Current Projects

Fall 2021 Projects

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Legend: 1 = Primary Discipline | 2 = Secondary Discipline | 3 = Optional Discipline(s)

Company Name Project Title Faculty Contact BME CHE CMPEN CMPSC DS ED EE EGEE ESC IE MATSE ME NUCE
Aleo BME, Inc. Delivery Device for A Newly Invented Surgical Glue in Plastic Surgery Field Yeware, Amar 1 0 0 0 0 3 0 0 0 0 0 2 0

Non-Disclosure Agreement: NO

Intellectual Property: YES

Physical Prototype or On-Campus Equipment: YES

Seroma, a buildup of fluids in dead spaces where tissues are removed in a surgical procedure such as abdominoplasty or mastectomy, is a common, painful, and serious surgical complication. Current treatment by post-operative drains is uncomfortable and leads to unsatisfactory results. We developed a nature-inspired surgical glue to effectively close the dead spaces and thus prevent seroma formation. An applicator to deliver the glue materials is the critical part of the surgical glue product. This project aims to develop delivery tools including applicators for the surgical glue intended for plastic surgery.

Deliverables:
- Understand the key features of delivery tools that meet surgeon's needs, mainly in abdominoplasty, mastectomy and similar surgical fields
- Prototype of delivery tools that can easily deliver the surgical glue materials (we will send glue materials information and samples)
- Delivery tools are designed to be easy-to-use and can be used in the operation room environment
- Drawings of Delivery tools and applicators
Company Name Project Title Faculty Contact BME CHE CMPEN CMPSC DS ED EE EGEE ESC IE MATSE ME NUCE
American Crane & Equipment Corporation Development of Innovative Ski Boot Buckle Activation Concept Wang, Donghai 0 0 0 0 0 0 0 0 0 2 3 1 0

Non-Disclosure Agreement: YES

Intellectual Property: YES

Physical Prototype or On-Campus Equipment: YES

To develop an innovative concept & prototype for easier engagement/release of a ski boot buckle. A general concept / patent exists as well as a first-pass prototype. This is an opportunity for a team of students to take this concept to the next level of development. There is opportunity to use creativity to add to / improve the existing concept.

Specific tasks will include review of existing concept, development of one (or more) form(s) of the concept, creation of prototypes via additive manufacturing process, and installation of prototypes on a ski boot for proof-of-concept purposes and testing. ACECO will work with the student team as needed to provide application information, critical parameters, and general support throughout the process.
Company Name Project Title Faculty Contact BME CHE CMPEN CMPSC DS ED EE EGEE ESC IE MATSE ME NUCE
AMZ Manufacturing Corp. HIMARS Capacity Study Purdum, Charlie 0 0 0 0 0 0 0 0 0 1 0 2 0

Non-Disclosure Agreement: YES

Intellectual Property: YES

Physical Prototype or On-Campus Equipment: NO

AMZ Manufacturing Corp., located in York Pennsylvania, paints, assembles and manages the customer supplied inventory for the cab of the HIMARS (High Mobility Artillery Rocket System) military vehicle. The current production throughput is on average five cabs per month. The customer has requested a proposal to increase output form five cabs per month to six, eight and ten cabs per month.

Project Deliverables are as follows for each level of output (6, 8 and 10 cabs per month):
- Future state process design and layout.
- Resource requirements (employees, equipment, tools, etc.)
- Space requirements (warehouse and manufacturing)
- Direct and capital cost requirements
Company Name Project Title Faculty Contact BME CHE CMPEN CMPSC DS ED EE EGEE ESC IE MATSE ME NUCE
API Technologies Corp. Post Barrel Tumbling Separation Automation Wang, Donghai 0 0 3 0 0 0 3 0 0 2 0 1 0

Non-Disclosure Agreement: YES

Intellectual Property: YES

Physical Prototype or On-Campus Equipment: YES

After ceramic sintering, the product is placed into a cylindrical vessel (~0.3 liter) with prescribed quantity of water, tumbling media and sand. Vessel is sealed with a lid and placed on a roller for a set time/speed to round the capacitors corners and edges. Once rolling is complete, lid is removed; parts are washed out, separated and prepared for drying. Water is used throughout the unloading to separation process and is done in a sink with side shelf.

We would like to see the team devise a method using appropriate fixturing to simplify and speed the whole process from the point of unloading the vessel to parts separated and ready for drying.
Company Name Project Title Faculty Contact BME CHE CMPEN CMPSC DS ED EE EGEE ESC IE MATSE ME NUCE
Autodesk Inc. Optimized Space Telescope Structure using Generative Design Purdum, Charlie 0 0 3 0 0 0 0 0 3 1 3 2 0

Non-Disclosure Agreement: NO

Intellectual Property: NO

Physical Prototype or On-Campus Equipment: NO

Space-based telescopes, covering all wavelengths of light, are key to NASA's mission to reveal the unknown for the benefit of humankind. These telescopes require structures that are strong, light, stiff, stable, and cost effective. Autodesk Fusion 360 Generative Design combined with Digital Manufacturing has the potential to revolutionize telescope structure development, leading to massively reduced development time, lighter instruments, and lower costs. Generative Design leverages developments in AI and Cloud computing to rapidly generate optimized designs while ensuring compliance with requirements. Digital Manufacturing allows these complex lightweight designs to be efficiently manufactured by directly fabricating from the resulting 3D models. This includes both additive techniques, such as Laser Powder Bed Fusion (LPBF) and subtractive techniques such as automated CNC milling / turning.

