2019
ME CAPSTONE PROJECTS
ME Capstone Projects 2019 Categories CATEGORY: COMPETITION TEAMS 1 Sooner Off-Road
1
Student Team: Matt Muhlinghause, Haley Ricks, Devin Prochniak Sponsor: OU Advisor: Dr. Chang
6
Sooner Racing Team
2
Student Team: Ryan Cowdrey, Adam Flenniken, Justin Porter, Jack Sartin Sponsor: OU Advisor: Dr. Dalton
7
Sooner Powered Vehicle
3
Student Team: Guy Elisha, Jake Pannell, Philani Hlanze Sponsor: OU Advisor: Dr. Dalton
8
Sooner Rover Team
4
Student Team: Adam Kordsiemon, Jacob Clark, Jiaze Gao Sponsor: OU Advisor: Dr. Dalton
CATEGORY: EXPERIMENTAL AND TESTING 17
Flame Reactor for Synthesis of Mixed Transition Metal Oxide Nanostructures
5
Student Team: Alfredo Becerril Corral, John Keith, Garrett Poindexter, Amy Warling Sponsor: Dr. Merchan-Merchan Advisor: Dr. Hekiri
20
Test Bench for ESP Seal Section Permeability
6
Student Team: Logan Vitello, Marshall Thorpe, Travis Wilbanks, Logan Roys, Ifeanyi Ijioma Sponsor: BHGE Advisor: Dr. Lai
22
Two Phase Heat Transfer Chamber
7
Student Team: Rosa Lopez, Will Know, Derek Shaw, and Branimir Milicevic Sponsor: Dr. Shabgard Advisor: Dr. Lai
25
Thrust Bearing Test Apparatus
8
Student Team: Parker Charles, Jose Hernandez, Eugene O’Fallon, John Weichel, Andrew Zimmer Sponsor: BHGE Advisor: Dr. Mistree
26
Test Apparatus for O-ring Sealing Capability Student Team: Travis Barnett, Sean English, Ashley Kennedy, Riley Kostiuk, Weston Sleeper Sponsor: BHGE Advisor: Dr. Mistree
9
2019
ME CAPSTONE PROJECTS
29
Flow Loop Setup to Circulate a Debris Laden Fluid
10
Student Team: Dillon Kovar, Suman Adi, Mark Sukalski, Oumar Coulibaly Sponsor: Schlumberger Advisor: Dr. Siddique
30
Setup to Evaluate Debris-Scrapper Ring Designs
11
Student Team: Courtney Holloway, Haydn Kirkpatrick, Alex Nagy, Abel Rivera, Nick Son Sponsor: Schlumberger Advisor: Dr. Siddique
31
Setup to Evaluate Soft and Hard Platings on Metals
12
Student Team: Christian Morris Huerta, Deante Mahome, Haoruo Duan, Thomas Huber, Jie Su Sponsor: Schlumberger Advisor: Dr. Siddique
32
Setup to Conduct Permeation Experiments on Barriers
13
Student Team: Karim Aznag, Katherine Faux, Samuel Infanti, Austin McKee Sponsor: Schlumberger Advisor: Dr. Siddique
33
Setup to Measure Compressive Force of Gasket Rings
14
Student Team: Ujjwal Basnet, Yuhong Qian, Honglu Li, Richard Hoffman Sponsor: Schlumberger Advisor: Dr. Siddique
34
Reciprocating Setup to Accommodate Fluids with Abrasive Particulates
15
Student Team: Alex Lensing, Abdullah Asim, Abedalqader Al Zeghari, Caleb Friend Sponsor: Schlumberger Advisor: Dr. Siddique
35
Design an Experimental Setup and Methodology to Compare the Pitting Corrosion Resistance
16
Student Team: Josh Engle, Drew Fazzino, Vishma Senevirante, Chaymaa Bellahrach Sponsor: Schlumberger Advisor: Dr. Siddique
39
Recording System for Animal Ocular Movement
17
Student Team: Spencer Gallucci, Venus Luong, Josh McCraw, Shangru Wu Sponsor: Dr. Dai Advisor: Dr. Stalford
40
Vapor-Compression Cycle Control and Monitoring System
18
Student Team: Yunyu Zhou, Qilin Li, Ryan Scroggins, Steven McNabb, Ryan DeYear Sponsor: Dr. Cai Advisor: Dr. Stalford
CATEGORY: STUDIES 2 Hinge Fixture Design (Interdisciplinary with ISE)
19
Student Team: Christopher Tuttle, Jonathan Tuttle, Addison Fehl, Kolton Topetchy Sponsor: Tinker AFB Advisor: Dr. Chang
3
Low Cycle Fatigue Life Cycle for Turbofan Engine Student Team: Blake Knighton, Hugo Perez, Jordan Shelby, Zhi Xie Sponsor: Tinker AFB Advisor: Dr. Chang
20
2019
ME CAPSTONE PROJECTS
4
B-52 Spoiler Fixture Redesign
21
Student Team: Morgan Wolfe, Alex Arment, Alex Mudd, Tyler Thibodeau, Roshan Mathews Sponsor: Tinker AFB Advisor: Dr. Chang
5
3D Printing for Shape Memory Polymers
22
Student Team: Robert Beem, Ryan Bodlak, Wyatt Maney, Colton Ross, and Luke Whitney Sponsor: Dr. Lee Advisor: Dr. Chang
12
Jet Engine Test Cell Reliability Analysis
23
Student Team: Krishna Tiwari, Nick Morris, Myles Swaner, Jacob Palfreyman, Trey Leal Sponsor: Tinker AFB Advisor: Dr. Hekiri
13
Blast Media Recovery Optimization
24
Student Team: Josh Feyerabend, Thomas Hightower, Douglas Yancy, Abraham Yihdego Sponsor: Tinker AFB Advisor: Dr. Hekiri
14
Landing Gear Yoke Redesign
25
Student Team: Noah Golly, Christina Moreno, Emily Rogers, Matt Cook, Kaylee Buckley Sponsor: Commander Aircraft Advisor: Dr. Hekiri
15
B-52 Mounting Tray Vibration Analysis
26
Student Team: Bao Do, Rodney Hurt, Teddy Nguyen, Thomas Tran Sponsor: Boeing Advisor: Dr. Hekiri
16
B-52 Bonded Stiffener Trailing Edge Panel Redesign
27
Student Team: Zach Pelton, Will Lauterbach, Austin Coldiron, Zack Martin Sponsor: Boeing Advisor: Dr. Hekiri
18
Air Flow Analysis for Diaper Panel Control
28
Student Team: Justin Schmidt, Elizabeth Alig, Dawaylon Barnes, Ann Broostin, Michael Albertson Sponsor: Kimberly Clark Advisor: Dr. Lai
19
Improving Product Control Conveyor Access
29
Student Team: Meagan Johnson, Trent Pence, Luke Phillips, Rachel Sandlin Sponsor: Kimberly Clark Advisor: Dr. Lai
21
Redundant Chiller and Boiler Design
30
Student Team: Austin Laukoter, Cole Massad, Drew Knox, Kevin Helm Sponsor: Tinker FAA Advisor: Dr. Lai
23
Boiler and Condenser Modification
31
Student Team: Stephanie Prado Carbonell, Kyle Christenson, Rick Hahn, and Abdenbi Lamzabi Sponsor: Hitachi Advisor: Dr. Lai
24
ESP Motor Test Well Support Design
32
2019
ME CAPSTONE PROJECTS Student Team: Colin Bray, Cameron Greer, Brandon Hunkin, Frederick Kordsiemons Sponsor: Dr. BHGE Advisor: Dr. Mistree
36
FAA OSHA Compliant Climbing Methods for Human Safety
33
Student Team: Wesley Dale, Brent Fenske, Lauren Tangney, Jon Ballard Sponsor: FAA Advisor: Dr. Stalford
37
Vehicle Mast: Raising/Lowering Methods
34
Student Team: Austin Petit, Sarah Mailot, Armahn Roozbeh, Michael Evans and Luke Starks Sponsor: FAA Advisor: Dr. Stalford
41
Piezoelectric Sensors for HVAC applications
35
Student Team: Ryan Perkins, Spencer Hinkle, Joseph Nostrand Sponsor: Dr. Song Advisor: Dr. Stalford
CATEGORY: PROTOTYPE DESIGN 9 Interactive Gymnastics Exhibit for Science Museum Oklahoma
36
Student Team: Bryan Boone, Covey Barlow, Isaac Pryzant, Garrett Parkhurst, Jared Alex Sponsor: SMO Advisor: Dr. Dalton
10
Package Belt and Chute Redesign (Team 1)
37
Student Team: Marquez Byrd, Riley Least, Brock Maldonado Sponsor: USPS Advisor: Dr. Dalton
11
Package Belt and Chute Redesign (Team 2)
38
Student Team: Lejla Sisic, Michael Moore, Tami Alabi Sponsor: USPS Advisor: Dr. Dalton
27
Robotic Arm System for Hospital Use
39
Student Team: Luis Donoso, Pum Mang, Aaron Vu, Tuan Vu Sponsor: Cara Gonzales Advisor: Dr. Mistree
28
Introducing Girl Scouts to STEM
40
Student Team: Moises Martinez, Nicole Reed, Emma Hensley, Dakota Martin Sponsor: Girls Scouts Advisor: Dr. Mistree
38
Gaming/Electronics Assist Equipment Student Team: Pranav Mohan, David Carris, Gerald Lance, Ashley Medice Sponsor: Ramirez Family Advisor: Dr. Stalford
41
2019
ME CAPSTONE PROJECTS
INDUSTRY SPONSORS
42
2019
1
CATEGORY: COMPETITION TEAMS
Sooner Off-Road
