• 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.
    • 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.
    • 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 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.
    • 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.
    • 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.
    • Continuous Hydrologic Modeling to evaluate a Stream Water Diversion

      Melchior, Lauren; Wagner, Noah
      A continuous hydrologic model (HEC-HMS) was developed and will be used to evaluate a water diversion for wetland creation in Evansville, IN. Continuous hydrologic models require continuous tracking of soil moisture changes. This requires vapor loss to the atmosphere via evapotranspiration (evaporation plus transpiration) to be modeled. Two methods were used to calculate evapotranspiration using 20 years of historic meteorological data. Field data was collected to aid in validation of the HEC-HMS model. This required installation of a staff gauge and a water level measurement station. The validated model will be used in future storage routing calculations to design a culvert to divert water towards the center of the site. A hydraulic model (HEC-RAS) developed by a previous capstone design team was also used to aid storage routing calculations with HEC-HMS. In addition to the developed model, water quality analysis was conducted to reinforce the objective of improving water quality at the site. The results from the model will provide estimates of water diversion quantities achievable over a wide range of meteorological conditions.
    • Creation and Implementation of Training Program

      Nelson, Alex
      This project covers the need, design, and implementation of a new training program. This project is aimed at helping meet the company’s belief that information, communication, education, and training are essential to the implementation of the quality and safety policy. The program itself will consist of four main areas of focus which are standardization, knowledge, implementation, and leverage to improve. To do this the company needed to select a new system for document control, learning management system, and creation of a new job position. This program will be sustainable and able to be continuously improved upon for the duration of its use.
    • 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”.
    • Deployable and Retractable Solar Array Mechanism for Satellite Applications

      Chesebro, Joseph (Joey); Frimming, Camden
      The following report presents the initial design, simulation, and construction of a deployable and retractable solar array mechanism for satellite applications. Most small satellites such as CubeSats, do not incorporate the use of deployable and retractable solar arrays, but these could add increased versatility while on mission. This report also discusses multiple other projects that are like the one that the team is going to design. These reports helped the team understand what is needed to have a successful project and where they went wrong in their designs and executions. First, the initial concepts are shown, and the final selection is discussed. Analyses of the two main subsystems, a compound gear train, and a scissor linkage mechanism are given. A prototype was constructed, and testing was attempted, however issues with the gear train were uncovered and attempted to mend with no success. The project resulted in a design that shows potential for success by calculation and simulation but was not implemented well ending in a nonfunctional prototype.
    • 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 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.
    • 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.
    • 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.
    • 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.
    • 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.
    • Designing a Layout Change to the Manufacturing Operations at Matrix Design Group

      Keele, Lucus
      This proposal addresses the development of a new layout change to the manufacturing operations at Matrix Design Group. Matrix Design Group manufactures and sells innovative technology products in the mining and transportation industry that increase safety and productivity. With the projected increase in demand for safety equipment in coal mines, it is essential for Matrix Design Group to increase its production rate of equipment produced to supply this demand. An increase in inventory space is also required due to changes in ordering policy because of the COVID-19 global pandemic. This project aims to facilitate an increase in production to meet anticipated demand and to increase inventory space to hold an inventory safety stock.
    • 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.
    • 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.
    • Electronic Whistle Transmitter and Receiver

      Warren, Presley; Schmidt, Erica; Harmon, Wyat
      American football players often have trouble hearing the whistle due to high intensity play, physical contact, adrenaline, and extremely loud crowds; so, they continue to throw, run, and/or tackle without realizing the referee(s) has stopped the play. This presents an added danger to the game and results in avoidable injuries that occur after the play is over. To increase player safety, this project consists of designing a secondary tonal system, placed in helmets, that alerts football players that a play has ended. The electronic whistle transmitter and receiver system uses low frequency wireless communication between two custom printed circuit boards that delivers an audible tone close to the players’ ears when the electronic whistle is activated. The electronic whistle transmitter and receiver system acts as an additional safety measure for the athletes.