Recent Submissions

  • Pneumatic Trainer

    Johnson, Evan; Keller, William
    The purpose of this project is to design a pneumatic trainer that will serve as a hands-on learning tool for any pneumatic section being taught. This device will allow students to apply what they have learned in class on physical equipment to better grasp air logic controls. This will also be done through labs that our team will create to highlight the trainer and help students better learn the class material. Designing the trainer required varied tasks to be completed. Initially, research had to be done to look at trainers on the market and for understanding of pneumatic logic. Components were then decided on based on client specification. After this, a completed computer aid design model was created. This model would help determine how the official trainer would be designed and how components would be placed. The trainer was then assembled according to the layout of the computer model and tested for quality before it was given to the client.
  • Solar Splash Motor Testing Unit

    Lee, Logan; Carr, Hunter
    My partner and I were tasked with designing a motor testing unit for the Solar Splash team. The team would use this to test the motor they purchased for their solar powered boat that will be used in future Solar Splash competitions. We had to design the testing unit to withstand the weight of the motor, the torque the motor will produce, and the forces that the outboard unit would create on the design.
  • Slope Stability Flume Report

    Brinton, Calvin; Hahn, Ethan
    This scope of this project is to design and construct a testing flume to be used by the USI civil engineering department. The flume will contain moist sand while all walls and base of the flume will be constructed of a Lexan material with a steel support structure. A floor jack will be provided that can raise the flume to manipulate the angle of the slope. The moist sand material, steel support structure, and Lexan sheet weights were all calculated to verify what caster wheels were appropriate for this flume.
  • Automated Medicine Sorter/Counter/Cutter

    Scarlett, Brayden; Briles, Langdon
    The purpose of this project is to design and build an automated pill sorter that sorts pills into seven-day pill planners with AM and PM containers. Additionally, the project will utilize a cutter system to sort pills by half dose as specified by the user and store the other half for future use. The project will also allow users to input pill medication names, dosages, and regimens via an onboard and computer-based user interface. These actions will be controlled by a NORDIC Semiconductor microcontroller which will retain pill data, operate the user interface, and control when doses are sorted via a master/minion system with two Arduino microcontrollers which will control the sorting and cutting systems, respectively. The project is also designed with user modularity in mind, allowing the user to sort as few as one type of pill or as many as six types. Finally, the cutter system being used has already been designed by a previous team. This cutter system was designed to cut pills in half with a minimum amount of mass loss.
  • The Creation of Battle Bots: iRobot Roomba Conversion

    Whaley, Joshua M; Hart, Paul B.; Buehl II, Frederick H.; Bruner, Patrick N; Campbell, Clifton
    The purpose of this project was to provide an opportunity for the seniors in the USI/NSWC Crane technician-to-engineer cohort to work in a small team setting and manage to completion, a project tasking of creating user controlled, battle type robots from an iRobot Roomba Vacuum platform. This project covered a wide variety of aspects including the design, construction, modification, and programming of the battle-bot. The ten members of the cohort were split in two, five member teams that were required to create at least one battle-bot per team. The bots would have to pass a speed test and a maneuverability test as required by the rules set forth by USI. After passing qualifying tests, both teams would battle in a three round main event, until a team’s bot expires or the three rounds end. The teams will be judged on the overall design, creativity, quality, and competition results. Early in the process, “DOOMBA” was decided as a team name. The name represents the roots of an iRobot Roomba vacuum system and the certain doom that would be brought to the bot’s opponents. With many tasks and a variety of areas from programming, frame construction, assembly, lab tests, interfacing, and proper teamwork, communication was vital to the success of the project. Our team quickly setup a file share drive, text chain, weekly electronic conferences and secured a workshop facility to utilize in the battle bot development. The team originally focused on creating a single battle-bot due to worries of budget constraints. Once budgetary requirements for a bot were calculated, it became evident that a secondary bot was financially feasible. Discussion then ensued about offensive weaponry and defensive tactics the bots should have. The team quickly decided that the two bots should have different weaponry and exterior makeup. This decision was driven in order to diversify skills and risks. If a bot’s weapons were ineffective against the opponent, the hope would be that the second bot would have a more effective set of attack. Defensively, if one of the bots were susceptible to the opposing team’s bot, then possibly the second bot would be less affected by their weaponry and mode of attack. The process began with the team studying champion level bots frequently seen on the television series Battle-Bots, along with You-Tube videos. After much thought and brainstorming ideas, it was decided to go with a wedge style bot (this became DOOMBA Dozer) and a second bot with spinning blades (this became DOOMBA Saw). The wedge style bot would be constructed of heavy material and its offense would be ramming or pushing the opponent. The defense would be the iii capability of taking repeated hits with heavy construction. The spinning blade bot offense would focus on hitting or cutting the opponents housing. The defense would be agility, due to the lighter weight construction. Through various question and answer sessions with the team’s advisor Dr. Brandon Field, it was determined that using the original wheel assemblies of the Roomba platform, was sufficient enough to be considered a “Roomba Platform”. The body and other components were not a criterion for the project, thus providing a large amount of freedom with respect to restrictions on the bot’s construction and makeup. Work began with scrapping the internals of the Roomba and replacing the electronics with an Arduino focused on controlling payload and another Arduino focused on controlling wheel motor speed and direction for each bot. A reduced C\C+ language was used to program the Arduino Uno’s. The Uno’s were used to control the weapons and steering capabilities for DOOMBA Saw as well as DOOMA Dozer. Once the programming proved functional with all components integrated, the housing design process was initiated. At that time, the team made the decision to split into two teams. One team made up of three working on the Dozer and the other team made up of two people working on the Saw. This was enacted with the understanding that all personnel’s skill sets and capabilities were available to both subgroups at any time, to assist in completion of tasks. In the end, team DOOMBA created two different battle[1]bots named “DOOMBA Dozer” and “DOOMBA Saw”.
  • Rehabilitative Design & Structural Health Monitoring of New Harmony Bridge