A continuously variable transmission (CVT) is a type of vehicle transmission that is used to transfer torque and power from the engine to the wheels. The current CVT being used by Sooner Off-Road does not have the tuning or performance capabilities desired by the team. Goals in creating a new CVT are to decrease weight, decrease cost to the team, increase tunability, and improve acceleration and top speed. These goals have been achieved through the iterative design process and CVT theory calculations. Through our research, we created a new CVT that uses a different geometry. A spider arm design uses flyweights as opposed to the curved ramps in the model that the team currently uses. The ramps have the cam profiles that determine how the CVT will be shifting as the engine RPM increases. Our team created a cam profile analysis tool (CPAT) that was able to determine the CVT performance through static and dynamic calculations. CPAT was tested by placing the CVT on a dynamometer and verifying the results, which showed an error of less than 1%. The openness of the new CVT design allowed for a large decrease in weight. Many unnecessary components were either removed or reduced, taking the final weight from 8lbs to 3lbs. The acceleration of the vehicle changed from 5 seconds per 100 feet to 4.5 seconds per 100 feet. Tunability was increased by making the preload on the spring adjustable. The final cost of the CVT was reduced from $2200 to $250.
1
2019
6
CATEGORY: COMPETITION TEAMS
Sooner Racing Team
The Sooner Racing Team has developed a vehicle aimed at winning the 2019 Formula SAE Lincoln event. A pneumatic shifting system was developed so the driver can easily shift the car via the use of paddle shifters. A fuel system was developed to provide sufficient fuel to the engine while allowing for easy disassembly for servicing. These systems were designed to be lightweight and reliable for the car to perform at a high level without system failure. A data acquisition system was created to monitor the output of the vehicle’s engine using an engine dynamometer. The average torque output of the engine was found to be 45.8 ft-lbs. at 6750 RPM. In addition, a more accurate way of tuning both the engine fuel map and timing curve has allowed us to increase the engine’s overall performance. Steady-state and transient vehicle dynamics simulations were developed. The developed simulations will help to optimize suspension setups and future vehicle designs. The 30 degree of freedom state-space model for transient simulations allows for study of transient vehicle response for corner entry, straight line acceleration, and driving over uneven road surfaces. Testing was completed to simulate the forces the chassis will see during racing, to gain a more accurate understanding of the true behavior of the chassis and suspension in a racing scenario. This will allow the team to more accurately set up the suspension on the 2019 car and design to more accurate goals on future cars.
2
2019
7
CATEGORY: COMPETITION TEAMS
Sooner Powered Vehicle
This project set out to investigate the effects of adding a fairing to the Sooner Powered Vehicle in order to improve performance. The team considered 5 different materials (carbon fiber, E glass, S glass, Kevlar 29, Kevlar 49), and used a house of quality framework to determine the relative importance of different material properties including cost, UTS, Young’s modulus, and fatigue strength. Based on these results, the team selected E glass as the best material for this project due to its low cost and adequate performance. Next the team developed fully enclosed and partially enclosed fairings in Solidworks. The team used Ansys Fluent 19.1 to find the drag coefficient of each considered concept, including the case with no fairing, at a free stream velocity of 4.75 m/s (Re ~ 6.3*105). Using these drag characteristics as well as masses obtained through Solidworks, the team evaluated each concept and found the partial fairing’s combination of improved drag characteristics and low weight to be optimal. Once the partial fairing was selected, the team performed finite element analysis to simulate the load cases given by the competition rules for rider safety and found the design to be within the competition’s guidelines. The team is currently developing a manufacturing plan for the fairing, which will be delivered along with a complete CAD package of the design and the aerodynamic and structural analyses.
3
2019
8
CATEGORY: COMPETITION TEAMS
Sooner Rover Team
The 2019 Sooner Rover Capstone was formed to optimize the chassis of the school competition team’s rover. The main focus of this was finding a more effective way for to distribute the weight of large components mounted to the frame such as the arm. With these components attached, the current rover has difficulty on the extreme terrain that it is expected to drive for competition. Several concepts were considered that could potentially solve this problem, including the commonly used Rocker-Bogie concept used by NASA [1]. After looking at cost and time for this project, many of these concept were eliminated leaving alterations of the current Marsokhod design [2]. These concepts were then subjected to static analysis focusing on the forces of the frontal forces and how they were distributed as the pitch of the rover changed. This allowed for a determination of the strongest and weakest aspects of each concept allowing for the concepts to be optimized in an attempt to reduce the weaker points. The remaining concepts were subjected to SolidWorks comparative analysis, observing how each rover behaved differently in the same situations. The concept with a flat frame and a single point of rotation had the best overall performance from these steps and was selected as the final concept. An easy to manufacture design was created and FEA was performed to verify its feasibility. For proof of concept, a half-scale model of the current rover was created that could be tested and the performance compared to the half-scale model of the new chassis.
4
2019
CATEGORY: EXPERIMENTAL AND TESTING
17 Flame Reactor for Synthesis of Mixed Transition Metal Oxide Nanostructures The purpose of this project is to design a reactor chamber for the synthesis of mixed transition metal oxides. The chamber consists of 6 subsystems including, flame reactor, deposition plate holder for multiple deposition plates, exhaust system, the wire feeder and the chamber. Each subsystem to be designed must be manufacturable and cost effective. Flame characteristics are a primary concern during synthesis; therefore, the enclosure’s interior will be isolated from the outside atmosphere while the flame reactor is in operation. This also serves to shield operators from harmful fumes. Designed to hold multiple deposition disks, the deposition disk holder allows for the flame to only interact with one disk at a time and flow smoothly around the disk with little variation in the flame’s profile. This sub-function is also setup to be adjustable in elevation, and distance to the reactor so that the flame may strike the deposition plate completely orthogonal to the plate’s face as the angle of the reactor is adjusted. The wire feeder serves to feed source material into the flame and can be adjusted in elevation and distance to match the angle of the reactor. The exhaust system is responsible for evacuating the combustion gases from the interior of the chamber and safely transporting them away from the operator and immediate area. A secondary requirement designed into the exhaust system is the ability to easily disconnect the diffuser section within the chamber and connect a flexible hose to pinpoint the exhaust in a specific location within the chamber.
