• Designing a Fixed-Wing 3D Printed Aircraft

      Knackmuhs, Joel; Mayer, Landon; Rouch, Glen; Whitehead, Isaac
      A 3D Printed Aircraft Competition hosted at the University of Texas Arlington challenges students to design an aircraft while employing the advantages and considering the constraints of 3D printing. This allows students to explore the capabilities of 3D printing in prototyping and fabrication uses as an alternative or supplement manufacturing method. This report presents a review of research in the field of aircraft design, an analysis of conceptual designs, and features the designs for a 3D printed fixed-wing aircraft. The objective of the project discussed in this report is to design and construct a 3D printed fixed-wing aircraft to compete in the 6th annual 3D Printed Aircraft Competition hosted at the University of Texas Arlington. With the goal of designing an aircraft for maximum flight time, numerous design tradeoffs were considered. Similar designs from engineering teams that competed in past competitions were reviewed and learned from. The aircraft design was largely constrained by the capabilities of 3D printing and by the competition requirements. After designing the aircraft, a working prototype that met the requirements of the competition was constructed. The aircraft was operated in test flights, and each design was improved upon for the next iteration.
    • 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.
    • Design and Implementation of an Automatic Let-Down System for an Archery Draw Board

      Harris, Ross
      The objective of this project was to design, test, and implement an improved archery draw board system. An archery draw board is a device that allows the user to draw and analyze characteristics of a compound bow. The bow is placed in the device and a winch mechanism is used to draw the bow string for analysis of bow parameters such as cam alignment, cam timing, and draw weight. Analysis of these parameters can allow the user to tune the performance of the bow. A new feature, the Automatic Let-Down System, was designed, tested, and implemented to achieve this goal. The design objectives for the Automatic Let-Down System were to improve the ease of use, speed, and safety of the draw board. The system allows the bow string to safely come to rest from full draw at a reduced speed without manipulation by the user. This improves upon current draw board designs that require the user to manually turn the handle of the winch to return the bow to a state of rest. The device was successfully designed, implemented, and tested with the design objectives in mind.
    • 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.
    • Vision Guided Robotic Work Cell

      Cullison, Jesse; Chandler, Blake
      Vision Guided Work Cell which utilizes a vision system, and Kawasaki Robot
    • 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.
    • 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.
    • The Automated Vertical Carousel Storage System

      Sizemore, Jack; Starr, Adam; Wilson, Lyndon; Zieg, Nick
      The goal of this project is to design and implement a vertical carousel storage system that is small enough for tabletop usage in a classroom setting. It can be used in manufacturing classes to be studied and analyzed in lectures or labs. This will bring greater knowledge towards the younger generation of engineers to eventually help with organizational issues in the future. Another focus for the carousel storage system is to keep the electrical components for labs (resistors, capacitors, etc.) organized and easy to locate.
    • 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”.
    • Photoelastic Effect Demonstration Device

      Carpenter, Blaine; Rexing, Brant
      The purpose of this project was to design and build an affordable device to demonstrate to engineering students stress patterns in loaded samples of different geometries using the photoelastic effect. These devices use light and polarization filters to demonstrate the photoelastic effect in transparent materials and show their stress patterns. This project aims to improve upon existing designs of similar devices and create a functional device that professors can use to educate students with a visual real-life example. This paper focuses on the research done, design considerations, final decisions, and what was learned. Also, this paper discusses conceptual ideas for designs. First, research was done for the team to get a better understanding of similar devices. After this, research had to be done to better understand the fundamentals of optics relevant to this project. Then, once there was a better understanding of the problem and a better engineering background, some conceptual designs and one final design project for the device was designed. With our education we were able to design a device that meets the requirements and will function as intended. We were also able to provide more detailed information about what photoelasticity is and how polariscopes work. Also, we were able to simulate stresses on the device and ensure that the device will not fail under the intended amount of load. The team looked at each design and decided upon a final design to build for the final project. The team chose 10 unique geometries for the Lexan samples that will be tested in the polariscope, most of these geometries can be found in engineering textbooks used for talking about stresses. One design choice the team made for the project was to build a device that can fit on an overhead projector so the polariscope can be used in classrooms and projected onto a wall. The team had to cut a piece of square aluminum tubing that is about 5 inches long so the arm holding the head of the projector could be extended upward allowing for the projector to focus further from the base of the projector giving the team more room to build the rest of the project a little taller. The team built the polariscope so that it can be used as a linear or circular polariscope. The filters and mechanism used for applying tension are also easily adjustable up or down to allow for the sample to always be in focus.
    • 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 Build of a Launching Mechanism for Space Debris Capture

