Fall 1999 Design Projects

Project 1: Electrically Operated Orthotic Elbow

• Team Members: Sandhya Clarke, Matthew Bassin, Kent Spencer, Larry Berrhill
• Sponsor: Dr. A. Peethambaran, U of M Orthotics and Prosthetics Center
• Supervisor: Prof. Sridhar Kota
• Abstract: The project goal is to design an electrically operated orthotic elbow joint to power a paralyzed arm through a full range of motion. The device would aid persons with one or two paralyzed arms in their daily routine. This is to be accomplished while still maintaining minimum weight and bulk on the arm. The student team investigated different approaches and finalized on a design that employs a self-locking worm gear that is driven by a motor so as to move and lock the arm into an infinite number of positions. The design would be battery powered and controlled using myoelectric sensors.

  

Project 2: Automotive Luggage Door Torsion Bar

• Team Members: Matthew Jannausch, Jason Brown, Cheryl Lim, Anita Arora
• Sponsor: Toyota Tech Center
• Supervisor: Prof. Panos Papalambros
• Abstract: A single torsion bar was designed to replace the dual torsion bar system in many existing automobile trunks. The goal was to match performance standards while reducing cost and production time. A prototype based on the Toyota Camry has been assembled to demonstrate an improvement in performance, weight and cost. The design involves primarily a new geometry and layout of the torsion bar system.

  

Project 3: Airflow Measuring Device for Automotive Alternator

• Team Members: Kelly Sharland, Kevin Kwiatkowski, Thanh Tran
• Sponsor: Visteon Energy Transformation Systems
• Supervisor: Prof. Nicolae Orlandea
• Abstract: In a typical automotive alternator, cooling fans dissipate the heat produced by the electrical current generating process. These fans are responsible for a significant portion of the alternator-radiated noise. Currently, fan noise studies are conducted in Visteon's alternator noise test chamber, but there is no means to simultaneously measure alternator radiated noise and airflow rate. Therefore, an airflow measuring device was designed which easily fits to an alternator, portable, and easy to calibrate without adversely affecting the radiated noise characteristics. This would save considerable test time and would provide a more complete assessment of various fan designs. The final solution employed an Integrated Hot Wire Sensor.

  

Project 4: Automotive Alternator Fan System

• Team Members: Joseph Zawacki, Brain Pine, Kevin Janicki, Ali Arghavani
• Sponsor: Visteon Energy Transformation Systems
• Supervisor: Prof. Nicolae Orlandea
• Abstract: The anticipated demand for higher output alternators, with resulting higher component temperatures, and the demand for quieter alternators have created a conflicting need for lower noise fans with higher flow rates. The objective is to design a fan system with maximized flow rate and minimized noise. The student team generated and evaluated many alternate designs. The team optimized fan blade geometry, number of fan blades, position of fan blades, and housing inlet/outlet modifications.

  

Project 5: The Dumpster Loader

• Team Members: April Nelson, Nick Schmidbauer, Robbie Linkner, Erik Chubb
• Sponsor: Great Lakes Construction Services
• Supervisor: Ms. Kerr-Jia Lu
• Abstract: The goal of this project is to design a dumpster mechanism that is universal, safe, portable, inexpensive, and durable. There is a great need for such a device because the current methods of loading a dumpster are inefficient and cause many potential health risks and nothing of this type exists. The final design is a stair-type dumpster loader device with four basic parts including: (i) adjustable hooks which can adopt to dumpsters of varying heights; (ii) a platform which enables workers to look over the dumpster and know where the refuse will land; (iii) foldable steps which can be used in different work environments and attach to all types of dumpsters; and (iv) reinforcement wires which provide the strength to support the workers and heavy debris.

  

Project 6: Low Cost Lumbar Support

• Team Members: Jason Morris, Ryan Kennel, Ana Malusev, Mitchell Stovall
• Sponsor: Johnson Controls
• Supervisor: Ms. Kerr-Jia Lu
• Abstract: Over the years, seats in modern automobiles have evolved to satisfy the general customer's need. To provide optimum comfort for as many people as possible, seats have become fully adjustable and have adopted many integrated features. One of these features is an adjustable lumbar support. Although typically found on higher priced vehicles, the demand for low-cost lumbar support in all vehicles is strong. After generating a number of design alternatives, the student team settled on the final concept of an air pump system, which includes a pump/valve assembly to actuate the system, an air bladder to support the lumbar region, and a support plate attached to the seat frame.