5
2019
20
CATEGORY: EXPERIMENTAL AND TESTING
Test Bench for ESP Seal Section Permeability
Baker Hughes, a GE company, assigned our team with a project to build a test bench for ESP Seal Section permeability testing. ESP’s, or Electrical Submersible Pumps, are a common type of artificial lift used for production in the Upstream Oil and Gas industry. These pumps are comprised of three sections: the motor, the seal section and the pump. The seal section is used to house the motor oil, absorb axial thrust and protect the motor. The oil is contained inside an expansion bag, separating the oil from the wellbore fluids. Baker Hughes wants to prevent the amount water permeating through these materials and into the motor oil. In order to do this, they’ve assigned us with building a test bench that allows them to test the permeability of different seal section materials. The final design of our test bench included a vertically oriented chamber that held heated and pressurized water on top and motor oil on the bottom, separated by the seal section material. We tested the permeability by circulating water through a heat bath at about 140° Fahrenheit, inducing a pressure differential of about 30 psi. Upon the conclusion of testing, the extracted oil sample did show signs of water contamination. Through light analysis testing, the team approximated that there was about 0.15mL of water per 60mL of oil. The test analysis also showed that no leakage had occurred during testing, supporting the claim that permeation through the material was the only cause for contamination. The team’s test bench prototype proved complete proof of concept.
6
2019
22
CATEGORY: EXPERIMENTAL AND TESTING
Two Phase Heat Transfer Chamber
A novel thermally-driven multiple-effect vapor chamber distillation (MVCD) system is presented for compact and portable desalination applications. The MVCD system consists of several vapor chambers connected in series with the condenser section of the upstream vapor chambers serving as the evaporator section of the following effect. A thermal network model using MATLAB coding accounts for the major thermal resistances is developed to predict the heat transfer and distilled water production rates through the MVCD system. The effects of the hot-end temperature, number of vapor chambers, and salinity of the input water on the performance of the MVCD system are investigated. It is found that for a fixed number of effects, increasing the hot-end temperature increases the distillation rate and decreases the second law efficiency. An energy analysis is also conducted to quantify the efficiency of the system from the viewpoint of the second law of thermodynamics. The effects of the hot-end temperature, number of vapor chambers, and salinity of the input water on the performance of the MVCD system are investigated. A prototype was designed using three chambers. The structure consist of acrylic and steel plates for the structure as well as the use of valves and pressure gages to maintain pressure within each chambers. Analysis was conducted using parameters of prototype with the MATLAB model. The increased salinity of the input water results in smaller distillation rate and improved second law efficiency. The prototype thermal desalination system presented has the potential to be inexpensive, compact, and potable in order to address the problems associated to the fresh water crisis.
7
2019
25
CATEGORY: EXPERIMENTAL AND TESTING
Thrust Bearing Test Apparatus
We are a team of consultants for SR&L, Self-Realization and Learning community. This consulting firm is led by CEO Farrokh Mistree and is designed to utilize experiential learnings to prepare us to hit the ground running as junior engineers. As consultants, we’ve been contracted to work with Baker Hughes and tasked with designing a test apparatus for their thrust bearings. The capabilities of this apparatus are dictated by newly accepted ISO 15551-1 standards designed to simulate the environment that the bearing will experience in down-hole submersible pumps. The ISO standards require thrust bearings to be tested under the following conditions: i. Oil Temperature = 400 F ii. Revolutions = 3,500 rpm iii. Max Loading = 32,000 lbf iv. Time of Test = 30 minutes As a consulting team, we have implemented several features into the design of this test apparatus so that it is capable of meeting each of the requirements provided by the ISO standards. Beyond the requirements, we have created a linear lift system to simplify and increase safety during the thrust bearing replacement process. Below is a list of features included in our design and how each feature contributes to meeting ISO requirements: v. A Hydraulic Cylinder to apply the 32,000 lbf load vi. An Electric motor capable of reaching rpms of 3,500 vii. A linear lift system has been implemented for ease of test replacement viii. The support bearing and additional supports provide protection to the electric motor In conclusion, our team of SR&L consultants has successfully delivered all project deliverables to Baker Hughes including a CAD package of the design, Process & Instrumentation Diagram, FEA of the external structure and a bill of materials with costs included. Baker Hughes receives value from these deliverables by gaining a design that will both satisfy the necessary ISO 15551-1 requirements as well as verifies the reliability of their thrust bearings. SR&L gains value from this project by developing a relationship with the industry sponsor which will lead to future collaborations and profits. Each consultant has also utilized experiential learnings from this project to equip ourselves with competencies to assist us in hitting the ground running as junior engineers.
8
2019
26
CATEGORY: EXPERIMENTAL AND TESTING
Test Apparatus for O-ring Sealing Capability
BHGE has contracted team BHGE3, a team of consultant engineers for the Self Realization and Learning Community (SR&L), to design a testing apparatus for variable geometry O-ring seals. BHGE currently does not have a way to quickly characterize the sealing capability of their Zero Extrusion (ZX) seals, which can be simulated by elastomer O-rings. The sealing capability of O-ring seals is defined as the working pressure versus the contact pressure used to engage the seal. The device’s design must meet a host of requirements that simulate what ZX seals can be subjected to during operation in an oil and gas well. The overall objective of the device is to generate data that is used to more accurately predict the strength and limitations of ZX seals. For BHGE, modeling the sealing ability of elastomer O-rings and utilizing that data for their ZX seals has a direct impact on their predicted performance. When the testing device is utilized, BHGE can make improvements on the quality of their product and better estimate potential limitations related to operating parameters. To summarize the results of the project, BHGE3 generated a CAD model for the test apparatus, performed FEA to verify functional feasibility, developed a bill of materials, and provided a weight estimation based on CAD models. While the project took every design requirement into account, the preliminary results and findings indicated that compromises to the modularity (variety in O-ring sizing) and weight requirements are necessary. BHGE3’s design meets significant portions of all requirements provided by BHGE and serves as a recommended path of exploration for their problem.
9
2019
29
CATEGORY: EXPERIMENTAL AND TESTING
Flow Loop Setup to Circulate a Debris Laden Fluid
The Capstone #29 team was tasked with designing and manufacturing a flow loop that circulates a mixture of water, xanthan gum viscosifier, and aluminum oxide particulates in order to test and compare different seals in oil transfer samplers, which were provided by the sponsor, Schlumberger. Targets of 8 ft/s flow velocity at a fluid pressure of 100 psi were given. This was achieved by placing the samplers between a pump rated to flow 22 gpm at 100 psi, the requisite flow rate for 8 ft/s in a 1 inch diameter pipe, and a ball valve that acts as a flow choke to create the requisite fluid pressure. The samplers discharge small samples (~1.04cc) of the fluid into sealed receptacles placed on a weigh scale, located beneath the samplers. Controllers provided by the sponsor and configured by the capstone team measure actual weight of the fluid in the receptacles, as well as readings from an RTD thermocouple and pressure transducer. Actual fluid weight is compared with expected fluid weight into a performance factor. A performance factor of 1.00 is ideal, with failure determined at +/- 10% of this value. A secondary branch of the loop houses a turbine flow meter to confirm flow rate before experiments are run while insulating the fragile meter from particulates. Preliminary testing confirms a flow rate of 23 gpm at 100 psi, and controllers are confirmed to accurately measure performance factor. Extended testing of the samplers is to begin during the summer months.
10
2019
30
CATEGORY: EXPERIMENTAL AND TESTING
Setup to Evaluate Debris-Scrapper Ring Designs
The scope of our project requires the creation, design, and assembly, of an apparatus to test scraper rings to failure and evaluate results. Scraper rings, provided by Schlumberger, were placed inside a piston-cylinder assembly and reciprocated within a debris-laden fluid. Failure is defined by a sudden, drastic drop in pressure. Major components of our test apparatus include a test stand, piston-cylinder assembly, linear actuator, hydraulic accumulator, data acquisition system, heating bands, nitrogen tank, pressure transducer, and thermocouples. Various team members worked to fabricate the test stand used to hold the piston-cylinder assembly. The actuator is controlled with limit switches to reciprocate the piston over a 2� stroke. A hand pump initially fills the system with the working fluid, then 220 grit aluminum oxide debris is added. The system is then heated using a PID controller with the heating bands to 200°F to simulate real-world environments in which scraper rings will be used. The assembly is then pressurized with nitrogen gas to 1000psi. The hydraulic accumulator allows the system maintain pressure with gradual fluid loss, allowing the scraper ring to be tested over a longer period. After pressurization, the piston-cylinder assembly begins reciprocating and the cycles are tracked along with pressure and temperature using team-written code. The system reciprocates until the internal pressure falls below the user-controlled threshold, initially set to 800 psi. Therein, failure is assumed, and the test concludes. Test runs with only O-rings and without heat have averaged 56 minutes, approximately 1108 cycles.