      Choate, William; Cosby, Zachary
      In this project a launching mechanism for space debris capture was designed, built, and tested. Space debris capture mechanisms capture space debris and then deorbits with the debris. If the space debris issue is left unchecked, it will spiral out of control and pose a risk to infrastructure and astronauts. This project aims to create a prototype to test centrifugal force for spin deployed nets. This prototype was designed from the inside out starting with the net. Some FEA analysis was conducted to help with the design process. The prototype was then constructed and tested for deployment. The prototype was successful in spin deployment at roughly 12 rad/s. All requirements of the project were met except for the actuated linear deployment velocity of 1 m/s.
    • 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.
    • 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.
    • Slope Stability Flume

      Maddox, Nicholas; Hamzic, Amel
      The scope of this project is to continue building and designing a slope stability flume for the USI’s civil engineering department. A slope stability flume is a device used to simulate landslides, water erosion, evaporation, etc. The flume will be made by using steel bar stock, Lexan siding, and other materials. A floor jack will be provided to be able to tilt one side of the flume when used for testing, as well as casters for easy movement. The flume will also be able to support the weight of moist sand, along with easy cleaning solutions. The flume will also double as a storage bin and desk for students when it is not being used.
    • LInear Axis Rail System

      Englert, Samuel; Northener, Logan
      The purpose of this project was to design, fabricate, and implement a linear-axis rail system for use with the Kawasaki RS03N six axis robots located in the Applied Engineering Center at USI. After the rail system is completed, individuals can issue positioning commands to the motor-driven platform, which will move the platform to different locations along the track. This project was set into motion by a group of past students who were tasked with determining the proper specifications for the rails, slides, bearing and motor. Given that they had to research all that information their overall design portion of the linear-axis rail system lacked some of the qualities instructors were looking for. To design the rail system, significant CAD work was performed to identify the proper solution to the design to make it more robust and user friendly. Upon completion, this project will allow the Robotics (TECH 272) curriculum to expand, by allowing instructors to discuss the importance of motion control systems in manufacturing, and how to implement them. This is a design that instructors are interested in as well which involves implementing the linear-axis rail system for future use in their Robotics labs to further expand the capability of the robot and what the operator can do.
    • 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.
    • Recycling of Compressed Air Within an Industrial System

      Havill, Kyler; Stoll, Mason; Kimmell, Aven
      Compressed air is used for a wide variety of manufacturing processes, including a thermoforming process at Berry Global which produces 30 ounce plastic cups. Currently, the machine used to produce these plastic cups uses a substantial amount of 80 psig air, roughly 1400 gal/min, which is being exhausted to the atmosphere. It was determined that the cost to provide the necessary air for this one machine is approximately $3.34 per hour. The objective of this project is to design a system that is capable of recycling some of the air that is currently being exhausted to the atmosphere. To begin the design process, previous solutions to this problem were researched. The three preliminary designs developed by the team were inspired by the previous solutions researched. The preliminary designs were all considered, and the final design was chosen. The design chosen for critical design captures a portion of the exhausted air and boosts the pressure back to 80 psig where it can be reused in the current system. This design was divided into three main subsystems, each of these subsystems was designed, and a model for the entire system was developed. The model was a key factor for determining the cost savings of the system and the specifications of the different system components. Next, the determined specifications were used to select the system components. These components, as well as the installation costs, were arranged into a budget. The final system cost was then divided by the cost savings to determine a Return on Investment period. Finally, future changes and improvements to the design were discussed.
    • 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.
    • Drainage & Structural Design - Administration Building for the State Bank of Whittington

      Sturgeon, Madelyn; Owens, Justin; Bohlen, Paul
      The purpose of this project was to redevelop the site and build an administrative building for the State Bank of Whittington. The preexisting site consisted of five single-residential homes, one small commercial building, and two small parking lots. These structures were demolished, and the parking lots were removed. The proposed building is an 8,305 square foot, single story building that was designed to equip offices and conference rooms. The drainage system for the site collects all storm water runoff from the roof, parking lot, and surrounding areas into two detention basins that drain into the preexisting city storm sewer. In addition to the site design, the administration building was structurally designed. The post construction site will consist of one, steel frame, administration building, one parking lot, and a sufficient draining system. Collectively, the site and structural aspects were designed to meet the project and community’s needs.