Fall 1998 Design Projects

Project 1: Design of Loader/Unloader in a Sheet Feeder

• Team Members: Charles Bambenek, Sarah Drews, Chris Lake, Lindsay Morga, Kelly Pohl
• Sponsor: L&L Engineering & Manufacturing, Inc.
• Supervisor: Prof. Jun Ni
• Abstract: L&L Engineering and Manufacturing, Inc. has built an automation system, called "Sheet Feeder", for Ford Motor Company. It is used for the forming of vinyl covered interior door skins. The task at L&L is to redesign and build a different size of press automation in order to produce parts for another car line. The task for the ME450 team is to design the main drive section of automation to accommodate the new press size, to eliminate unused functions, and ease the fabrication and installation. L&L will be responsible for most of the manufacturing and the MEAM students will be responsible for design, analysis and some components manufacturing.

  

Project 2: Design of an Improved Thermostat for Engine Cooling

• Team Members: David Depto, Mark Fanone, Michelle Liedtke, Adam Szymczak
• Sponsor: Ford Motor Company
• Supervisor: Prof. Liwei Lin
• Abstract: The thermostat is placed in the engine system and should accomplish the following goals: rapid engine warm-up during start-up and maintain engine temperature over a variety of different engine operation conditions. Current thermostats have the following characteristics: $1~$2 dollars, relatively high warranty, may have leakage, slow response, unstable and overshoot. A new design concept or improvement of current designs is the goal of the project. It is recommended that a targeted package application (e.g. V-8 truck) be considered in the design and manufacturing process.

Project 3: Flexible Rack for Dish Washer

• Team Members: Tricia Allam, Jason Kiehler, Carol Lee, Jeff Sawka, Tim Sherman
• Sponsor: Whirlpool
• Supervisor: Mr. Peter Halliday
• Abstract: Whirlpool is one of the leading companies in the world of consumer appliances. The goal of this project is to design a flexible dish rack in Whirlpool's dish washers such that consumers can load "all" kitchen wares effectively (different size, weight, geometry, flatness, etc.). The design should not compromise cleaning or drying performance and should enhance both functions. The prototype rack will be manufactured and placed into a dish dryer for testing.

Project 4: Integral Transmission Shipping Strap

• Team Members: Jason DeWeerd, Gregg Overfield, Scott Padilla, Daniel Peterman
• Sponsor: Ford Motor Company
• Supervisor: Prof. Jun Ni
• Abstract: Current shipping straps require four fasteners to hold the torque converter. The goal of the project is to redesign the strap to eliminate fasteners and to add a quick snap-on feature to the device.

Project 5: Automated Pasta Spreader/Shaker Machine

• Team Members: Jason Laws, Jessica Linnert, Kavel Singh, Rahul Tendulkar, Mike Yeaster
• Sponsor: Al Dente Pasta Company
• Supervisor: Prof. Liwei Lin
• Abstract: Al Dente is a small gourmet pasta company that produces a variety of pasta using old recipes mixed with modern technologies. Currently, they are spreading and shaking their pasta that is freshly fabricated with the help of several workers. The pasta must be distributed evenly in order to be dried optimally in the oven. This is a very time consuming and tedious job by human operation. The goal of this project is to design an automated pasta spreader/shaker to improve the manufacturing process.

Project 6: Watch Balance - Wheel and Escapement Exhibit

• Team Members: Richard Bodey Jr., Jessica Gabourie, Kendra Lohrmeyer, Maggie McArthur, Suzanne Volkman
• Sponsor: Ann Arbor Hands-On Museum
• Supervisor: Prof. Liwei Lin
• Abstract: WatchWorks' mission is to design and construct an exhibit for the Ann Arbor Hands-On Museum. This exhibit will demonstrate the time-keeping mechanism of a watch, specifically the escapement. The goal of this project is to integrate a learning tool and a fun activity into an interactive display which may be part of a traveling exhibition that explains "how things work".

  

Project 7: Pulley/Chair Hoist Exhibit

• Team Members: Jackie Buttrick, Prem Mukherjee, Lindsey Rooks, Jennifer Schweda
• Sponsor: Ann Arbor Hands-On Museum
• Supervisor: Mr. Peter Halliday
• Abstract: The National Science Foundation has donated funds to the Ann Arbor Hands-on Museum to develop "hands-on" exhibits that will travel across the country to a variety of locations. The focus of these exhibits is to explain how things work. The goal of this project is to design and manufacture a differential chain hoist pulley system with a seat for a person to sit in and raise himself/herself up.

Project 8: Ball Socket Tester for Cyclical Fatigue & Wear

• Team Members: Jeffrey Catana, Jaymi Kornak, Brian Lee, Nicole Robbins
• Sponsor: Visteon Automotive Systems
• Supervisor: Mr. Peter Halliday
• Abstract: The purpose of this project is to investigate ball socket and bushing durability in the wiper/washer systems by understanding cyclical fatigue & wear. An apparatus will be designed and built to simulate the loading and motion between contacting surfaces. This apparatus should have the following functions: 10 million cycles at maximum rated load, adjustable loads in the range of 50-250 lbs., capable for up to eight sockets and 1.5 million cycles per sample, load calibration capability, cycle counter and wear tracking/measurement.

  

Project 9: Design of Fascia to Improve Air Flow for Brake Cooling

• Team Members: Joshua Macy, Alexander Rosaen, Doug Spearot, Shannon Weakley
• Sponsor: Ford Motor Company
• Supervisor: Prof. Nicolae Orlandea
• Abstract: This 2002 Expedition Navigator (sports utility vehicle) which is currently in the design stage at Ford would like to have an advanced fascia design. They would like to add the function of directing air flow for cooling of front brakes into the design of the front bumper fascia. The design should also consider the manufacturing issues such as material and assembly with other components. A good simulation is expected before the prototype demonstration.

