holder that can comfortably be

used with one hand for photography

• Easily accessible storage container

that fits a tablet and wallet


Phone holders designed for electric

wheelchairs cost around $200 where our

design cost was around $50. Non

leveling table attachments cost around

$500 while the overall cost of the self

leveling table came out to $200. All of

these attachments allow the client

freedom and the ability to do tasks they

love which attachments on the market

do not allow. You can not put a price on

freedom


Image #1




Image #2


what we are seeing

Fall 2018

Figure 2: New Adjustable TableFigure 1: Previous Table

Team Members: Mark Alvord, Eric Garcia, John Nowobilski, Miguel

Rodriguez, Ryan Smith


The S-RCV team aims to provide a remote

control vehicle that can not only inspect sewer

pipes but bring multiple tools on board for

cleaning and removing blockages. Current

remote controlled vehicles are limited to

sewer inspection only as well as carry a high

price tag. The S-RCV will provide a lower

price and more capable machine for blockage

removal and inspection.

Problem Statement The S-RCV must be capable of:

● Navigating a 12 inch diameter sewer pipe

● Maintaining traction in wet and difficult

terrain

● Clearing both solid and viscous blockages

via rodding and jetting

● Maintaining an upright position

● Relaying location and movement of motors

to the user interface

● Vertical launch and retrieval from surface

level openings

Design Tasks

The S-RCV is capable of navigating in a dry

environment simulating an obstructed sewer

pipe. The S-RCV is capable of clearing

hardened blockages and simulated root build

up in a 12 inch cardboard and plastic pipe.

The onboard electrical system allows

monitoring of all motor movement as well as

positional and rotational movement. The user

interface allow control of rodding components

and directional drive of all wheels.


This prototype remote control vehicle comes

in at under $1200 for all components and test

environments. A final design of a water and

pressure safe vehicle with a stand alone

interface would be near $3000.


Image #2


what we are seeing

Fall 2018

S-RCV prototype with root saw attachment on the rodding

system allows for solid waste breakdown and cleaning.

Unique wheel design- the tapered profile gives high grip on

pipe walls and wedges vehicle under rotational forces. High

traction treads allow for navigation in messy conditions.

Vehicle Camera Jetter Rodder Price

S-RCV ✓ ✓ ✓ $3,000

LT2-F-W ✓ $20,000

SCT-32-

W

✓ $12,000

Team Members: David Kaliniec, Erick Gonzalez, Collin Seidelman

Project Advisor: Dr. Sahar Vahabzadeh, Dr. Ji-Chul Ryu

Humidifier Incubator Shaker

For biological and tissue engineers, in

vitro experiments require the control of

the environment. Most affordable

incubators on the market do not have the

ability to control the humidity inside the

closed environment. The humidity is

important to our client for cement

environment control applications. This

Humidifier Incubator Shaker offers an

affordable all in one system alternative to

this problem.

Problem Statement

• User ability to control shaker speed

up to 200 RPM

• User ability to control temperature

up to 80 °C

• User ability to control humidity

from ambient to 100% relative

humidity

• Display live feedback from sensors

within unit

Design Tasks

Humidifier Incubator Shaker’s features

include:

• User interface with large display

• Arduino controlled components

including motor, ultrasonic

humidifier, and heating element

• Temperature, platform speed, and

humidity control

Final Design/Deliverables The R&D, electronic components, raw

housing material, and fabrication cost of

the unit is $1,395. When the assembly

process is optimized, the unit can be

mass produced for approximately $600

each unit. Similar units with similar

features cost around $16,000, such as

the NEW BRUNSWICH INNOVA 44R.

Our unit offers control of all features

desired.


Fall 2018

Figure 1: Image of unit built with aluminum exterior, stainless steel interior, and electrical bottom housing.

Figure 2: Table of Controllable parameters. As shown, our unit offers control of all desired parameters at a fraction of the cost of the INNOVA 44R.

Controllable Parameters

Shaker Temperature Humidity Cost

Our Unit $1,995.00

Innova 44R $16,000.00

Shake N Bake $5,000.00

SteadySHAKE $4,800.00

Team Members: Benjamin Starcevich, Mark Lafrentz, Benjamin Bentley,

Daniel Nevarez


Shadow Track

Currently, spotlights are manually

controlled by light operators in

uncomfortable and often unsafe

conditions. The mission of the Shadow

Track autonomous light system is to

provide a reliable, safe, accurate, and

low-cost way to follow a presenter.

