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Welcome to the 2011 Senior Design Clinic! What you see here today are 13 working
prototypes which 8 months ago were nothing more than ideas. Ten companies and
non‐profits have engaged our students with the real life experience of asking, “is it
possible?” then letting the teams go to work. The teams will all tell you that at times
it got tough and they themselves weren’t sure how it was all going to unfold. And
that is exactly what we are trying to capture in the St. Thomas Senior Design Clinic.
Where the comforts of well‐defined textbook problems are abandoned, real
engineering emerges. What you see here today is the manifestation of that
uncertain process of translating ideas into reality.
In short, what you see here today is engineering.
On behalf of the School of Engineering faculty, I would like to thank you for coming
today. We are grateful for the support of the sponsoring companies and non‐profits
who have committed the funds, equipment, and time to truly make this a great
experience for our students. And lastly, we are especially grateful for the support of
the family and friends that each one of our seniors has relied upon to make it this far
in their incredible life journey.
Again, thank you and enjoy!
Don Weinkauf ‐ Dean of Engineering
2011 Senior Design Clinic
@Engineering St. Thomas
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Future Force, LLC
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Table of Contents
Solar‐Wind Hybrid Power System‐ Windstrip LLC .......................................................... 1
Graphics Applicator‐ 3M .................................................................................................. 2
Fall Detection Device‐ Courage Center ........................................................................... 3
Electrolysis Based Water Purification Device‐CTI / Cargill Foundation. ........................ 4
Steam Quality Monitoring System‐ Emerson ................................................................. 5
Formula SAE Frame Design – FSAE Club / University of St. Thomas. ............................ 6
Magnetic Drive Transmission ‐ Future Force .................................................................. 7
Precision Plenum Monitor for Laser Cutting‐ LasX Industries, Inc. ................................ 8
Static Electricity Jacket for Power Generation – Lockheed Martin. .............................. 9
Persistent Gliding Waterframe (Seaglider)‐ University of Beira Interior ‐ Portugal .. 10
Multi‐Linkage Mechanical Creature ‐ University of St. Thomas .................................. 11
Pipe Lining System‐ 3M ................................................................................................. 12
Wind Tunnel Test Section –Emerson/ University of St. Thomas ................................. 13
2010 Senior Design Clinic Projects‐ .............................................................................. 14
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To find out more about how your company can get involved with the Senior Design Clinic at St. Thomas, just call our main office.
(651) 962‐5750
or email: [email protected]
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Solar‐Wind Hybrid Power System
Team: Scott Adkins, Jeffrey Bucholz, Kelsey Hofmeister, Joe Maniaci, Kris Meyer, Linda Lininahazwe
Clinic Advisor: Greg Mowry
Industry Representative: Juha Rouvinen
(Left to Right: Kelsey Hofmeister, Linda Lininahazwe (seated),
Scott Adkins, Kris Meyer, Joe Maniaci, Jeff Buchholz)
Project Summary:
The goal of the Windstrip project is to create a standalone Hybrid Power System (HPS) for powering cell phone towers. The HPS combines the power output of a photovoltaic array and a vertical‐axis wind turbine. The wind turbine will be mounted on the cell phone tower while the PV array is ground mounted. Prior to the start of this project, preliminary design work had been completed on the electronics and the wind turbine blades. On the electrical side, the project objective was to complete and test the
electronics and software for the HPS. On the mechanical side, the objective was to design a 50 ft retractable tower and a solar array installation. By allowing the tower to be remotely retractable, the wind turbine may be lowered in extreme weather conditions or for maintenance. The solar array and wind turbine will have a combined power output of approximately 5 kW (respectively 2kW and 3kW). Design Goal:
The goal of the project is to create a HPS consisting of a wind turbine and solar array that will be installed in Sebeka, Minnesota at the headquarters of the West Central Telephone Association. Design Constraints:
The electronics must be able to handle 5kW
of combined HPS power.
Windstrip’s wind turbine was designed to be
attached to a cell phone tower with a weigh
of approximately 650 lb.
2
3M Graphics Applicator
Team: Faisal Aldhafeeri, Andrew Kanne, Christopher
Victor, Joseph Waidelich
Clinic Advisor: Chris Haas
Industry Representative:
Ronald Steelman and Mike Kesti
(Left to Right: Chris Victor, Faisal Aldhafeeri, Joe Waidelich,
Andrew Kanne)
Project Summary:
3M needs an improved heat applicator to apply
its large scale commercial graphics onto various
textured surfaces. The large scale graphics are
printed on thermoplastic films. Heat is required
to soften the film and pressure used so the film
can be bonded deep into the textures of various
surfaces. Today, 3M uses the TSA‐4 (Textured
Surface Applicator) ‐‐ basically an electric heat
gun ‐‐ to apply commercial graphics at varying
different heights, angles and positions. The TSA‐
4 requires access to a typical 120 VAC wall
outlet, which limits where jobs and applications
can be performed. The emphasis on providing
greater portability was our primary design
criteria.
