• 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.
    • Rapid Prototyping with Robotic Milling

      Ramsey, Jacob; Sherman, Kaylee
    • Vision Guided Robotic Work Cell

      Cullison, Jesse; Chandler, Blake
      Vision Guided Work Cell which utilizes a vision system, and Kawasaki Robot
    • 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.
    • Power Regeneration for BLDC Bicycle Motor

      Lopez Moreno, Luis Miguel; Fleming, Evan
      The purpose of this project was to design and build an electric bike conversion system capable of self-charging. The inspiration for this project originated with the idea of further empowering those in Third World countries who are not able to afford expensive means of transportation. Bikes are the most affordable personal transportation and using the power regeneration system with an e-bike conversion system will allow the user to use the system as a whole without the need to connect to an electric grid for recharging of the e-bike’s batteries. We achieved this by using the e-bike’s brushless DC motor in connection with a rectifier, boost converter, and a recharging integrated circuit to monitor and control the output of the energy created from utilizing the motor as a generator.
    • 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.
    • 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.
    • 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.
    • 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.
    • Punching Bag Trainer

      Czoer, Michael; Shan, Paul
      In this project, a trainer for a punching bag was designed to help a boxer improve their reaction time and recognize their punching force. This trainer consists of a wrap for the bag and a pair of wristbands. These modifications for a punching bag of any size improve how a punching bag can be used. The accelerometers used for this project will be in the wristband of the boxer to keep them from breaking. The display on the punching bag wrap will express to the boxer how they are doing through a graph that displays the average punching force and the boxer's reaction time throughout their training sessions. The purpose of this project is to design modifications for a punching bag that help the user independently train themselves at boxing by measuring the force of their punches and seeing how quickly they can throw a punch.
    • 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.
    • The Design of Mechanical Subsystems for USI's Solar Splash Team

      Kurz, Melissa; Bittner, Lily; Dudas, Alyssa
      This is a University of Southern Indiana senior design report for the design of three of the mechanical subsystems for USI’s 2022 Solar Splash boat: the solar panel frames, drive train, and trim angle adjuster and propulsion system connection. Solar Splash is a collegiate solar boating competition that takes place annually, and USI intends to participate in the 2023 competition. This report discusses the benefits of design and development of different mechanical systems. It discusses lessons learned from past projects and how best practices found in literature and benchmarking can be leveraged to solve previous deficiencies. It discusses the engineering knowledge required to complete the project and presents conceptual designs with a final design selection. Final critical engineering designs are analyzed and presented for each subsystem. The report establishes the objective, deliverables, schedule, and budget for the project. It also includes a concept of operations, a system hierarchy breakdown, and a failure mode and effects analysis for the competition. The report details how the solar panel frames were designed and how the subsystem was built. It also details how the drive train, propulsion system connection, and trim angle adjuster were designed and how assembly and manufacturing instructions will be provided to the future team for development of those systems. The mechanical subsystems for USI’s Solar Splash team will improve the boat and team performance for the 2023 Solar Splash competition.
    • Concentrated Solar - Implementation of Small Scale Parabolic Trough Heliostat

      Tunny, Michael; Wester, Nicholas
      This project aims to create a small scale, low-cost concentrated solar parabolic trough system to further research into renewable energy technologies at the University of Southern Indiana. This system uses a reflective mylar film bonded to a Lexan substrate as a cost-effective solution to traditional glass mirrors. 3D modeling is used to develop a plywood base and parabolic frame. Computer aided manufacturing is used with a computer navigated control router to produce most of the components that are needed. The control system is a novel design that uses light dependent resistors, 3D printing, and an Arduino embedded system to track the sun throughout the day. Mechanical rotation is provided by a stepper motor and worm gearbox. The system was successful in automatically tracking the sun with an average tracking error of 0.655◦ ± 0.1◦. The system also had a maximum temperature of 394◦ F with an average temperature of 290.3◦ using air as a heat transfer fluid. However, these temperature results only provide a baseline, as a true thermodynamic analysis would need to consider fluid dynamics. Additionally, delamination of the reflective film is expected in this system in the future. More research and experimentation is needed to provide a better solution for bonding of the reflective mylar film to a substrate. This project was successful in providing a platform for other senior design projects in renewable energy systems for the future.
    • 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.