    Scales, Jared; Butler, Zachary Cole
    This project analyzes the structural design of the New Harmony Bridge and suggests a redesign of the deck in order to meet modern standards. The New Harmony Bridge (opened in 1930) holds a significant historic value which attracts a high public interest. The age of the bridge is again reinforced in the unique structural elements such as rolled Carnegie steel shapes throughout the bridge and its use of the K truss. Sensors were strategically placed on the bridge to measure short-term moving loads over multiple tests. These results provide insight as to how the structure reacts to different load cases which is useful considering the bridge has been out of commission since 2012. More specifically, these tests explore any load sharing capabilities the beams may have. Additionally, a conceptual design for the repaired concrete deck was developed using shear studs to achieve a composite beam design. This included 2D models in RISA to determine demand and analyses in Microsoft Excel to determine capacity. The overall goal is for the redesign to withstand the loading of an HS-20 per AASHTO code.
  • Minka Hardscape/Red Mango Expansion Site Design

    Bultman, Brayden; Moss, Daniel; Meier, Trevor
    This project consists of the Minka Learning Lab and Red Mango patio located south of the Science Center on the University of Southern Indiana’s campus. The main focus of this project is to create a safe and sustainable environment outside of, and in conjunction with, the Minka House. The purpose of the Minka House is to serve as a learning lab to be a model of geriatrics, which is the branch medicine and social science of care for the elderly. Geriatrics focuses on aging in place as a positive alternative to indefinite residence in a retirement home. As such, the site design incorporates many features which would be beneficial in geriatrics. This site design will include environmentally minded systems, an improved landscape and hardscape of the Minka's immediate surroundings and will also tie in upgrades to the Red Mango store front with the goal of beautifying campus and providing increased student involvement.
  • Battle Bots

    Scott, Eric; Bailey, Tanner; Eaker, Aaron; Callahan, Noah; Gomez, Tim
    The Clean Sweep team designed and deployed the Sweepy McMurderbot battle robot built on the iRobot Roomba 600 Create 2 Open Interface platform. This platform provided two drive wheels and one front caster wheel along with an integrated power source and motion-control electronics with a serial interface. The mobile platform was enhanced with a rotating flail type weapon, a top side shield, and wireless Joystick control capability. Solidworks was the common engineering environment the team selected for modeling and as a virtual integration platform. Three Arduino Uno’s were utilized. One controlled the stepper motor that powered the flail weapon, LEDs, and the audio. One controlled the Roomba and sent commands over serial to the Roomba and the weapon controller. The last one interfaced to a Joystick and allowed the operator full control over the robot and commands via WiFi to the Roomba controller. All software subroutines were written using C/C++ language via the Arduino IDE This design project was completed within a 16-week period with a project cost of $1,000.00. The end goal of this project was to demonstrate fundamental engineering design capabilities and understanding, as well as designing and deploying a winning battle bot that will crush the competition – or at least smash them to bits.
  • Electroencephalogram Controlled Electric Wheelchair