Design Goal:
To design and create a low‐cost prototype that
demonstrates the capability of producing more
radiant energy to heat the graphic film without
requiring access to 120VAC electrical power.
Design Constraints:
The prototype must be lightweight and portable.
The prototype must avoid an electric heat source.
The Prototype should meet graphic application requirements and cost less than $500 to manufacture.
3
Fall Detection Device
Team: Rasheed Abdulkader, Jason Berger, Angela
McGehee, Dan Rodemann
Clinic Advisor: Dr. Ramesh Rajagopalan
Industry Representatives: Erik Steen and Audrey Kintzi
(Left To Right: Jason Berger, Dan Rodeman, Angela McGehee, Rasheed Abdulkader)
Project Summary:
One of the biggest dangers of an elderly relative
or a rehabilitative patient living alone is the risk
of falling, and not being physically able to call
for help. Injuries can become more severe
when help is out of reach. Our design
automatically detects a fall using a combination
of two sensors: an accelerometer (which
provides information about the user’s change in
speed) and a gyroscope (which measures how
fast the user rotates). This in‐home device is to
be worn above one’s chest, near the collarbone.
Design Goal:
To create a small, unobtrusive, low cost device
that will accurately detect a fall. The device will
have a detection accuracy of 90 percent, a
battery life of 20 hours, communicate to a
computer up to 40 meters away, and will be
smaller that 3x3x1 (inches). Once a fall has been
detected, an automatic alert message will be
sent to a caretaker of the user’s choice. The
rechargeable device will operate independent of
charge for a day.
Design Constraints:
In order to detect a fall using a gyroscope, it is
necessary to determine how a person is
oriented relative to the ground. The process of
detecting this orientation and the different
movements
4
Electrolysis Based Water Purification Device
Team: Ahmed Abuabdullah, Kyle Biddle, Christopher Cogan, Anna Garin and Elizabeth Langer
Clinic Advisor: David Gasperino—Cargill
Industry Representative: Dr. H. Murali
(Left to Right: Anna Garin, Ahmed Abuabdullah, Kyle Biddle, Chris Cogan, Beth Langer)
Project Summary:
Compatible Technology International (CTI) is a
nonprofit organization that alleviates hunger
and poverty in the developing world with simple
life‐changing food and water technologies. CTI
requested that our design team develop a low‐
cost water purification device using electrolysis
as the purification technology. The water
purification device eliminates common
pathogens from water sources found in
developing countries and provides clean water
for the day‐to‐day needs of a typical family. The
water purification device is human‐powered,
extremely durable, and easy to use. The device
can be manufactured using tools and materials
readily found in the countries where CTI plans to
deploy the technology.
Design Goal:
The design goal is to design a device that can kill
99% of Escherichia coli (E. coli) present in five
gallons of water using 46 watts generated by
human power in 30 minutes with a device that
must be under $50, excluding the power
generation.
Design Constraints: The water purification unit must be $50 or less
excluding the power source. It will include a
pre‐filter screen and will use electrolysis with
common table salt as the electrolyzer to create
chlorine for killing E. coli. The unit must be able
to purify five gallons of water in 30 minutes.
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Steam Quality Monitoring
System
Team: Kirk Baglien, Kirsten Halstead, Alan Intveld, Joe
Murphy
Clinic Advisor: Chris Haas
Industry Representative:
Roger Pihlaja
(Left to Right: Joe Murphy, Kirsten Halstead, Kirk Baglien, Alan
Intveld)
Project Summary:
The engineering challenge for our group was to
design and build a low‐cost, in‐line device to be
used for measuring the quality of saturated
steam. There are currently no devices on the
market capable of such measurement. Steam is
used in a wide variety of fields that utilize steam
for process heating, electricity generation, and
heating of liquid tanks. The usage of steam as an
energy transport medium can account for up to
25 percent of a plant’s total cost in utilities. The
ability to monitor steam quality insures the
customer that they are getting the highest
quality of steam possible and allows effective
management of their energy usage. An effective
steam flow metering device could serve the
market today by saving the customer 10 to 15
percent in their total fuel cost.