11
2019
31
CATEGORY: EXPERIMENTAL AND TESTING
Setup to Evaluate Soft and Hard Platings on Metals
Our task was to design, build, and test an evaluation system for different surface treatments on both 4140 steel and Inconel alloys. The value of this project to Schlumberger is to increase durability, life, and safety for Schlumberger machine parts. The design parameters include testing at a range up to 250,000 psi of contact pressure and for the circular tip design to have a maximum of 0.06 inches in diameter. Additional requirements of knowing the speed and coefficient of friction of each test were added to the design parameters later in the semester causing justifiable delays. Designing and building a test setup to Schulmberger’s specifications proved to be a challenge for our group. Through several technical issues and work arounds, our capstone group has been able to produce a working test setup to their specifications. The basic setup comprises of a hydraulic press with a 4140 steel tip and a linear actuator that pushes and pulls an Inconel coupon under the press. A pressure transducer collects the vertical load of the hydraulic press while a load cell collects the horizontal load needed to overcome the friction. An NI-DAQ subsystem records both loads and allows our team to calculate a coefficient of friction per test sample. The successful completion of designing and building this system allows this project to enter into the final testing phase where we will begin to rank the different surface treatments on Inconel Alloys on the basis of durability and coefficient of friction
12
2019
32
CATEGORY: EXPERIMENTAL AND TESTING
Setup to Conduct Permeation Experiments on Barriers
Schlumberger is the largest Oil and Gas Services Company in the world and is involved in everything from downhole tools to reservoir simulation computer programs. Many of the machines and equipment used for field operations experience harsh conditions with some operating at very high temperatures and pressures. These environments cause the downhole components to rely on various O-rings and seals to keep dangerous gases away from sensitive material including the environment. In order to prevent leakage of dangerous gases in these conditions it is important to understand the permeability of the materials used. This project deals with manufacturing an apparatus that can conduct permeability tests at pressures up to 1500 psi and temperatures up to 150°C utilizing Argon, Helium, and Carbon Dioxide. Previous designs were analyzed, and a new bore-andpiston design was created for the permeable cell. Four materials were tested including: FKM rubber, HNBR rubber, Teflon, and glass-filled Teflon. The permeated gases were then analyzed using Mass Spectrometry to determine the gas abundance using a two-way collection valve at the low-pressure end of the permeation setup. The results of this project help Schlumberger to decide which materials to use depending on the environmental conditions.
13
2019
33
CATEGORY: EXPERIMENTAL AND TESTING
Setup to Measure Compressive Force of Gasket Rings
The objective of the project was to build an apparatus to test compression and overpressure of gasket rings before and after oven ageing to determine spring characteristics. For the compression test we designed an annular load adapter to distribute compression load from the Instron machine to a gasket ring enclosed between two parallel metal plates. From analyzing the compression data recorded by the Instron machine, we calculated the reaction force exerted by the gasket ring’s spring. For the pressure test we sealed a toroidal region bounded on top and bottom by two plates, outside by an Oring, and inside by a compressed gasket ring. We then applied pressure to the toroidal region, ranging from 0 psi to 60 psi (gauge) in increments of 10 psi, and held each pressure for a minute. At each pressure stage we recorded any signs of gasket ring leakage. We heated gasket rings in the oven for multiple time durations ranging from 12 hours to 49 hours and tested these gasket rings for compression and pressure after each heating cycle. From our experiment we determined that the compression force on the gasket rings decreased by over 30% after they were heated for the first cycle, with a sharp decline in maximum external pressure the gasket rings could resist. Subsequent heating showed a nonlinear relationship between cumulative heating time and the decline in the spring’s reaction force, with the steepest decline being in the first heating cycle of 12-24 hours.
14
2019
CATEGORY: EXPERIMENTAL AND TESTING
34 Reciprocating Setup to Accommodate Fluids with Abrasive Particulates This project reviews the findings for testing the failure parameters of hydraulic seal 214 O-rings. The current method for testing these seals was to observe their parameters within a bore of a housing component. The issue with this design is it only test the static components of the seals. To better understand how the failure parameters are affected when motion is induced the seals were placed on a piston rod. In order for the seals to be able to nest on the rod a totally new design for both the housing and piston components had to be designed, since the project was using a setup from a previous experiment. The redesign also changed the way pressure is induced and created a negative volume for the rod. Two seals were then placed on the piston separated by the negative volume. To simulate real world conditions in which the seals would be used in, abrasive particulates along with fluid were loaded into the negative volume and tested at different pressures while the piston moved in a reciprocating motion. The failure parameter, which this project was determining, was the amount of leakage the seals allowed overtime when the previous stated conditions were applied. It was observed that as the pressure increased, the forces on the rod and seal increased resulting in the degradation of the seals. The data gathered can be used to characterized how the seals work under certain conditions to show their effectiveness and potential use.
15
2019
CATEGORY: EXPERIMENTAL AND TESTING
35 Design an Experimental Setup and Methodology to Compare the Pitting Corrosion Resistance Corrosion has been a challenge that affected many industries’ projects for decades. It occurs when metal is exposed to the atmosphere or seawater, which are ranked as the most corrosive environments, resulting in chemical reactions that cause deterioration. In this project, we are interested in the study of pitting corrosion. Pitting corrosion is a localized form of corrosion that produces hollow spaces in a material’s surface. Our main goal was to design an experimental setup and methodology to determine the onset of pitting corrosion and then compare the pitting corrosion resistance of different greases provided by Schlumberger. To achieve these goals, we determined the best apparatus for creating a controlled and consistent environment, created a methodology that ensures repeatability of testing conditions and preparation, acquired baseline data through testing pitting corrosion on the ASTM G48-11 standard sample without any lubricating greases and compared the results by recording changes in mass and depth of corrosion to quantify severity of pitting corrosion in each of the 4 grease samples provided by Schlumberger. The effectiveness of each grease was then calculated by comparing the time to onset of corrosion for each grease sample against the baseline sample which had no grease. In all cases, the grease delayed the onset of corrosion.
16
2019
39
CATEGORY: EXPERIMENTAL AND TESTING
Recording System for Animal Ocular Movement
Capstone project #39 is to setup up a video-oculography (VOG) system for small animals. This system tracks the movement of the subject’s eyes while the subject is experiencing multidimensional body movement. In mammals, there is an organ called the vestibule in the inner ear. The vestibule enables the sense of rotational movement and instantly adjusts eyeball movement to stabilize vision. This process is called vestibular-ocular reflex (VOR). It is an important indicator of vestibular function, which is the function of balance. Damage of the vestibule due to pathology, injury or age-related degradation can cause dysfunction of VOR and lead to dizziness, tinnitus or even loss of the function of balance. Dr. Dai is now working on investigating the vestibular function under healthy and damaged conditions. This VOG setup will be one of the key technical methods to allow us understanding the mechanism behind VOR and offer a guideline for therapy treatment and design of the medical device in vestibular dysfunction in the future. The VOG system itself consists of a gimbal, motors, cameras and computer interface. Utilizing the AME machine shop, the gimbal and camera mounts were machined out of aluminum and constructed in the lab. The electrical system were wired and programmed to be able measure real-time 3-dimensional binocular eye movement in response to 3-dimensional head/body movement caused by a motor system. To track the eyes, digital cameras have been implemented and programmed to track an array of three fluorescent non-collinear markers attached to each of the animal’s eyes.
