STUDENT INITIATED PROJECTSMaddie Burke Sean Harriman Kevin FerraroAndrew Nauss Marie Rohrbaugh Robert Hughes

Problem Statement: Successfully implement a turbocharger system on the current WR450 single cylinder engine.FSAE Turbocharger

Background Information Turbocharger system must be light

weight, reliable, serviceable, and efficient

Appropriate size will be determined based on intake restrictor, spool time, and chassis space

Heat management and cooling aspects are essential

Turbo is favorable over supercharger due to vibration issues and torque curve

Added weight must be justified through reduced lap times, power increase, and increased fuel efficiency

http://www.atpturbo.com/mm5/graphics/00000001/Catalog%20Images/Turbochargers/GT15-72TRIM-43AR_450-1.jpg

Stakeholders RIT FSAE Racing Lead Powertrain

Engineer – Phil Vars Project Manager –

John Scanlon Potential hardware

sponsor – (Honeywell, Garrett, Borg Warner, etc.)

FSAE Project Mentor – Alan Nye

Affinity Diagram

Problem Statement: If the Rochester Institute of Technology is focusing on a more sustainable and green future and Watkins Glen International is only an 1.5 hours away WHY IS RIT NOT COMPETING IN THE GREEN GRAND PRIX?

Alternative Fuel Vehicle to Compete in the Green Grand Prix at Watkins Glen

Background Information Green Grand Prix:

An educational and competitive event which showcases motoring technology that aims for a cleaner environment.

Only Official SCCA road rally that promotes entry of all road- legal vehicle types and fuels in North America.

Time Speed Distance (TSD) Rally Fri:130 mile fuel economy event on WGI 2.45 mile track Sat:140 mile fuel economy event on public roads around

Seneca Lake Current Teams

Cornell 100+ mpg Car Redshift Alfred State Honda Insight

Edison2 Roo Pod

Different Vehicles

Background Information Continued Relevant RIT Courses

Intro to Automotive Design and Manufacture Basic overview of vehicle design

Internal Combustion Engines Learn theory and faults/inefficiencies of IC engines

Vehicle Dynamics Powertrain System and Design

Research Activities RIT eBike Club

Center of Sustainable Mobility

Human Powered Vehicle

Stakeholders Sean Harriman (me)

Captain of former WIHS Solar Car Team, 1st in 2005 Tour De Sol.

Bob Gillespie Chairman of Green Grand

Prix Dr. Alan Nye

Assistant Department Head, Head of SAE

Unidentified Faculty Member of Golisano Institute of Sustainability Center of Sustainable

Mobility

WHY: Knows electric vehicles, TSD

races, car fabrication

Running event past 8 years, offshoot of Tour De Sol

Knows vehicle design, ME department faculty and space, former senior design projects

$4 Million Dollar Grant from U.S. Department of Transportation to assess impact of different alternative fuel and propulsion technologies

Affinity Diagram (Work In Progress)

Problem Statement: Build a water tunnel for use within the Kate Gleason College of Engineering

Water Tunnel at RIT

Background Information Water tunnels used for

hydrodynamic testing Water tunnel has

applications in research and educational use

Many past projects would have benefitted from such a testing capability

http://www.rollinghillsresearch.com/Water_Tunnels/Model_0710.html

Background Information Applicable courses-

Thermofluids Lab I Fluid Mechanics Transport

Phenomena Relevant topics

Incompressible Inviscid flow

Aero/Hydrodynamics Dimensional analysis Lift/Drag of objects Energy harvesting

Benchmarks- ELD Model 503

Benchmarks- MSE FlowLab

http://www.measurementsci.com/products_flowLab.html

Benchmarks- Rolling Hills Research 0710

http://www.rollinghillsresearch.com/Water_Tunnels/Model_0710.html

Stakeholders Dr. Ghosh (initial project

idea/educational uses) Mr. Ed Hanzlik (educational uses/testing) ME Students Dr. Lamkin-Kennard (education/testing) ChemE Department (lab use) Dr. Steven Day (research) Sarah Brownell (sustainable projects)

Initial Affinity Diagram

Affinity Diagram

Problem Statement: Reduce the Effect of Ambient Helium in Can During External Leakage Testing

MOOG External Leakage Test Improvement

Background Information

Helium Port: Valve is fixtured here

Mass Spec Port

Restricted from outlet flow

Helium in at pressure specified by customer

Valve Outlet

Inlet

In Fixture

Background Information Moog’s Customers require the valves meet

specifications Pressure into unit requirement Maximum Flow out of unit Vacuum requirement

Always a constant leakage rate for each valve Air is .0005% Helium Leakage rates present at 8E-6 scc/sec Spec at 5E-5scc/sec

Assumptions Made Fixture leakage from ambient Helium is moving around O-ring seals

Sealing surfaces that release to ambient pressures

Stakeholders AGT Product Engineer- Rob Bauer

(Primary) Product Engineering Manager- Peter Kerl Contamination Control Engineer- Ray

Gorecki Product Engineers Quality Engineers Clean Room Managers Operators Moog’s Customers

Affinity Diagram

Operator must be

safe at all times

Proper Trainin

g

Wire and plumbing

maintenance underneath can

Need Space

to move

AGT is currently a crowded

Area

Safety And Comfort

Analysis of all Failure

PossibilitiesPreventative measures in

place for possible failures

Risk Mitigation

Proper Instructions for changes in process

Minimize delay

caused by Confusion

Updated Software Package

Ease of Operator Use

All new equipment

must be certified clean

Material does not

“Shed or “ Flake”,

New equipment can not introduce

contaminate to valves

Contamination Control

New Feature Holds

VacuumLower

Leakage Data

Minimize Helium

detection in Mass Spec

Eliminate False

Failures

Product IntegrityMinimize

GN2 Consumpti

on

False Failures Result in extreme

man hours

Pneumatic

equipment can be

expensive

Minimize any excess

time per unit

Waste and Efficiency

Software controls the

whole system

Update plumbing

configuration

SoftwareHelium is

pumped at high pressures into valves and

then into vacuum

environment

Remove helium from fixture before it can leak into canVacuum causes

pressure through O-rings

Fixture Leakage

Long lastingRobust System

Problem Statement: Broaden participation and collaboration in nanoscale science by creating remotely accessible instrumentation.Nanomanipulator Phase Two

What Is a Nanomanipulator? Ultra high precision

position instrument Maneuver objects at

micro and nano scale Many uses in research

Inject into individual cells

Motivation Commercially available

manipulators are ~25k Not controllable over

the internet Increase access,

interest and participation in nanoscience Accessible Via Internet Affordable (Goal 1K)

Phase One

Stakeholders Prof Schrlau (RIT Mechanical

Engineering) Prof Stevens (RIT Mechanical

Engineering) Nano-Bio Interface Laboratory Staff Phase 1 Senior Design Team End users of product

(Students/Scientists)

Affinity Diagram

Summary/Questions?

FSAE Turbo Successfully implement a turbo on the WR450 engine Compile a reliable, light weight, and efficient turbo system

Water Tunnel

Useful water tunnel for education, research, and testing

Control flow and visualization capabilityMoog External Leakage

Minimize leak of test stand Well developed utilization plan of improved

equipment

Green GP High Efficiency road registered vehicle Funding, Space and University Support

Nanomanipulator Phase 2

Develop remote control nanomanipulator Make nanoscience more accessible