Problem Statement

The design should consist of the following:

• Fully automated

• Fast response rate

• Smooth transitions

• Cost competitive

Design Tasks

An infrared (IR) sensor is used to locate

an IR light source worn by the

presenter. Using a proportional

derivative control, the system

successfully directs the spotlight to the

target position. The response rate of the

autonomous system is 1.02 seconds

faster than human control. The system

can also be implemented for existing

lighting systems.

Final Design/Deliverables Theatres and concerts alone are multi-

billion-dollar industries. Chicago itself

has over 500 dance and performance

theater companies. Equipment and

installation for individual autonomous

lights can cost upwards of $50,000.

We project our system will provide a

fully autonomous upgrade for $500.

This projection is based on

calculations for the industry’s most

commonly used lights.


Fall 2018

Figure 2: Concept Prototype

Figure 1: Spotlight Operator

Team Members: Arsensio Aguilera, Anthony Greco, Tim Jackimek, John

Oberlander, Sam Schmalz


Hybrid Collector

Typical Solar Air Heaters can only run

on the sun’s energy during the day.

This leads to the problem of providing

heat during times of little to no sun. To

resolve this issue, heating elements

have been installed and arranged to

allow continuous heating of air during

all hours of the day, while being

powered by a solar panel. This leaves

the end user with a sustainable way to

capture heat while using less energy

over time.

Problem Statement


• Manufacture a solar collector that

harvests solar thermal & light

energy

• Eliminate fossil fuel usage & the

necessity for external heating

devices

• Limit expensive & intrusive

installation

• Achieve an average temperature of

(55º F) for 24 hours in conditioned

area

Design Task

The Hybrid Collector meets all

objectives. The addition of heating

elements separates the Hybrid

Collector from the competition.

The additional heat generated by

the Hybrid Collector can save the

end user over $2,000 per year.


Fall 2018

Performance

Metric

Typical

Collector

Hybrid

Collector

Cost ~ $800-$1000 ~ $400

Operating

efficiency

~ 8 Hours ~ 24 Hours

Energy Savings

annually

~55% ~65%

Auxillary Heat

Generation

0 W ~ 60-80 W

Outside air

coming in

Heated air

entering space

Figure 1: Hybrid Collector installation

Figure 2: Hybrid Collector design

Team Members: Ryan Bielman, Jeffrey Good, Michael Koeplin, Kyle Sullan


Mobile Dynamometer For STEM Outreach

Within the FIRST Robotics Competition

community (FRC), a common method for

evaluating custom driving-type robot

designs is to simply test drive them. Test

driving leaves a lot to be desired because it

does not quantify parameters such as power

and efficiency. Many different test stations

used across a wide variety of industries

exist to measure this but none are both

mobile and tailored to these robots.

Problem Statement

o Spec torque transducer, hysteresis

brake, couplers, shafts, bearings, etc.

o Package system onto custom cart

o Chassis mounting method for a wheel-

to-drum interface

o Central weldment structure

o Allow for bench-top testing using

battery and motor controllers

o Linearize thermocouple signals and

use an Arduino to output to a HMI

Design Tasks

The Mobile Dynamometer is used to

provide data that aids in designing robot

drivetrains. It measures the torque, power,

speed, efficiency, and temperature of the

robots under dynamic loading conditions.

The station is a self-contained unit so it can

be a transportable learning tool for the FRC

community.

Final Design

Genesis Automation sponsors a team in the

FIRST Robotics Community, so the goal

of this project was to aid them in their

mission to help students get involved in

STEM. Thus, in order to help the

community of 3,140 teams and 91,000

high school participants, this project was

made open source.

Market Analysis

Fall 2018

Above is the Mobile Dynamometer Station. An impact driver can be used to quickly raise the feet. A laptop is used tooperate the Magtrol equipment and the electrical cabinet in the back which contains: roboRIO, motor controllers, PSU,bus bar, Phoenix contact terminals, PDPs, K-type thermocouples, Dataforth linearizers, Arduinos (with multiplexers).

Robot Mount

Roller Drum

Weldment

80/20 Extrusion

Magtrol Equipment

Leveling Feet (4)

Magtrol Hysteresis

Brake

Shaft coupling (2)

Rotary Torque

Transducer

Bearings (2)

Blower Unit

Team Members: Amro Shanshal, Oscar Barba, Patrick Maglaya, Josh Marble

Project Advisor: Dr. Brianno Coller

Project Icarus

Grid failure resulting from natural

disasters, such as Puerto Rico’s 2017

major blackout, can obstruct first

responders’ ability to evaluate the disaster

site and allocate resources effectively.