17
2019
40
CATEGORY: EXPERIMENTAL AND TESTING
Vapor-Compression Cycle Control and Monitoring System
Dr. Cai is researching the most efficient way to control a variable speed compressor to achieve the maximum efficiency in an HVAC system. Our project was to create a LabVIEW controls and monitoring system for a vapor compression cycle with a custom graphical user interface as well as a technical document package with an overview of the sensors installed and wiring diagrams for the lab. The biggest design requirement for our team was for all our deliverables to be easily modified so that if the set up in Dr. Cai’s lab were to change, he and his team would be able to easily adjust the GUI as well as the wiring diagrams. The graphical user interface for the LabVIEW program was developed by our team in Solidworks, which is a program that Dr. Cai and his group have access to in lab. The GUI is designed to communicate how the HVAC system is performing by displaying sensor measurements where they are located in the system. It is this main page that will allow all the programming done in LabVIEW to be useful to Dr. Cai and his research team. The sensor installation, which was completed prior to the LabVIEW program, required the team to quantitatively justify why the sensors were placed in their positions by analyzing both the requirements of the sensor being installed as well as the sensors around it. At the conclusion of our project, we will be delivering to Dr. Cai a comprehensive technical document including wiring diagrams and sensor information as well as a turnkey controls and monitoring program.
18
2019
2
CATEGORY: STUDIES
Hinge Fixture Design (Interdisciplinary with ISE)
Tinker Air Force Base is responsible for the upkeep and maintenance of much of America’s airpower. They provide direct labor for the manufacturing and replacement of new components on a variety of airplanes, and one such part is a continuous hinge. These hinges come in a variety of lengths, but all have an incredibly small hole through their hinge teeth. In part production, a hole depth to diameter ratio of greater than 10:1 is known as “deep hole drilling”; a manufacturing technique that is difficult to achieve in many cases. Due to the pin diameter of these hinges, either 0.093” or 0.187”, and their corresponding lengths, all of Tinker’s hinges fall into the category of deep hole drilling, having a depth to diameter ratio of somewhere between 139:1 and 533:1. Tinker has purchased a gun drill for the deep hole drilling of these hinges, is in the preliminary stages of manufacturing design, and is interested in a design for a jig or fixture that would ameliorate the drill walking problems they are currently experiencing in their testing. The design proposed by this paper is a counter rotating jig, one that holds the workpiece and guides the drill bit. This design is supported by literature review and multiple practicing subject experts. Not only would this design potentially solve Tinker’s drill walking problems, but it would also provide benefits of repeatability, accuracy, and interchangeability in their hinge manufacturing.
19
2019
3
CATEGORY: STUDIES
Low Cycle Fatigue Life Cycle for Turbofan Engine
The objective of this project was to provide Low Cycle Fatigue (LCF) analysis on the F107-WR-101 1st stage, high-pressure turbine rotor. To begin this project, research was done on the theory behind low cycle fatigue. After this, the team completed further research, which consisted of LCF technical reports, software available for LCF analysis, and documents provided by the sponsor, including the Williams Engine Report and Teledyne Critical-Component Analysis. Pressure, velocity, and temperature values were obtained from the Engine Report and used as inputs for both CFD and static structural analyses. A cylindrical enclosure was made around the rotor in order to recreate fluid flow with the 3 major operating point parameters. The total temperature contour of the rotor was symmetrical with the highest temperature of 1471 K at the tip of the blades and 1287 K at the bore. The static structural analysis loading consisted of pressure, temperature, speed, and torque, with a fixed support at the bore for each of the 3 load cases. Load case #2 was determined to be the worst-case scenario and yielded a maximum stress result of 294,650 psi and a maximum strain value of 0.0107 in/in. During calculation of the strain-life properties, it was determined that the data which is required to compute the ductility coefficient and exponent does not exist for the rotor material, MAR-M-247. Substituting these properties from Incon 718, a similar material, a strain life analysis was performed, and the bore was found as the life limiting feature with 1187 cycles.
20
2019
4
CATEGORY: STUDIES
B-52 Spoiler Fixture Redesign
Our team was tasked by Tinker with redesigning the B-52 spoiler fixture. The fixtures allow technicians to check the alignment of spoiler ribs before attaching the skin. However, the fixtures are also now being used to hold the spoiler while the skin is riveted on. The primary goal of the redesign was to conserve floorspace by consolidating from seven fixtures to three or fewer and replace several components which had failed due to extra stresses incurred by the riveting process. To conserve floorspace, our team proposed five methods to consolidate the seven fixtures such that a single fixture can accommodate all seven spoiler configurations. After presenting our ideas at Tinker, we unanimously chose the “Swappable Railâ€? consolidation method, which involves seven interchangeable pairs of rails that hold the components to locate the spoiler’s ribs. Each pair of rails corresponds to a unique spoiler configuration and can be swapped onto a single frame. To combat deformation of the clamps, we recommended clamps that had a higher gauge wire and proper bushings. We also suggested using a more appropriate material for the pins and designed the pins so they could be changed out if they did break. We used ball-lock quick-change clamps to replace weaker and less accurate clamps. We exceeded our goals by consolidating down to only one fixture and making design improvements to four other problem areas. We estimate ~1,100đ?‘“đ?‘Ą 2 will be saved and our improvements will pay for themselves in 11 months by saving Tinker time and replacement parts.
21
2019
5
CATEGORY: STUDIES
3D Printing for Shape Memory Polymers
Shape memory polymers (SMPs) are smart materials with excellent shape memory and shape recovery features. We aimed in this capstone project to develop a novel 3D printer capable of manufacturing an SMP material into complex geometries for potential use as an embolic device, as no such SMP manufacturing method has been developed in previous literature. First, scientific material investigations were conducted to determine the properties and behaviors of single SMP drops, namely the viscosity and rapid curing behaviors, under varying temperature levels and cure times. Then, an extrusion system was adapted from previous literature for use with a commercial 3D printer that allows extrusion of the SMP at sub-millimeter accuracies. Comprehensive studies were then performed to determine optimal 3D printer parameters for the SMP material by 3D printing several basic geometries. We determined optimal printing parameters for the (i) syringe motor extrusion speed, (ii) print bed temperature, (iii) printhead planar movement speed, and (iv) printed layer heights. Complex parts were successfully printed with more intricate designs (porous, rounded edges) and larger total heights. This project clearly demonstrates the capability of our developed SMP 3D printer. Major technical challenges of this project included precisely printing a liquid material and managing the SMP's curing process, both of which we have overcome. Future steps for the project will entail using image data to 3D print SMP embolic devices tailored to patients’ unique aneurysm geometries.
22
2019
12
CATEGORY: STUDIES
Jet Engine Test Cell Reliability Analysis
The T9 Test Cell is a facility used by Tinker AFB to test the mechanical readiness of newly built and repaired jet engines. The engine’s exhaust is directed through the augmenter tube and deflected upward by turning vanes in the rear deflector section. The problem is arising from of the use of the new more powerful F135 engine. Vibrational and heat damage can be seen throughout the deflector structure. To remedy this issue our team focused on two approaches, structural reinforcement and redesign of the turning vanes. Structural reinforcements were found to increase the risk of vibrational damage to the concrete outer structure and were not pursued further. Focusing on vane redesign, a model of the augmenter tube and deflector section was created in Solidworks FlowSim using design schematics and F135 exhaust parameters. The original turning vane design was then compared with five potential variations: a 25° flat plate, 45° flat plate, 25° flat turning vanes, 45° flat turning vanes, and a curved plate. A fluid flow analysis showed that the 25° flat plate, 45° flat plate, and 25° flat turning vane designs produced an unacceptable amount of backpressure in the augmenter tube. The 45° turning vanes have acceptable flow characteristics and reduce max fluid pressure by 30%. The curved plate has acceptable flow characteristics and reduces max fluid pressure by 60%. The 45° flat turning vanes are recommended as a low-cost solution and the curved plate is recommended as a more effective infrastructure overhaul.
23
2019
13
CATEGORY: STUDIES
Blast Media Recovery Optimization
Tinker Air Force Base is responsible for stripping paint off of the B-1 Lancer Aircraft using plastic media blasting. During the process, the used plastic media is pushed into an auger system that transports it into a recovery system consisting of two trap metal magnet devices. Our team of capstone engineers has been tasked with evaluating the system and submitting a design modification package that will optimize the removal of media contaminates and eliminate the need for personnel to manually clean and monitor the system during use. Our team has focused on modifying the current pneumatic in-line bullet magnet by striving to meet three primary objectives: Maintaining the current magnet effectiveness, autonomous cleaning, and uninterrupted pneumatic line air flow. After several concept variations, the helical scrapper design was selected. By rotating the current cylindrical magnet within a helix scrapper, ferrous material that is attracted will be guided up the helix structure to a containment area. These particulates are then forced into a vacuum port by a rotating sweeper, spinning on the same shaft connected to the magnet, resulting in a safe and effective self-cleaning magnet operational within a pneumatic line. With additional focus on feasibility and ease of use, this design is made of mostly purchasable parts or simple modifications to the pre-existing system and a procedural package has been developed detailing cleaning and assembly. By implementing this concept, TAFB will also increase cost and time savings, all detailed within a cost analysis report developed in conjunction with the procedures and design submittals.