  

Project 7: Automobile Fuel Tank Motion/Force Simulator

• Team Members: Courthney Crouse, Rolando Gonzales, Chris Aichler, Michael Pitsch
• Sponsor: G.T. Products
• Supervisor: Prof. Nicolae Orlandea
• Abstract: G.T. Products designs vent valves for the fuel tank. A test fixture that simulates a fuel tank to test the valve under different driving conditions is desirable. A design project involving hydraulics, pneumatics, and control systems is proposed. The project goal is to design a dynamic fuel tank slosh fixture to simulate the motion of an automobile fuel tank and the forces applied to the tank as close as possible. Data from real life experiments is to be used to simulate the slosh for the valve and fuel tank durability. The team found that a Stewart Platform system in combination with additional degrees of freedom for increasing the range of the simulator in two directions was the best solution to reproduce field data. Extensive kinematic analysis and load analysis was done in designing such a system.

  

Project 8: Gas Connector Test Mechanism

• Team Members: Gregory Sims, Tom Campbell, Jason Forton, Akunna Olumba
• Sponsor: Brass Craft Mfg.
• Supervisor: Ms. Kerr-Jia Lu
• Abstract: Brass Craft Manufacturing find a solution to their testing needs when testing the connector tubes. Previous test fittings failed due to wear of the seals. The type of seal employed was one, which was inserted into the test specimen then expanded to mate on the inner diameter and form an airtight seal. This seal allowed subsequent pressure testing of 3 psi to be performed. After scrutinizing Brass Craft's process, the student team generated solutions to critical engineering issues. The final decision is to use a flat seal which is the simplest and most reliable solution. These seals will be actuated with a pneumatic cylinder.

  

Project 9: Extendable Bumper

• Team Members: Caroline Skiba, Darin Cepeda, Aaron Peavey, Brain Brunzell
• Sponsor: General Motors Corp.
• Supervisor: Prof. Sridhar Kota
• Abstract: Currently in automotive design there is a demand for more stylish , and smaller vehicles. In the event that these smaller vehicles are involved in a collision, they do not exhibit the energy absorption properties of larger vehicles. The reduced energy absorption is greatly influenced by the size of the vehicle, that is, the distance between the front of the vehicle and the passenger compartment. In effect, increasing this distance increases the crush zone and decreases physical injury to the passenger. The project goal is to design a bumper that extends upon sensing an impending collision, after which the bumper locks out, effectively making the vehicle's dimensions that are much longer and its energy absorption characteristics that much greater. The project team also generated many alternate solutions.

  

Project 10: Ultra Close Tire-to-Body Wheel Openings

• Team Members: James Min, cynthia Phillips, Brian Conti, Teresa Willams
• Sponsor: General Motors Corp.
• Supervisor: Prof. Sridhar Kota
• Abstract: Advanced car styling concepts, which depict very tight wheel and tire body cutouts can not be produced with conventional technology. Clearances for suspension travel and wheel steering dictate a large clearance between tire and body. The goal is to make this ultra close tire-to-body wheel opening possible. A sketch illustrating the design specification is available.

  

Project 11: Advanced Vehicle Battery Pack - Thermal Support Unit

• Team Members: Shih-Yuan Lee, Robert Prucka, Brian Peterson, Christal Canevet
• Sponsor: General Motors Corp.
• Supervisor: Prof. Panos Papalambros
• Abstract: This project involves a new design concept for a Battery Pack Thermal Support Unit (BPTSU) specifically developed for applications both in an electric vehicle and in a laboratory environment. In a laboratory setting, the BPTSU can simulate vehicle conditions on the road in order to test battery life. In the electric vehicle application, the BPTSU can be used to regulate the thermal environment of the battery pack. The design was developed in the context of other state-of-the-art systems with similar functions and it exhibits superior performance.

  

Project 12: Next Generation Dishwasher Rack

• Team Members: Aaron Feiner, Cynthia Moon, Daniel Archibald, Robert Surma
• Sponsor: Whirlpool Corporation
• Supervisor: Prof. Panos Papalambros
• Abstract: This project involved creation of an innovative and reliable, yet aesthetically pleasing dish rack and winged plate holder for Bauknecht, a German subsidiary of Whirlpool Corp. The dish rack has clear plastic sides and a flat-bottomed wire substructure that supports all the weight. A winged plate holder fits different plate sizes, can be placed into and taken out of the dish rack with ease. The holder is activated only when a plate is placed in it, allowing for pots and pans to be easily placed while it remains folded. The design has a dish rack with a slide-in plastic collar and a flat mesh substructure, as well as a modular plate holder with feet that interact with the rack.