Design Goal: To design and build a low‐cost, in‐line device to
be used for measuring the quality of saturated
steam.
Design Constraints:
Overall manufacturing cost to be less than $20,000
Steam quality measurement to occur every ten minutes with accuracy of 10%.
Design must be consistent with applicable design and safety standards
Max. operating pressure of 250 psi and temperature of 406 °F
6
Formula SAE Frame
Design
Team: Michael Cowdrey, Hans Pflaumer, William Besser, James Moorman, Sven Hendrickson
Clinic Advisor: Don Weinkauf (Left to Right: Michael Cowdrey, Hans Pflaumer, William Besser,
James Moorman, Sven Hendrickson
Project Summary:
The Senior Design Clinic objective for the
Formula SAE (FSAE) team was to research,
design and build an improved open‐wheeled
race vehicle frame. The benefits of a superior
design are twofold. First, forces experienced by
the frame are distributed throughout the entire
vehicle, which limits the effects from sudden
changes in force while racing. Secondly, a frame
that is designed to be stiff provides exceptional
suspension performance, which in turn leads to
better overall vehicle performance. In the
design of this frame, improvements will be an
increase in torsional stiffness of at least 15
percent, while maintaining all FSAE competition
criteria and not increasing weight or cost
significantly. Our baseline for improvement was
a frame produced for the FSAE competition by
Marquette University.
Design Goal:
To build a Formula SAE vehicle frame with 50%
increase in torsional stiffness with no increase in
frame weight.
Design Constraints:
The construction of the frame was constrained
by rules set out by the Society of Automotive
Engineers (SAE) for competition. These rules
impact construction material, material
thickness, frame member location, and frame
member length.
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Magnetic Drive
Transmission
Future Force, LLC
Team: Mohammed Al‐Mohsin, Jeremy Berghoff, Erik Eaton,
Brian Jensen
Clinic Advisor: Ranjan Chakravarty
Industry Representative: Alex Hine
(Left to Right: Erik Eaton, Mohammed Al‐Mohsin, Jeremy Berghoff, Brian Jensen)
Project Summary:
Traditional gear drive systems arelimited by
individual gear wear or failure and the need for
lubrication ‐‐ costly aspects in maintaining a
properly functioning geared system. Future
Force has developed a functioning prototype of
an in‐line Magnetic Drive that avoids those
issues. In place of meshed gears, it uses rotating
magnets on the input shaft to transfer torque to
the output shaft. Our task was to design three
different gearboxes with 2:1, 5:1, and 15:1
ratios. We were fabricated a functioning 2:1
gearbox to demonstrate design
manufacturability.
Design Goal:
Design a magnetic drive that maximizes ease of
assembly and manufacturability while
minimizing assembly time and cost‐to‐
manufacture. Quality, simplicity, and safety
were other key factors in determining our final
design.
Design Constraints:
Maintain 982% efficiency Withstand 3600 rpm output
Safety factor of 3 with maximum load requirements
Radial tool direction
Removable cover
Low cost to manufacture
8
Precision Plenum Monitor for Laser Cutting
Team: Josh Jeske, Kyle Mader, Craig Martin, and Matt Moore
Clinic Advisor: James Ellingson
Industry Representative:
Kevin Kingbeil
(Left to Right: Matthew Moore, Kyle Mader, Craig Martin, Josh
Jeske)
Project Summary:
LasX Industries cuts precision parts from web‐
based materials using a precisely guided laser. A
plenum is attached to the work surface and a
vacuum system is used to remove debris and
heat from the processed material. Material
displacement is caused by changes in pressure
at the work surface during processing. The
pressure at the work surface is currently not
controllable by the current plenum and vacuum
system.
Vertical displacement in the web during
processing can lead to out‐of‐specification parts.
Deflection of the web during cutting creates
errors due to changes in spot size and location.
The kerf or width of the cut becomes larger as
the material moves away from the focal point
and the beam is more spread out and therefore
is less powerful. Vertical displacement of the
web during cutting also creates error in the cut
due to the processing angle of the laser.. The
combination of increased kerf and position
changes reduces the accuracy of the parts and
may cause the production of invalid parts.
Design Goal:
To build a control system that will monitor and
control plenum vacuum to minimize deflection
changes in the material during cutting to keep a
cut part tolerance of ±50µm.
Design Constraints:
One of the biggest challenges our team faced
was controlling the vacuum and deflection of
the material at the very high speed of the laser
process.