24
2019
14
CATEGORY: STUDIES
Landing Gear Yoke Redesign
Commander Aircraft Corporation hopes to regain their federal certification to begin manufacturing certified aircraft parts. Specifically for the 114B and 114TC models, Commander must manufacture a variety of parts to finish building new aircraft. To manufacture landing gear yokes, Commander must machine forged blanks to the final part dimensions, of both the left and right side, using a CNC machine. The goal of this project was to assist Commander Aircraft in achieving their goal of once again manufacturing landing gear yokes in Norman, OK. The required end products for Commander Aircraft were a SolidWorks package of the finalized landing gear yokes, a Manufacturing Processes Report, preliminary jig designs, and approximate CNC machine costs. The SolidWorks model was created by manually measuring the final landing gear yoke using a variety of tools. Then, the model was mirrored to create both a left and right yoke model. The Manufacturing Processes Report compares the casting, forging, and machining processes for aluminum. It compares the grain structure, defects, and cost of the three processes by referencing textbooks and scholarly articles. The report will be used to gain FAA certification for “Parts Manufacturer Approval� by proving proficiency of the manufacturing processes for this part. Lastly, information on future machining possibilities, such as preliminary machining jig designs and CNC machine costs, were compiled as a resource for Commander. This project has the potential to help grow the aerospace industry in Oklahoma by helping Commander to manufacture aircraft parts in Norman.
25
2019
15
CATEGORY: STUDIES
B-52 Mounting Tray Vibration Analysis
The United States Air Force currently has 76 B-52’s in its fleet. Each contains a mounting tray that secures a line replaceable unit (LRU), an electronic box that can be used for various purposes such as controls and navigation. An LRU mounting tray designed by Boeing had failed vibration testing set by military standard 810F; making it ineligible for flight operation. According to the military standard, the mounting tray must hold 20 pounds and pass vibration testing for eight hours, each on the x-, y-, and z-axis. The project’s goal is to reverse engineer the existing tray using 3D CADD and develop a design improvement that qualifies the tray for flight time. This project proposes two design revisions. Design modifications of the mounting tray were tested using ANSYS Mechanical, a Finite Element Analysis (FEA) software, to yield visual and computational representations of stress conditions during vibration testing. Computational results of the design showed a 21,000% increase in minimum fatigue life. Analytical calculations are provided to verify computational results and show that the proposed design is suitable for flight operation. Significant changes in the design have been incorporated into a prototype, which was manufactured in the University of Oklahoma’s AME machine shop. The vibration filter and mounting adapter were constructed to allow for vibration testing. However, the testing could not be completed due to unavailable resources. The cost of each prototype is estimated to be $443 and $382 which falls under the original cost of $500. Ultimately, the proposed designs satisfy all the project requirements and is recommended for implementation.
26
2019
16
CATEGORY: STUDIES
B-52 Bonded Stiffener Trailing Edge Panel Redesign
Team 16 has been tasked to reverse engineer a B-52 trailing edge panel that is susceptible to corrosion. The initial fabrication technique used adhesive bonding to fasten the panel’s magnesium face plate to aluminum hat stiffeners. Because of the bomber’s extensive years of operation, weathering and exposure to the environment has resulted in corrosion on critical locations of the panel. Corrosion deteriorates the adhesive bond and decreases imperative material properties of the panel. In order to eliminate this problem, the team has altered the structure and material of the panel, used technical analysis to ensure the functionality and integrity of the panel, and researched practical manufacturing methods to create the new panel. It is important to understand how the context of our capstone project impacts our re-design choices and selections. While ideal concepts revolve around maximum value and return, the team must consider the feasibility and economics of our design with the corporate perspective of Boeing. Balancing expenses and assets while generating an innovative design solution is key to the project. Ultimately, a new panel design utilizing T-stiffeners was used while manufacturing the stiffeners and skin as one piece. By doing this, the moisture entrapped in the bond line between the skin and stiffeners causing corrosion was eliminated. The structural capability of our new panel design was confirmed by matching the stiffness of the hat stiffeners and T-stiffeners, comparing the compression crippling stress to the compression yield strength as well as an oil canning analysis of each panel.
27
2019
18
CATEGORY: STUDIES
Air Flow Analysis for Diaper Panel Control
Objective This research study is to determine air-flow variables: pressure, angle of nozzle, and type of nozzle that will prevent flapping of the training pant panel. The second goal is determining the difference of stiffness, elongation and airpermeability between Kimberly-Clark’s soft training pant material and not-as-soft material. The final goal KimberlyClark would like is a finite element analysis of the material. Procedure Using an apparatus, a air-bar, air-knife and an air-blade affixed will point towards the training pant side panels at different angles using the sponsor’s set pressure’s as a retrofitted treadmill is sped to 6, 8, 10 and 12 mph speeds to create an angle-speed curve for each blade. We also researched and applied test methods to determine the stiffness and elongation using a tensile machine. The air-permeability test was determined using a wind tunnel, pressure transducers and a program to determine the difference in air pressure. A finite element analysis was used to show the stresses that occur on the fabric by setting boundaries and forces similar to the panels on the conveyor. Results The final results showed that air-blade nozzle is more effective at keeping the training pant panel flat on the conveyor at 77.1° and an air-pressure of 10 psi by extrapolating from the angle-speed curves. The results for the stiffness determined that the softer material was stiffer by 76.9 kPa. The softer material also elongated by 3.65 times its original length. The material is also non-linear due to the graph not showing linear material behavior compared to literature stress-strain graphs. The softer material is more air-permeable than the non-soft material by 5.5733*10-5m2 in the parallel flow case and – 1.1742*10-4m2 in the perpendicular flow case. Overall, the new material is both stiffer and permeable than the non-soft material and the air-blade set at a 77.1° angle.
28
2019
19
CATEGORY: STUDIES
Improving Product Control Conveyor Access
Safety, quality and production are top priorities at manufacturing plants such as the Kimberly-Clark plant located in Paris, TX. Kimberly-Clark has identified an opportunity for improvement to one of their production conveyors that fastens the Huggies training pull-ups. Restricted access to the area in-between the conveyors that make up this machine, cause delays and safety issues when performing routine maintenance. Group 19 was provided with a set of requirements with a goal of increasing the access to the conveyor area, while maintaining safety and quality of the assembly. Group 19 explored various design concepts utilizing pneumatic actuated motors to raise the conveyor vertically to maximum height. The design was constantly adjusted to maximize feasibility of construction as well as safety and quality. Research was conducted in order to find pneumatic motors that would accommodate the lift height and weight required. Linear bearings were also incorporated into the design to guide the lift of the conveyor to ensure the lift does not cause unwanted tilt. A safety device was also integrated into the final design that will secure the upper conveyor when it has reached maximum height. As a result, the design significantly improves safety for the conveyor operators that perform maintenance on the machine. The operators will be able to access the conveyor easier with the significantly increased area, so this design will also improve the time in which it takes the operators to perform maintenance. This will ultimately save Kimberly-Clark money as their production can continue at a faster rate.