Rapid deployment of aerial surveillance

and local communication restoration for

extended flight times is integral to on-site

assessment and effective aid deployment.

Problem Statement • System shows less than 5 minute

autonomous take off, altitude

management, landing capabilities

and more than 2 hours of flight time

• Adjustable camera gimbal to live

stream on-site video

• Ability to operate in acclimate

weather conditions

Design Tasks

• Communications restoration during

grid failure

• Improve effectiveness of aid and

relief logistics

• Improved situational awareness for

first responders

• Modular aerial platform for

additional firefighter and law

enforcement devices

Final Design/Deliverables Current market solutions include high

budget military and special operation

applications. Icarus provides an

affordable solution for first responders,

as well as agricultural and construction

site support.


Fall 2018

Icarus Surveillance System

Benefit Total

No FAA Drone Training

Requirement

$3,000

Alternative to Manned Helicopter

Survey

$400

No Drone Pilot Requirement $38

No Additional Cameras

Monitoring

$300

Sum of Benefits $3,738

Cost Total

Purchased Parts $1037.67

Manufactured Parts $112.78

Labor $450

Sum of Costs $1,600.45

Cost Benefit Ratio Retail

Cost

2.3 $3500

Industrial and Systems

Engineering

Team Members: Abdullah Alhajji, Sonja Marquette

Project Advisor: Dr. Damodaran, Dr. Nguyen

Redesigning the Stone Assembly Line

The Stone High Volume Assembly

Line was originally designed in 2013

to run with seven operators and have

a throughput of 160 units per day.

However, the demand for the product

has fallen, leading to a greater

variety of products with higher

complexity being run on the line

with fewer operators.

Problem Statement

In order to successfully design a

new layout, the following had to be

done:• Analyze product mix on the line

• Calculate the daily demand requirements

• Time studies on total cycle time and

individual work elements

• Determine ideal number of operators

• Balance the work load between operators

• Create new work instructions

Design Tasks

The final design for the new layout

includes a straight assembly line with

a station for offline work. This new

layout will meet the updated demand

requirement of 120 units per day

while only requiring four operators

to work an eight hour shift.


The cost of the new layout was

minimal by reusing the work

benches already in place.

Furthermore, there are additional

cost savings from reduced labor and

overtime costs. Finally, the line has

better ergonomics, which can reduce

costs due to injury.


Fall 2018

In the new layout, operators will be able to easily move between

stations.In the current layout, work is not balanced

between the stations, leading to a buildup of WIP.

Team Members: Gilbert Bwetabure, Joshua Moore, and Parth Thakkar

Project Advisor: Dr. Damodaran , & Dr. Nguyen

Title of Project Zeeland Value Stream

Cell : 963 Architecture

In the next three years, Woodward

is expected to have 47% increase in

manufacturing valve sets demanded

by Zeeland. The current 963 cell

layout is restricted to certain

number of operations. Some

operations gets outsourced to other

departments causing 3-5 days delay

in material flow. The current state

of the cell meets demand, but will

fail to meet forecasted demand of

value sets in the future.

Problem Statement Design Tasks

After compiling an future state map,

the production lead time for the

centerless and flow family were

reduced by 388% and 194%

respectively.


With a proposed ideal future state

map, total costs of adding new

machines to the cell are just under

$2 million. A stakeholder’s analysis

comparing reward and effort will

allow management to decide on the

most necessary costs.


Image #2


what we are seeing

Fall 2018

• Analyzed the material flow of Zeeland

parts through cycle times, process flow

charts, spaghetti diagrams, and value

stream mapping.

• To reduce delays, machines such as

lasemark, heat treat, passivate, and

centerless grind should be moved into

Cell 963.

• Update or expand the layout of Cell

963 to accommodate the machines

moved to the cell. As a result it will

minimize the material flow and meet

the forecasted demand.

Before the ideal future state map, delays were a serious

problem to the material flow. Some parts took more than 10

days to complete.

After moving multiple operations within the cell, the delays

were dramatically decreased. No part takes more than 2 days

to make.

Technology

Team Members: Jason Kors, Christian Morales, Kamil Polniak

Project Advisor: Dr. Martin and Dr. Mills

Development of a Low Cost Hand-held

Spectrometer

We believe that due to relevant

problems in current lighting such as

health, safety and productivity; we

need to design a tool with which one

can further analyze and understand

their environmental lighting in an

effort to more adequately reduce the

problems associated with it.