9
Static Electricity Jacket for Power Generation
Team: Ryan Huynh, Nicholas Pooler, Hans Rieckmann, Dan Schupp
Clinic Advisor: Ranjan Chakravarty
Industry Representative: Bob Monson
(Left to Right: Nick Pooler, Hans Rieckmann, Ryan Huynh, Dan Schupp)
Project Summary:
Static electricity is everywhere. We run into it
on a daily basis when touching a door knob,
petting a cat, or drying laundry. Very little is
known about converting static electricity to
useable energy. We drew on existent
knowledge and created a wearable jacket that
harnesses static electricity. The energy is
generated passively by the ruffling of the jacket
that naturally occurs while the wearer is
moving. This static electricity is built up and
usually wasted. Our jacket captures the static
charge, then stores and regulates it for practical
applications. This system could reduce the need
for extra or large batteries being carried by the
armed forces, travelers, or those in remote
locations.
Design Goal:
To design a jacket that produces a useable
amount of electrical energy through means of
static sequestration.
Design Constraints:
The jacket must look like a normal jacket, being
both comfortable and unobtrusive. It must be
completely safe to wear, causing no harmful
interference in the user’s activities and life. The
jacket will generate power and store it in a
battery for convenient usage, and the power
output will be regulated to 5VDC that can be
used by USB chargers.
10
Persistent Gliding Waterframe
Team: Matthew Deutsch, Sean Engen, Jim Giancola,
Josh Kleven, Frances Van Sloun, J.B. Korte
Clinic Advisor: Chris Greene
Industry Representative: Scott Morgan
(Left to Right: : James Giancola, Sean Engen, Francis Von Sloun,
J.B. Korte, Josh Kleven, Matthew Deutsch)
Project Summary:
This project is a collaborative effort between
Scott Morgan, the University of Beira Interior,
Covilhã, Portugal (UBI) and the University of St.
Thomas, St. Paul, MN. The Persistent Gliding
Waterframe (PGW) will serve as a sensor
platform in a coordinated international effort to
quantify and monitor the oceans ability to
produce sources of protein destined for human
consumption. An underwater glider uses a
change in buoyancy, wing configuration, and
dive angle to “propel” itself forward using very
low power consumption. This constitutes the
first year of a five year‐long project. During its
first year, the UST team had to determine
suitable subsystem requirements from the
system requirements, then design subsystems
to meet those requirements and designed and
tested the propulsion, navigation, control, and
power subsystems while collaborating with UBI
which designed the waterframe.
Design Goal:
Develop a low‐cost, effective, efficient,
autonomous underwater vehicle for production
in mass quantities.
Design Constraints:
Capable of autonomous operation for a minimum period of four contiguous months
Useful life of two years for the navigation and power systems
Accuracy within 1000 meters upon returning to the surface after a dive of 300 meters
Ability to determine a new trajectory and headings for the next dive
Ability to recharge batteries during mission
11
Multi‐Linkage Mechanical
Creature
Team: Alex Benson, Ryan McCarthy, Michael St.
Dennis, Adam Truhler, Matthew Maurer
Clinic Advisor: Mike Hennessey
(Left to Right: Alex Benson, Ryan McCarthy, Michael St. Dennis,
Adam Truhler, Matthew Maurer)
Project Summary:
The purpose of this design project is to develop
a robot to serve as a legged locomotion
technology demonstrator. This robot, named
A.I.R. (Awe Inspiring Robot), uses linkages
designed by Theo Jansen to achieve an animal‐
like walking movement as an alternative to a
rolling motion. This design uses a chassis of
expanded aluminum, supported by two sets of
eight‐bar linkages. The robot is driven by two
0.75 hp 12VDC Leeson electric motors and
powered by a 12 VDC deep‐cycle battery. Due
to the range of possible venues – parades or at
football halftimes, for example – it must be
operable on a variety of hard surfaces without
causing damage. Key decision considerations
included means of locomotion, operating
capabilities, size, public safety and system
reliability.
Design Goal:
To build a robot that uses multi‐linkage legged
locomotion.
Design Constraints:
Must be portable in a knock‐down state and easily reassembled.
Must have low emissions and operate below 85dB.
Must walk at 2‐4 mph
Must be able to be in continuous operation for at least 2 hours
Must be able to walk at least 2.5 miles without stopping
Must be suitable for operation in high density areas
12
3M Pipe Lining System
Team: Ying Yang, Derek Olson, Shane Norman, Nate McNamara, Austin Wittrock
Clinic Advisor: John Wentz
Industry Representative: Clint Jones – 3M
(Left to Right: Ying Yang, Derek Olson, Shane Norman, Nate McNamara, Austin Wittrock)
Project Summary: 3M formed the Water Infrastructure EBO
(Emerging Business Opportunity) in response to
a global demand for in‐situ water main
rehabilitation. Current efforts are focused on
applying a rapid setting polyurea lining within
pipes ranging from 6 to 24 inches in diameter.