29
2019
21
CATEGORY: STUDIES
Redundant Chiller and Boiler Design
This experiment was conducted to analyze the feasibility of implementing a single cooling and heating water loop system to serve five high-use training facilities at the Federal Aviation Administration’s Mike Monroney Aeronautical Center campus, rather than each facility operating on its own systems independently. The team was instructed to base the research and analysis on the system running at 40%, 50% and 60% of the max load. When designing the new loop system, Team 21 took into consideration the following factors for implementation including: equipment tonnage, pipe size, pipe length, trenching, installation, heat loss, insulation size, head loss and additional pumps needed for the system to sustain the five high-use training facilities. Once these factors were accounted for, the total cost to execute this new system could be obtained using the RSMeans Mechanical Cost Estimating Book which supplied cost estimates for all aspects of achieving this system. The payback periods for installing a single cooling and heating water loop system running at 40%, 50% and 60% of the max load resulted in 104, 75 and 66 years respectively. Although the payback period does not provide a realistic or beneficial opportunity for the FAA, Team 21 has recommended that the FAA pursue installing a single cooling water loop system for the existing chillers alone. Creating a single cooling water loop would reduce the payback period for running the system at 40%, 50% and 60% of the max load to 44, 35 and 28 years respectively, providing a feasible option for the FAA.
30
2019
23
CATEGORY: STUDIES
Boiler and Condenser Modification
The purpose of this capstone project is to identify solutions to three problems Hitachi is facing in the Norman, Oklahoma facility. The first problem is that the current boilers in use are oversized and as a result they never run at full capacity. This leads to a high natural gas consumption and soot build up in the burner side tubes that requires frequent maintenance. The sponsor identified their need of a gas to steam boiler replacement. The proposed solution is to replace the current boilers with more appropriately sized boilers. To accomplish this, the required heat output into the facility was determined to be 2.68 MMBTU/HR. The selected boiler satisfies the calculated target heat output and the requirements set by the sponsor. The selected boiler is the Cleaver Brooks 80 HP Firetube Boiler. According to the calculations the new boiler will have an efficiency 4-5% higher than the current unit and as a result Hitachi will save approximately $ 2,000 and 838 MMBTU per year in natural gas consumption. The new unit has a max output of 2.81 MMBTU/HR which will allow it to operate at 99% capacity during the average cold conditions of the coldest month of the year. The new boiler will operate at 20-33% higher capacity than the previous unit. Operating at a higher capacity can lead to a significant decrease in the required boiler maintenance. The sponsor also tasked the team with researching alternate methods of humidifying the air in the facility. Currently, the boilers are also used to provide steam to humidify the air. This is causing an increase in natural gas consumption and water buildup in the duct work. The proposed replacement to the seam injection is the MeeFog system. The MeeFog system is a humidification system that uses a high-pressured water pump to dispense water though specialized nozzles that atomize water into droplets that are then absorbed into the air. This system is 40% more efficient than gas to steam systems. Hitachi will save approximately $7,160 and 3,815 MMBTU in natural gas consumption annually. Finally, the sponsor tasked the team with the modification of a condenser. A rooftop condenser emits vibrations to the main conference room when the compressor cycles on and off. The vibration causes the conference ceiling to shake and it disturbs the staff. To solve this problem a vibration analysis was conducted on the condenser. The results show that the condenser has a frequency of 10-20 Hz when it cycles on/off and pumps down. The proposed solution is a Tune-MassDamper that matches the vibration frequency of the compressor to eliminate the vibrations traveling through the roof of the facility. Another proposed solution are vibration isolation pads that can be placed uniformly under the condenser. The combination of these two solutions will ensure that vibrations to the main conference room are reduced.
31
2019
24
CATEGORY: STUDIES
ESP Motor Test Well Support Design
Testing to validate new motor designs for the Electric Submersible Pump (ESP) assembly is traditionally conducted in the vertical orientation. However, BHGE’s new testing facility will conduct the testing of the motors in the horizontal orientation. The motors are only attached to the well at the end and thus need support along the length of the well. The goal of our team’s project is to design supports for 3 different motor sizes for this new testing orientation along 5-foot intervals within the test well casing. The supports must minimally interfere with collected data. Therefore, they must maintain the centerline of the motor along the centerline of the well casing and must minimally influence fluid flow and heat transfer. Furthermore, the supports must be easy for the BHGE workers to install and remove manually. Team BHGE1 chose to approach this problem as consultants representing the Self-Realization & Learning Community (SR&L). After researching our client's problem, we created a Venn diagram with respect to our Requirements List to illustrate how the problem overlaps within the Technical, Ergonomic, and Economic domains. We integrated the Principles of Engineering Design (POED's) learned during our pre-capstone course and created new POED's to solve our client's problem. We utilized SolidWorks and ANSYS software to produce CAD models of our solutions and subsequently verify our designs through FEA and CFD analysis. As a result, BHGE1 has designed an ESP motor support solution coined "Teardrop Skate Support." In order to meet the requirements in each domain, the support includes salient features such as a steel skate base, a hydrodynamic thermoplastic shell, and a hose clamp. Our support designs are technically feasible, functionally feasible, economically feasible, ergonomically feasible and buildable. Moreover, our support designs were completed under budget and ahead of schedule. Through working in SR&L, we learned how to sell our design as consultants through emphasizing its salient features. Furthermore, our completion of this project has reaffirmed the relationship between SR&L and BHGE.
32
2019
36
CATEGORY: STUDIES
FAA OSHA Compliant Climbing Methods for Human Safety
The Federal Aviation Administration (FAA) currently owns 76 FLIR trucks. These trucks have a 25 foot mast that often gets stuck in the upright position. During these times, the worker will have to climb on the top of the truck and manually lower the mast. While on top of the mast, the worker is out of OSHA compliance for climbing in general industry because they currently do not have a proper fall arrest system. The objective was to create a personal fall arrest system that will connect the worker to the FLIR truck. By completing a load path analysis of the mast and one of the plates on the lower system, ensuring the safety factor was above 2, it was determined that the weld lines and material would not fail. These points were chosen because they are convenient for the worker and remain within OSHA compliance. After ensuring our connection points could bear the load of a hypothetical fall, two individual models made from 7075 T-6 aluminum were designed for each point. A reinforcement plate with a shackle for attachment and a clamping system with two shackles were designed for the lower system and mast, respectively. An FEA analysis was conducted on both models, resulting in a safety factor of 3.46 for the plate and 2.81 for the clamp. Finally, a cost analysis for the materials and manufacturing processes for both designs was completed. In result, a total price per truck would equate to approximately $431.18, assuming each truck will have 2 reinforcing plates and 1 clamping system.
33
2019
37
CATEGORY: STUDIES
Vehicle Mast: Raising/Lowering Methods
The purpose of this capstone group was to investigate the different methods that are available in the raising and lowering the masts of the FAA’s surveillance vehicle. The vehicles are used by the Customs and Border Patrol (CBP) to monitor the U.S. border. To accomplish this, each of the CBP vehicles have an articulating mast that houses a suite of sensors that are powered by a battery bank on the vehicle. The team troubleshooted the components of the mast that are known to cause major problems/failures. These major components include computer malfunctions, inconsistent software communications, and power failure. The team analyzed these known failures and investigated new avenues for the mast to lower. In order to accomplish this, the team split into sub-teams to focus on specific areas for solutions. One team focused on computer and software malfunctions, another focused on the cable/direct work around and the last team focused on mobile power generation for the battery bank of the vehicles. Each team would then find additional solutions for each of the subsystems and test each of them to ensure accuracy. After testing each of the solutions for the trucks, the team found that the best solution for the vehicles was a combination of all subsystem's solutions. The team’s combined solution is attaching a permanent generator to the vehicle for battery charging, replacing current laptops with new/better laptops mounted on anti-vibration pads, and adding a direct cable work around on the truck.
34
2019
41
CATEGORY: STUDIES
Piezoelectric Sensors for HVAC applications
The sponsor has designed and plans to implement an artificial intelligence (AI) distributed HVAC performance optimizer which has the potential to increase the efficiency of industrial HVAC systems up to 30%. This AI optimizer requires powerless/wireless sensors that produce continuous real time data of important system parameters such as pressure. To collect this pressure data, our group has designed two pressure sensor housing units which utilize piezoelectric and RFID technology, respectively. The Piezoelectric housing unit design uses a piston to transfer pressure from the HVAC system to the piezoelectric disc. This housing unit was manufactured using common plumbing components which can be bought off the shelf, and it requires minimal additional machining. In total, the piezoelectric housing unit costs $67.62 to manufacture. Bench testing for the piezoelectric housing unit has been conducted on an air system. However, the data obtained from this testing requires additional processing so that the voltage data from the disc can be correlated to pressure. The RFID housing unit was only concepted due to the groups limited budget. The RFID housing unit is made from a dielectric material and uses an anulus design to transfer the pressure from the HVAC system to the RFID sensor. Testing for the RFID concept was conducted using a 4-gallon pressure tank to determine the numeric constant necessary to determine the water pressure of a system using an anulus design. However, our group is in the preliminary stages of testing for this concept and further testing needs to be conducted to verify the numeric constant.