  

Project 13: Hip Joint Power Measurement Device

• Team Members: Kristi oikarinen, Joseph Zogaib, Bill Kasiske, David Lin, Huang Hao
• Sponsor: Dr. Neil Cole, Dr. James Ashton-Miller
• Supervisor: Prof. Panos Papalambros
• Abstract: An important example of mechanical power used in the human body is in the function of the hip joint. This joint is used in a number of daily activities such as walking, running, getting up from a chair, or kicking a ball. However, the hip joint performance, even in these daily activities, can be dramatically hindered by certain kinds of disease and sicknesses. Biologic is a local company marketing an electromechanical machine that measures the maximum power output in the human hip joint to support biomechanics research. The machine consists of a padded bed, on which the patient lays on his hip. One leg is then extended, and rested against a leg level, and the maximum power output is measured through a torque transducer. This device has been redesigned for improved performance.

  

Project 14: 2000 Formula Car: Adjustable gas/brake/clutch pedal assembly and steering

• Team Members: Jeff Roselli, Srinidhi Nagaraja, Temin Lee, Charles Chung
• Sponsor: SAE (Society of Automotive Engineers)
• Supervisor: Prof. Nicolae Orlandea
• Abstract: In the previous years, the Formula SAE (Society of Automotive Engineers) team has designed adjustable seats to accommodate drivers' height and position preferences. However, the undesirable seat motion during hard cornering seems to be very disconcerting for drivers. Therefore, the student team designed adjustable pedals keeping the seat fixed for next year's competition. The Formula car team consulted with the U of M Transportation and Research Center to establish positive ergonomics in the chassis design. The goal is to design a low cost and light weight adjustable pedal unit.. The Formula SAE team has also designed and fabricated a generic steering rack system that meets the specification for racing and has reduced friction and weight compared to the current designs.

  

Project 15: Automated Sample Transfer System for Nuclear Reactor

• Team Members: James Cummings, Robert Hutchinson, Kristin Miller, Kay Shen
• Sponsor: Ford Moter Corp.
• Supervisor: Prof. Sridhar Kota
• Abstract: The Ford Nuclear Reactor, a division of the Phoenix Memorial Project at the University of Michigan, is updating their pneumatic tube system that is used to send samples to the reactor core for irradiation. Currently, the samples are manually loaded individually at the send station and launched to the reactor per the pneumatic tube system. After forty years of use, the tubing system has begun to leak and an automated system is desired. The student team has designed an automatic launch station that will launch multiple samples without any user intervention and track the samples throughout the tubing system. This system will be PC controlled and compatible with the other subsystems being designed by the laboratory.

  

Project 16: Delta Parallel Robot Project

• Team Members: Nicolas Wetzler, David Pratt, Ben Vander Ploeg, Jeff martin
• Sponsor: Prof. Nicolae Orlandea
• Supervisor: Prof. Nicolae Orlandea
• Abstract: Delta parallel robot is a three degrees of freedom parallel robot that is used for material handling and sorting. The diversity of the materials that can be handled range from screws to chocolates and its productivity makes it attractive. However, these robots require a control system even for the simplest tasks such as executing a straight-line path by the end effector. The structure of the delta robot that was built by students in ME450 during the Spring 1999class was successful; however, the driving mechanisms and controller were not robust.. The student team redesigned the driving mechanism and the controller to satisfy the specification of 6-10 work cycles per minute.

  

Project 17: Gates and Timing System for Cub Scout Pinewood Derby Races

• Team Members: Theresa Waugh, Bryan Cless, Chad Stock, Emily Kraft
• Sponsor: Prof. Noel Perkins
• Supervisor: Prof. Noel Perkins
• Abstract: The Ann Arbor Cub Pack 78 holds a pinewood derby race every spring in which 50 or more cub scouts race their vehicles. This is a competitive event and one that is a highlight of the scouting activities planned each year. The Pack would like to use an automatic gating device and timing system to insure that the races are efficient and the timing is accurate. The student team designed and fabricated the starting gate, the stopping gate, and a PC based timing system. The gates can be attached to an existing race track that was made available for this project. The PC collects and processes the start and stop signals from the sensors and display the race times as output in an organized fashion.