The existing spray delivery system involves
pumping resin through a 700‐foot heated
umbilical and statically mixing the two‐part
chemistry shortly before it enters a spinning
cone that centrifugally applies the chemistry to
the pipe wall. The current application motor
uses pneumatic power to spin the cone, and it
has the tendency to stall when coming into
contact with any external force during the pipe
lining process due to insufficient torque. There
are currently no sensing capabilities
downstream in the spray delivery system to
measure operating conditions within the pipe
being rehabilitated. An alternating current
electric motor and drive system has been
chosen to be prototyped. The prototype will
possess more than 10x greater stall torque than
the current design and will offer operating
condition feedback and control to the operator.
Project Mission:
To implement a motor with higher torque while
maintaining acceptable cone speed, create a
process controller with feedback to the
operator, build a working prototype that will
successfully coat a six‐foot section of pipe within
the 3M test facility.
Design Constraints:
The motor must be able to operate in pipes
ranging from 6 to 24 inches in diameter
while accommodating bends up to 20
degrees, thus all rigid sections must be less
than 18 inches in length.
The motor must be able to be powered
through a 700‐foot umbilical.
13
Wind Tunnel Test Section
for Fluid Dynamics
Demonstration
Team: Benton Garske, Daniel Lucey, Brian Osende,
Nathan Uecker, Chad Weigelt
Clinic Advisor: Don Weinkauf
(Left to Right: Ben Garske, Brian Osende, Nathan Uecker, Chad
Weigelt, Dan Lucey)
Project Summary: The Wind Tunnel Team was tasked with
providing a hands‐on demonstration device to
supplement the new Engineering Course on
Fluid Dynamics. The team first established the
need for an educational device to provide a
hands‐on experience and that a wind tunnel
would fulfill that need. The team fully
instrumented the test section to measure
temperature, drag and lift forces, and wind
velocity, and constructed a test section designed
to simplify experiment set‐up. The wind tunnel
sytsem will allow students to explore different
fluid dynamic principles including drag/lift,
blockage, flow around blunt objects, heat
transfer, and the Bernoulli principle.
Project Mission:
The objective of this project was to provide
undergraduate engineering students at the
University of St. Thomas with a hands‐on
experience in fluid dynamic concepts.
Design Constraints:
The device must demonstrate fluid dynamic
concepts in an understandable and controllable
manner to provide a strong educational
experience. The device must make use of the
university’s limited lab space, necessitating a
small footprint. The device must be safe,
reliable, and robust, and must add a strong
hands‐on component to the fluid dynamics
curriculum.
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2010 Senior Design Clinic Projects
Three Phase Flow Meter for Oil Well Monitoring‐ Emerson ..........................................
Retroviewer Redesign for Retro‐Reflective Film Authentication‐ 3M ...........................
Pediatric Vein Transilluminator‐ Designwise Medical ......................................................
Introducer Sheath for Femoral Artery Surgery‐ Cardiovascular Systems, Inc. ................
Electrical Generator Heat Pipe System‐ Lockheed Martin ...............................................
Gastro‐Intestinal Implant‐ Metamodix, Inc. .....................................................................
Retractable Windscreen for Touring Motorcycle‐ Polaris ................................................
Pavement Marking Road Groove Depth Sensor & Logger‐ 3M ........................................
Hydrogen Peroxide Decomposition Chamber ‐ Future Force, LLC. ..................................
Machine Vision System for Laser Cutting‐ LasX Industries, Inc .......................................
Control Panel Assembly Cart‐ Design Ready Controls ......................................................
Fast Retraction Metal Punch‐ Mate Precision Tooling .....................................................
Reduced Effort Motorcycle Clutch‐ Polaris .......................................................................
Shea Butter Mixer‐ Shea Yeleen International .................................................................
Vortex Wind Energy System‐ Lockheed Martin ................................................................
Design of Z‐Axis Scan Head for 5kW Laser‐ LasX Industries, Inc. .....................................
Seed Potato Cooling Structure for Rural Mali ‐ USDA ......................................................
Magnetic Car Top Bike Rack System‐ Four Peaks .............................................................
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Thank you, Seniors!