Problem Statement

• Analyze three spectral sensors

• Integrate with a microcontroller

or microcomputer

• Based on operational

characteristics develop a final

meter design

• Possible integration into

previously developed wearable

sensor array

Design Tasks

For our final design, we present a

working spectrometer prototype.

From our research and findings, the

spectrometer functions as most

others on the market providing

similar data as would be gathered

from other spectrometers. We also

are including proper manuals and

documentation for our design.


For our design, our goal was to

maintain a final assembly price of

$500. When not including amortized

pre-production design work, we

have come very close to that goal.

Every reproduced unit can now be

assembled for approximately $500,

compared to other marketed units

ranging from $1500 - $5000.


Fall 2018

Typical Spectral Power Distribution (SPD) for Common Types of Lighting

Final 3D CAD assembly of our hand-held spectrometer.

Team Members: Annalyssa Bell, John Mayer, Erik Osterby

Project Advisor: Dr. Andrew Otieno

Weber Grill

Focusing on the Go-Anywhere Weber

Grill, there are various projects that go

into creating a grill such as Bill of

Materials, Assembly Line, Shipping and

Handling, and the Re-Designing to

satisfy customer complaints. The main

customer complaint was the heat that the

grill was giving off and temperature

control. The grill warps the ground when

grilling.

Place Company Logo Here

(if applicable)

Problem Statement

At the beginning of the year, the

team created Bill of Materials for

the Grill along with a packaging

assembly line. For the last semester,

we focused on the main customer

complaint, temperature control. The

Team redesigned the legs to be

adjustable and the heat dampers to

have a consistent control of heat.

Design Tasks

The final design of the grill includes

legs that can be adjusted by height

and also can sit level on an unlevel

surface. The Adjustable legs

decreased the temperature of the

ground underneath the Go-Anywhere

Grill. For the heat dampers, the

group added a simple punch design

to get the same temperature for every

use.


The team wanted Weber to spend the least

amount of money as possible for a redesigned

premium model. The deliverables where

designed to limit processes and reduce

overall costs while upselling the Go-

Anywhere Grill Premium Model. The heat

dampers adds no extra step to the stamping

process and the legs go through the same

bending process. The only cost we are adding

would be the leg adjusting blocks. The

estimated cost of the leg blocks is $9.54 per

unit.


Fall 2018

The legs are configured for a more

sturdy base. They flip up and lock

the lid in place for easy portability.

Heat dampers are cut for easy and

accurate adjustability (not shown)

Added Weber Grill certified

thermometer to easy

temperature reading

Team Members: Farhan Alghamdi, Arturo Avila, Isaias Cervantes,

Stephen Slager

Project Advisor: Dr. Hogan

Electronic Assisted Knee Walker

The purpose of the electronic

assisted knee walker we are building

is to improve the overall safety.

Many knee walkers currently on the

market have flaws including:

● Lack of assistance going uphill.

● Tipping over.

● Sudden stops due to obstacles

in wheels’ path.

Problem Statement ● Design and build a durable

prototype.

● Test the strength of the design

using a finite element analysis.

● Calculate the force and torque

required to move the knee

walker uphill.

● Motor size was selected using

power and work formulas.

● Write a program for ultrasonic

detector that will work along

with a visual alarm which

activates when an object is

detected in the front of the knee

walkers path.

● Calculate tipping angle when

knee walker is performing turns

and in the straight position.

Design Tasks

● The final design of knee walker

is a 3 wheel design for increased

stability, two wheels in the front

and one in the rear.

● Our base is designed to contain

all electronic features such as

the motor, batteries, and other

power supplies.

● 24V, Electric DC Motor will

give assistance going uphill.

● Two batteries 12V, 12AH are

used to power the motor and

other electronics.

● Ultrasonic detectors on the front

wheels will be held by splash

guards to alert the user of the

hazards in the front of knee

walker.

● Tilt sensors will inform the user

of possible tipping risk..


● The total cost of the project is

$800 that included the materials

of the knee walker and

electronic and motor parts.


Fall 2018

3D SolidWorks Model Motor and connections Schematic

Team Members: Timothy Fisher, Michael O’Malley, Erich Wenzel

Project Advisor: Dr. Kilaparti

Automated Water Spray Booth

As the world continues to become more revolved around

electronics, water protection for these products is essential.