  

Project 18: ENDOTEAM - Catheter Insertion Training Simulator

• Team Members: Joshua Charm, Paul Hanna, Nader Iskandar, Felipe Velasco
• Sponsor: Prof. Brent Gillespie
• Supervisor: Prof. Brent Gillespie
• Abstract: The Endo-Team's goal was to design and prototype, for research purposes, a mechanical device that will act as a simulator for training endovascular surgeons, when coupled with supporting electronics and software. The device, called a haptic interface, facilitates the re-creation of the "feel" of the endovascular surgical procedure. The design created continually monitors the insertion (displacement) of a catheter, wire, or instrument that is inserted through a port by a trainee, and provides feedback information to a computer. In addition, the device creates an axial force along the catheter wire or instrument with its magnitude controlled by a computer.

  

Project 19: High-Strain Actuators

• Team Members: Dan Pangburn, Sandeep Khattar, Adam DeGrazia, Felix Chan
• Sponsor: Prof. Sridhar Kota
• Supervisor: Ms. Kerr-Jia lu
• Abstract: The objective is to develop an energy efficient means to amplify actuator displacement. Current smart material actuators have limited ranges in motion, power or frequency. The students were expected to achieve a target displacement at a certain operation frequency with sufficient block force for several possible applications, such as the aerospace industry. Based on examination of the performance of mechanisms that have been used in the past, and the limited capabilities of commercially available actuators, the student team employed a single-piece compliant mechanism compactly packaged with a mechanical actuator to accomplish these goals. The scope of application of this device will depend on the performance of this concept, which will be revealed through further quantitative analysis of mechanism concepts. This tentative stance is a result of the ground-breaking nature of the project-concept.

  

Project 20: Automatic Golf-teeing Machine

• Team Members: Maurice Finnegan III, Katherine Eggleton, Jeff Dieterle, Jamie Rademacher
• Sponsor: Prof. Sridhar Kota
• Supervisor: Prof. Sridhar Kota
• Abstract: The objective of this project is to design an automatic golf-ball teeing machine. The machine should automatically tee up a ball after a player hits one. This will prevent a golfer from having to bend over after each shot thus breaking his/her concentration. Several concepts already exist, but they are either costly or do not function well. The project goal is to design a low-cost and a reliable golf-ball teeing device. The student team designed a simple four-bar linkage mechanism to meet the design requirements. The device is designed to fit within a typical automobile trunk and has (a) a container to hold balls, (b) a linkage mechanism to transport balls from the container to the tee, and (c) a means of triggering ball-placement .

  

Project 21: Mobile Transfer Device to Aid the Wheelchair-Bound

• Team Members: Fred Barrigar, Mari Endo, Eric Beckhold, Stacey Durham
• Sponsor: PROCEED, Customer: Steve Laux
• Supervisor: Prof. Sridhar Kota
• Abstract: For a person confined to a wheelchair, an action as simple as transferring from the wheelchair to a bed can be impossible without assistance. For this reason, there is a need for a device that would allow a disabled individual to make this transfer on his or her own. Working closely with the customer who is in need of such a device, the student design team has developed an innovative design that will uniquely fill this need. The device is mounted on casters for mobility within the living environment and docks with the wheelchair. It has a boom, which can swivel and carries a sling for transferring patient to and from wheelchair to bed. An electric motor powered by the wheelchair battery drives a winch, which is attached to the sling via ropes and pulleys.

  

Project 22: Home Recycling Facilitator

• Team Members: Alexandra Platusich, Diana Bitleris, John Weinert, Jacob Wallace
• Sponsor: Padnos Design Competition
• Supervisor: Prof. Panos Papalambros
• Abstract: As environmental education becomes more widespread we realize that we must try to reverse negative effects accumulated over the years, and to conserve resources through recycling. The device designed enables people of all ages to participate in recycling and efficiently reducing waste with ease from within their own kitchen or garage. The Home Recycling Unit is designed to reduce the amount of recycled material that accumulates in the home by crushing aluminum cans and plastics in an effortless, safe, and efficient manner, at a cost that is affordable to the average consumer.