Project 10: Engine Start-up Simulation Test Bench

• Team Members: Mark Adams, Mark Bickenbach, Kris Hess, Leo McAfee, Heather McKee
• Sponsor: NTN Technical Center
• Supervisor: Prof. Jun Ni
• Abstract: The purpose of this project is to design and build a test bench to simulate the high acceleration rates encountered during start-up of automotive engines. Torque will be applied to automotive accessories as part of a durability test program. Potential components of this system are a speed controller, motor, flywheel, clutch/brake, automotive accessory (alternator) and belt drive. The motor will run a flywheel to maintain relatively stable speed. The clutch engages and accelerates the accessory quickly to drive speed. After a stabilization phase, the clutch disengages and stops the accessory. The cycle can then restart.

  

Project 11: Graphite Seal Life Test Rig

• Team Members: Chris Barager, Justina Cho, Rebecca King, Wendy Pan, David Thomsen
• Sponsor: Cummins Engine Company
• Supervisor: Prof. Nicolae Orlandea
• Abstract: In a diesel engine cylinder head gasket, we wish to use expandable graphite (similar to a flattened popcorn made of graphite) as a sealing element for fluid (coolant and oil) passages between the cylinder block and head. The graphite is to be constrained between a cutout in a solid steel gasket body. The project is to build a compact test rig that will allow 20 grommets to be tested simultaneously.

  

Project 12: New Anodizing Plant Design & Layout

• Team Members: Roni Mansur, Jon Rushman, Ala Saket, Ron Yang
• Sponsor: Alpha Metal Finishing Company
• Supervisor: Prof. Liwei Lin
• Abstract: Alpha Metal Finishing Co. is a manufacturing plant that has unique expertise in metal finishing. The company is planning to build a new plant to expand its working capacity. The purpose of this ME450 project is to design the layout for a new anodizing plant. The existing plant may be studied to determine work flow, space, environments, communications (data, supervision and training), and opportunities for automation. The goal is to increase capacity three-fold with a minimum of a well-thought out floor plan.

Project 15: Space Probe Release Mechanism

• Team Members: Justin Bill, Andrew Drake, Mustafa Ozturk, Peter Schoenfeld, Nathaniel Stott
• Sponsor: UM-EECS and AOSS
• Supervisor: Prof. Nicolae Orlandea
• Abstract: The UM's Space Physics Research Laboratory is participating in a NASA mission to demonstrate a new kind of in-space propulsion technology using electrodynamic tethers. We need a design team to develop, thoroughly analyze, prototype, and test a release mechanism for a 1m x 0.01m diameter probe. Surviving the launch/space environment and considering its brief exposure to high-energy propulsion products will be required.

Project 16: 1999 Formula SAE Rear Chassis

• Team Members: Todd Brittingham, Benjamin Bulat, Ravindra Kharmai, Peter Lazarevski, Joel VanderSchel
• Sponsor: UM-MEAM
• Supervisor: Prof. Nicolae Orlandea
• Abstract: The goal of this project is to design, analyze, and manufacture the rear frame, suspension, and drive train for the 1999 Formula SAE Car. Based on the guidelines of the competition, the rear chassis will emphasize: low cost, low mass, ease of manufacturing, safety, serviceability, aesthetics, build quality, and mechanical design. In order to produce a high performance and competitive car, the project group must integrate and optimize the aforementioned factors.

  

Project 20: A Mechanically Controlled Fuel Injection System

• Team Members: Leanne Frederick, Keith Janson, David Ternan, Koling Wai, Matthew Wang
• Sponsor: Inventors Design and Development Inc.
• Supervisor: Prof. Nicolae Orlandea
• Abstract: The project involves the design of a mechanically controlled fuel injection system for two stroke engine lawnmowers. The students would have to scale down and adopt an existing design that runs on four-stoke internal combustion engines to two-stroke engines. Upon design, we would have to test a lawnmower equipped with the new fuel injector in the Auto Lab, and demonstrate that it achieves slower emission levels than the unmodified, carburetored, state-of-the-art lawnmower.

Project 22: Design of a Material Handling System for Reconfigurable Machining Systems

• Team Members: Irina Feldman, Daryn Berger, Lamar Jones, Brian Stiber, Stefan Velkovski
• Sponsor: UM-ERC/RMS
• Supervisor: Prof. Jun Ni
• Abstract: The Engineering Research Center for Reconfigurable Machining Systems (ERC/MRS) at the University of Michigan is in the process of designing and building an RMS testbed. In order to meet the future demand of agile and reconfigurable manufacturing systems, this testbed will be developed to produce a family of automotive engine heads. A group of four CNC machining units will be integrated into a small scale RMS. As an essential part of the RMS system, there is a need to design and build a material handling system for the CNC machining units.

Project 24: Design and Fabrication of a Custom Bicycle

• Team Members: Jesse Field, Charles Garnett, Bruce Lange, Christopher Marroquin, Laura McWilliam
• Sponsor: UM-MEAM
• Supervisor: Mr. Peter Halliday
• Abstract: The purpose of this project is to design and fabricate a bicycle for a physically-challenged rider. The rider's legs terminate at the knees and the rider has only one arm with a partial hand. This will likely be a three-wheel design with an emphasis on easy entry and exit.