35
2019
9
CATEGORY: PROTOTYPE DESIGN
Interactive Gymnastics Exhibit for Science Museum Oklahoma
In our project we created an Interactive Gymnastics Exhibit for the International Gymnastics Hall of Fame inside the Science Museum Oklahoma. Our team designed and manufactured an X-Frame designed to hold electronics and graphics that patrons within the Science Museum Oklahoma will interact with. These interactions include a display that shows the patron performing an iron cross in real time along with metrics related to their performance. These metrics correlate to their strength to weight ratio as well as their form. The data is captured using a raspberry pi, an industrial scale, and a camera. We utilized libraries within the python development environment to create a program that would integrate all of the hardware together. The graphics that we had designed detail how the patron interacts with the exhibit. The graphics show different options of testing that the patrons can attempt as well as step-by-step instructions on how to interact with the exhibit. These graphics contain educational content ranging from basic gymnastics facts to the anatomy of the muscles used while performing an iron cross. Additional graphics show specific technical information about the iron cross. Throughout the entire project safety was our number one priority. We referenced various resources such as ASTM standards and the museum staff. The constraints that we used to design and manufacture the X-Frame. In conclusion, the X-Frame, electronics and programming along with the graphics, make up a fun and interactive environment that patrons will be able to learn from and more importantly get excited about.
36
2019
10
CATEGORY: PROTOTYPE DESIGN
Package Belt and Chute Redesign (Team 1)
The United States Postal Service (USPS) has tasked the team with redesigning aspects of their automated parcel bundle sorter (APBS). Specifically, the team has redesigned the APBS load deck and chute. The load deck serves as an input for the system while the chute serves as the output. The operators have been experiencing repeated stress related injuries due to the recent increase in mail flow. Operators have been having to physically hold back mail from the rising belt due to the sensor not working properly. The operators are also experiencing injury due to having to repeatedly slide heavy packages across the load deck. The chute back-ups are caused by the lighter packages getting stuck on the stainless-steel chute. To unclog the chutes, operators must pull mail down chute with a long hook which causes repeated stress injuries over time. The team has come up with a more ergonomic solution for the machine. The team implemented a diffuse reflective BGS sensor which works in tandem with the current sensor to better control mail flow. The load deck table was redesigned by utilizing drop-in, flange ball transfer units. These were placed in the load deck surface and allow packages to slide more easily across the deck, reducing the stress workers endure during operation. The team implemented a UHMW chute cover with a lower coefficient of friction over the existing chute to allow for lighter mail to slide more efficiently down the chute. All redesigns succeeded in creating a more ergonomic design.
37
2019
11
CATEGORY: PROTOTYPE DESIGN
Package Belt and Chute Redesign (Team 2)
Our project is a partnership with the United States Postal Service, to redesign the loading deck on their Automated Bundle Package Sorted (APBS). A section of this machine is responsible for loading and scanning the packages to determine which bin they will be dropped in. This loading process takes place on a loading deck with operators moving the package from an inlet conveyor belt to this loading deck. This repetitive process causes injuries to these workers as they move packages over time, and machine downtime which results in a revenue loss. Our task is to develop an ergonomic approach design change that will allow a 20-25 pound plastic wrap bundle to easily load to the belt. Design must be able to control the mail flow to prevent the operator from having to hold the mail back with one hand and loading mail with the other. New design must incorporate a maximum size dimensioning template and mail feed orientation guide. Our design is focused on using roller bearings, placed inside the deck plate to provide a frictionless surface for the packages to slide across. These rollers will sit on top of the deck plate and transfer the packages from the inlet to the outlet of the loading platform. In addition, our design incorporates a footswitch with which an operator can start and stop the inlet conveyor belt. This gives the operator more control regarding how mail flows onto the loading deck.
38
2019
27
CATEGORY: PROTOTYPE DESIGN
Robotic Arm System for Hospital Use
As part of the Self-Realization & Learning Community, Team APOLLO which consists of engineering consultants, was tasked with designing a robotic arm system for hospital use for our sponsor Cara Gonzales. Our goal was to design a system that would be able to receive a patent, hold and charge electronic devices, and comply with OSHA/NIOSH regulations. To ensure we would be able to design such a system, we had to make sure we could satisfy functional, technical, buildability, safety, and patentability requirements, which we came up with based on our initial interview with our sponsor. The system we designed was able to meet all the major requirements. In terms of functional requirements, it will be able to extend and retract as well as support electronic devices. In terms of technical requirements, it will be able to charge electronic devices, be remotely controlled, and have an emergency breakaway. The bill of materials satisfies the buildability requirements, and the OSHA/NIOSH regulations we researched satisfy the safety requirements. We were able to deliver all that we promised which included a wiring diagram representing the electrical circuits of the system, a bill of materials with the materials and components along with the estimated of under $4500, a Frankenstein model showing how our system would operate, and a draft patent application which will help with the patent process down the road. By being part of the SR&L Community, we now view everything with a new mindset: we think and learn like engineers instead of students.
39
2019
28
CATEGORY: PROTOTYPE DESIGN
Introducing Girl Scouts to STEM
Girl Scouts of Western Oklahoma reached out to the Self-Realization & Learning Community (SR&L) in anticipation of the building of their new camp in Oklahoma City. This camp’s focus is on creating an immersive STEM learning environment for Girl Scouts throughout the camp. With this focus in mind, SR&L was commissioned to create a luggage hoist in their main stairwell with two main purposes: encourage stair usage over the elevator and introduce Girl Scouts to STEM through using simple machines. Through further research we found the Girl Scouts leadership experience model: Discover, Connect, Take Action. The leadership experience model in conjunction with the Girl Scout Mission became the theme of our project. We determined how to incorporate STEM and the Girl Scouts leadership experience model. In terms of science, we are providing Girl Scouts with the opportunity to Discover by generating a hypothesis, Connect by observing experiments, and Take Action by developing conclusions. In terms of technology, Girl Scouts can Discover using visual aids, Connect by relating simple machines to real world applications, and Take Action by changing parameters on the system. In terms of engineering, Girl Scouts can Discover by physically interacting with the system, Connect by understanding the purpose of simple machines, and Take Action by researching female engineers. Lastly, in terms of mathematics, Girl Scouts can Discover by seeing real world applications of units, Connect by encouraging team learning, and Take Action by converting units used in the pulley system.
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2019
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CATEGORY: PROTOTYPE DESIGN
Gaming/Electronics Assist Equipment
Project Team 38’s task was to increase the quality of life for Christopher Ramirez, a young man who does not have use of his arms or legs. Project Team 38 was charged with giving Christopher the ability to independently: 1. Read a book 2. Use a computer 3. Use an iPhone/Tablet 4. Use an XBOX With a similar level of proficiency as someone without his disability for the next 7 years. After extensive market research and design exploration, we decided to approach this problem with a systemof-systems approach, blending Commercial Off The Shelf (COTS) products and our own custom designs to meet Christopher’s needs. We designed and built systems for Christopher to read a book and use an iPhone/Tablet. An automatic page turner that far outperforms commercial alternatives was designed and built for Christopher to read a book. A flexible folding platform we’ve christened the Assistive Multipurpose Platform (AMP) allows Christopher to use an iPhone/Tablet without compromising his posture, along with serving as a mount for our other systems. We purchased, assembled, and usability-tested systems for Christopher to use an XBOX and a computer. For the XBOX, a mouth joystick called Quadstick was an excellent COTS option that provided a very high level of fidelity. For computer use, we used Dragon Naturally Speaking and Tobii Eye Gaze with open-source OptiKey software, yielding a flexible combination of speech to text and eye tracking control options for Christopher to control a computer.
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INDUSTRY SPONSORS
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2019
INDUSTRY SPONSORS
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2019
INDUSTRY SPONSORS
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