    Matthews, Nicole; McClain, Andrew
    The purpose of this project was to create an alternative method to control an electric wheelchair using an electroencephalogram (EEG). The primary goal of this project was for an EEG to collect data and transmit it wirelessly via Bluetooth to a microcontroller on board the wheelchair. This data is then processed and used to control the motor functions of the wheelchair. The EEG headset used in this project was the Unicorn Hybrid Black. This headset has eight data electrodes as well as two reference electrodes. Multiple microcontrollers were analyzed to determine the best fit for this project with the nRF52840 chip on the PCA10056 development kit ultimately being selected. Matlab and Simulink were used to receive and process the signal from the EEG headset. Then the logic to create the signal for the wheelchair motors and emergency brake controls was designed and loaded to the microcontroller onboard the wheelchair. The final system uses the EEG headset to collect data that is processed through a computer and outputs a signal to an Arduino that is connected to one nRF52 microcontroller which then transmits that signal via Bluetooth to the nRF52 microcontroller onboard the wheelchair.
  • FESTO Machine Part Fixtures, Parts, and Feeder System

    Stallard, Isaac; Altstadt, Blake
    There is a machine that in the Applied Engineering Center that is called the Festo modular production system transfer factory. The MPS transfer factory is intended for learning manufacturing processes using advanced automation technologies. The goal of the project is to design new parts to simplify the process and add variation to production. There was extensive use of building 3D models for the design of the parts. Computer aided manufacturing was used to create computer numerical control code used to machine the parts.
  • Design and Analysis of a Solar Panel Mount for Existing Utility Scale Wind Turbines

    Biehl, Eric; Hemrich, Kaitlyn; Mowrer, McKenzie; Wilson,  Katherine
    This project consists of a design and analysis of a solar panel mount for existing utility scale wind turbines. This project aims at a design that will attach to an existing wind turbine tower and hold an array of ten solar panels without causing serious deflection or stress onto the wind turbine tower. First, small scale examples were researched and discussed by the senior design team. The advantages and disadvantages of each example were analyzed to aide in creating a final design for this project. Then, four critical design iterations were considered before coming to the final design. Design Iteration 1 has solar tracking capabilities and therefor required too much maintenance. Design Iteration 2 was bulky and above the allowable weight. Design Iteration 3 was reduced in weight by almost 75% and unnecessary stress points were removed. This design had too much deflection on the solar panel frame when applicable loads were applied according to load analysis and FEA. The final chosen design, Design Iteration 4, had a reduced solar panel frame deflection, as the upper and lower arms were spread apart to evenly distribute the loaded weight. A finite element model of the final mount was made to ensure the mount’s structural integrity under normal loading and 90 mph wind loads. The project resulted in a designed solar panel mount for existing utility scale wind turbine towers that: weighs less than 15,000 pounds, fits a specific wind turbine (GE 1.5 MW), holds 10 individual solar panels, angles the solar panels 50 degrees form horizontal, has a factor of safety greater than 6, and does not cause damage to the wind turbine tower.
  • Design of a Test Fixture and Static Load Test for a NACA 0009 Horizontal Stabilizer

    Castillo Koussa, Diego; Jahraus, Dashel; Tate, Logan; Wilson, Ricki
    Aircraft horizontal stabilizers experience deflection and torsion during flight. The accompanying bending and shear stresses can cause failure if the aircraft is not operated within the correct performance envelope. Analytical models can be created to predict vertical and angular deflection as well as the shear center of the stabilizer. These values can also be found through experimental testing to verify the analytical models that can be used in the future. The proposed senior design project is to create the analytical models for a NACA 0009 horizontal stabilizer from an F1 Rocket of Frazier Aviation and design an experimental structural load test that can be used to verify the analytical models. As part of the experimental structural load test, the team must design a test fixture that will not deflect under the applied load.
  • USI Athletics' Complex Conceptual Design and Estimate