This is not only exclusive to electronic products, but because

electronics are being integrated into everything, the new

standard for these products is waterproofness. Ingress

Protection testing, or IP testing is what companies use to test

the waterproofness of a product. In industry, these testing

methods are manual and time consuming. If these testing

methods are not automated it will cost companies large

amounts of money and time. With our prototype, we set out to

take the first step in automating IP testing. Our prototype is a

foundation that companies can build from as it suits their

needs.

Problem Statement

Make the test more accurate by

eliminating human error and

increasing consistency

Minimize set-up/clean up time

Make structure adaptable for the

unique needs of clients

Increase user productivity

Use an actuator to adjust the height of

the product

Design Tasks

The final design consists of a

moveable frame to hold the nozzle

and control system. The control

system will control the spray

duration and display flow rate for the

selected duration.


To implement our design it would

cost $1411.50 with professionally

produced components. This product

would reduce the time per test and

will allow NTS to perform 5.7%

more tests increasing their profits by

over $5000 per year. The ROI on

our product is just over 3 months.


Image #1




Image #2


what we are seeing

Fall 2018

The assembled frame and table within the testing booth at NTS

Hose Holder

Rigid Moveable

Frame

Microcomputer

mount and desktop

Locking Non-

Slip Casters

Nozzle(s)

Programable

Table

Close up view of various components that make up the testing station

Interdisciplinary (Mechanical

and Electrical Engineering)

Team Members: Hnin Lin, Jazael Medina, Matthew Martone, Michael Bockwoldt, Michael

Duda, Nathan Luptak, Mary Carter, Mark Pacyga, Fahad Mohammedhussein, Bill Dedic


Motor Assisted Walker (MAW)

Individuals who are unable to walk

properly need rehabilitation devices

to prevent future health

complications. This motorized

walker aims to assist users in

developing healthy gait cycles while

strengthening hip and leg muscles.

Problem Statement

Design a walker with the ability to

provide walking support, lift the

individual from sitting to standing

position, and promote muscle

rehabilitation. In addition to being

motorized and manually controlled,

design to have the ability to prevent

unintentional collision.

Design Tasks

The final design of the

MAW supports the user by their

arms. The MAW contains a lifting

mechanism that allows the user to

both sit down and stand up while

being supported. The MAW also uses

joystick operated wheel motors to

assist the user when walking while

also using ultrasonic sensors to stop

the device from colliding with other

objects if the user gets too close. The

MAW has a walking area large

enough for the user to develop a

healthy walking cycle and can fit

through ADA approved door ways.


This walker is the only gait trainer

on the market that is electrically

assisted by motors. Most gait

trainers currently on the market are

unmotorized and cost upwards of

$2000. To remain competitive, our

target budget for the walker was

$1000, and our final design cost

was $1005.


Fall 2018

This picture shows the final design of the MAW in the

lowered position

Team Members: Syed Sabeel Hasan, Eric Walchli

Jeremiah Rodriguez, Lauren Anderson

Project Advisor: Mr. Eric Karlen, Dr. Donald Zinger

Electromagnetic Pulse (EMP) Welding

The current torque tube assembly at

UTAS requires drilling holes,

riveting steel and aluminum

components together and applying

chemical coatings at the joining

interface. This process is time

consuming and moisture may still

enter at the interface to induce

galvanic corrosion.

Problem Statement

• Construct coil and field-shaper

assembly that does not plastically

strain during welding process.

• Optimize ohmic and induction

losses to achieve weld with

minimum energy input.

• Establish quick and easy electrical

and mechanical setup for

positioning/welding workpieces.

Design Tasks

Final Design/Deliverables Business/Cost Analysis

Fall 2018

EMP welding is 99% faster than

traditional joining methods and can

be set up in under 5 minutes. The

coil design is reusable, and no

consumables are required to achieve

a weld. This process reduces parts,

failure modes, labor costs and

production time! The total one-time

cost for producing the welder

assembly is approx. $4,230.

The optimized model shown in

Figure 1 can withstand the structural

loads and produce the magnetic

pressures required to achieve a weld.

This welding technique does not

require chemical coatings, cause

galvanic corrosion and takes less

than 6 µs to produce a weld.

Steel tubeAluminum

tube

Dielectric

disks

Copper

disks

Field shaper

Senior Design Book 2018 · Technology Spectrometer (Sponsored by LEDIL) Jason Kors, Christian...

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