    Buechlein, Evan; Poulsen, Markus; Williams, Kendall
    This report includes the conceptual design process for an Athletics’ Complex for the University of Southern Indiana (USI). This process includes the preliminary sizing of the facility and the space that it will require to meet the standards of the National College Athletic Association (NCAA) and International Amateur Athletics Federation (IAAF). A location for the site was then established on the University’s property at the existing intramural and rugby fields. A site survey was performed, and data was recorded and supplemented with light detection and ranging (LiDAR) to produce a topographic map of the site. Then the alignment of the complex was established which required the existing Clarke Lane to be relocated to create enough space for the Athletics’ Complex. The possible alignments were analyzed and chosen to minimize the impact on the existing traffic flow. This was accomplished by routing the alignment around the Complex to the existing roadway. The impact of the increased hard surfaces and the runoff associated was analyzed to determine the impacts on the existing stormwater infrastructure. It was found that the existing infrastructure was able to handle the increase but will need to consider replacement due to its deteriorating state. A conceptual estimate was then created using parametric and historical data techniques of similar facilities. The total cost of a facility with these features was found to be $9,930,131.
  • Mechanical Design of an Automation Training Cell

    Fulkerson, Matthew
    This project covers the development of an automation training cell that will help introduce individuals to industrial automation. The design will include modern day automation equipment suited for industrial applications. Industrial automation is a growing field with a strong need for individuals who can understand the programming required to run the assembly lines. Many programmable logic controller trainers used today are insufficient in their abilities to teach real world applications. In order to solve this problem a better equipped training cell will be developed. This training cell is described to contain modern day automation technology and stay within a 12ft x12ft area. This training cell will incorporate a robot, programmable logic controller, part handling, vision inspection system, and safety protocols. The results of this project will include detailed engineering drawings and completed bill of material.
  • Acoustic Emission Application

    Degbe, Jerome; Klein, Matthew
    Communities exposed to landslide risk in low and middle-income countries seldomly have access to instruments to monitor slopes to provide a warning of instability because existing techniques are complex and expensive. Research and field trials have demonstrated that acoustic emission (AE) monitoring can be an effective approach to detect accelerating slope movements and to subsequently communicate warnings to users. The purpose of this project is to design, test, build, and implement a network-based landslide detection system along with an early warning system. The system will have the capability of monitoring and predicting a landslide and the ability to trigger an alarm to warn residents. This report describes the concepts consideration, the system overview, the sensor node, and the base station. Due to design specifications constraints, and global supply crisis, the students were not able to select an adequate sensor. The project resulted in the successful creation of a base station and network communication. While the inspiration for this project is a landslide detection system, similar systems that require low power long distance sensor networks could also utilize this project as a framework.
  • Process and Team Management, Hull Design, and Steering System Design

    Bolin, Margaret; McGlothin, Conner; Wagoner, Lucy Mae
    Solar Splash is an international collegiate boating competition where students design a solar powered boat to race in various events while promoting interest in science and technology. The strategy of the 2022 USI Solar Splash team is to analyze the results from the 2021 competition and apply that knowledge to design and build an improved boat that will serve as a baseline on which future teams can continuously improve. The senior design team will help support the USI Solar Splash team’s efforts by analyzing project management and team management from a process optimization standpoint, delivering an improved hull design, and addressing an oversteering issue. A strategic design approach will be taken, keeping competition considerations and the idea of continuous improvement in mind. The culmination of this project is to equip the 2022 Solar Splash team with detailed designs, materials, and implementation guidelines so that the systems can be constructed during the team’s build phase in the spring 2022 semester.
  • Analysis of Wheel and Tire Drum Testing Surfaces

    Hagan, Tristan
    The purpose of this project is to further the knowledge of Accuride’s dynamic fatigue testing processes. Accuride currently uses two different types of radial drum testing stations. The radial drum testing stations utilize a large diameter driven drum that will rotate. A wheel and tire assembly will press against the drum where the friction from the drum and the tire causes the wheel and tire assembly to rotate along with the driven drum. When this rolling effect is created a substantial load is placed upon the wheel and tires assembly to accelerate the fatigue test. This dynamic radial drum test is set to show the wheels ability to perform in the industry, where they are continuously used on large vehicles within the trucking industry. The cycles needed to pass the test standards are set according to the Society of Automotive Engineers (SAE), Association of European Wheel Manufacturers (EUWA) and other international organizations. All new wheel designs, wheel material changes, or wheel modifications must be tested to be qualified for sale. It is important to know that the different radial drum station types are similar when completing a fatigue test. There are two different styles of radial drum testing stations which are the concave and the convex systems, which refers to the side of the drum the wheel and tires assembly is placed upon. The goal of this analysis is to gain understanding of the effects each different type of radial drum stations has on the wheel.