Students will design and prototype an optimized structure for a Space Telescope using Autodesk Fusion 360 Generative Design and Digital Manufacturing. They will be given the needed requirements, typical for spaceflight structures, including loads, minimum first mode, minimum factor of safety, mass, mounting/mirror interfaces, and keep-out envelopes. They will learn to use Autodesk Fusion 360 Generative Design to input these requirements and generate design options. Based on performance and manufacturability students will select an optimized design for fabrication, including material selection and fabrication method. Students will then fabricate and test a prototype design or scale model.

Students will work in collaboration with Ryan McClelland, a Research Engineer in NASA Goddard's Instrument Systems and Technology Division, with experience on the Hubble, Webb, and Roman space telescopes. Students will deliver a technical report, similar to a short conference paper, detailing the design problem, development methods, solution, and results.
Company Name Project Title Faculty Contact BME CHE CMPEN CMPSC DS ED EE EGEE ESC IE MATSE ME NUCE
Bugingo Studios LLC CARTOGRAPHY Mapping Project Verbanec, Al 0 0 0 1 0 0 0 0 0 0 0 0 0

Non-Disclosure Agreement: NO

Intellectual Property: NO

Physical Prototype or On-Campus Equipment: NO

CARTOGRAPHY is a theater performance for young audiences that explores histories of migration and movement. The recent pandemic has immersed us in a simultaneously hyper-local and hyper global context. On the one hand we began asking ourselves how connected we really are with family and neighbors. At the same time we felt ourselves personally implicated in a crisis of global reach. The theater has always existed in this juxtaposition of the hyper-local audience who gathers for a brief moment to ask big questions about the world. For thousands of years we have honed theater as a technology to connect to ourselves, each other, and the world.

At one point during CARTOGRAPHY, the audience is invited to use their cellphones to show their personal histories of migration, which are then projected onto the stage as a collective map. With much of our national and international touring going virtual, we want to recreate the audience-specific interactive moment CARTOGRAPHY viewers share as they watch from their homes.

We are looking to translate the display application and server (currently run through Processing 3.3.7 off a designated computer) into an online hosted server on which groups of people could simultaneously input their personal data, or "migrations." Journeys are mapped country-to-country, ideally using a world map with geographically accurate dimensions.

The map application currently consists of three components, which will need online adaptations:
1. A client side map: this is where users input their journeys and submit them;
2. A Node-Express server: this serves the map website, receives and stores journey data from users, and relays this data to the display app;
3. A display application: this receives data from the server, displays it on a map, and communicates via Syphon with Isadora to project the map.

Currently, the client side shows a map of the world rendered as an SVG image. Users can use the browser's built-in gesture inputs to navigate: single drag to scroll, pinch to zoom, etc. Additionally, users can double-tap to select countries and add them to their journey. From their journey list displayed next to the map, users can UNDO, RESET, and SUBMIT, sending their unique journey data to the server. Users can also tap on a particular list element to remove it from their journey. The server handles requests from the audience clients, and keeps track of the journeys they input. It also keeps a journeys array with the master log of all journeys.

We would look forward to collaborating with the Learning Factory's teams to translate this mapping event for a remote audience who would be submitting their data asynchronously online. We would also look for details about scaling, security, and other functionality that may enhance the experience as we transfer this element of the work from the theater to the home.
Company Name Project Title Faculty Contact BME CHE CMPEN CMPSC DS ED EE EGEE ESC IE MATSE ME NUCE
CSL Behring 1 Device for subcutaneous delivery of immunoglobulin - Team 1 Yeware, Amar 1 0 2 0 0 0 0 0 0 0 0 3 0

Non-Disclosure Agreement: YES

Intellectual Property: YES

Physical Prototype or On-Campus Equipment: YES

The goal of this project is design of a drug delivery device for subcutaneous delivery of immunoglobulin by infusion. The target product is currently administered using a needle, tubing, and syringe infusion pump. The minimum target volume is 25ml, and the device should allow for patient mobility during infusion. The device should allow for start and stop of infusion, include a visual representation of dose delivery, and provide an indicator when the infusion is complete. The design should be scalable for high volume, low cost manufacture.

Deliverables include:
• concept design: sketches, drawings, CAD models
• description of delivery mechanism including pros and cons for use with target product or patient groups

Lead design will be selected for progression to a second semester for further design refinement, and proof of principal prototyping.
Company Name Project Title Faculty Contact BME CHE CMPEN CMPSC DS ED EE EGEE ESC IE MATSE ME NUCE
CSL Behring 2 Device for subcutaneous delivery of immunoglobulin - Team 2 Choi, Kyusun 2 0 1 0 0 0 0 0 0 0 0 3 0

Non-Disclosure Agreement: YES

Intellectual Property: YES

Physical Prototype or On-Campus Equipment: YES

The goal of this project is design of a drug delivery device for subcutaneous delivery of immunoglobulin by infusion. The target product is currently administered using a needle, tubing, and syringe infusion pump. The minimum target volume is 25ml, and the device should allow for patient mobility during infusion. The device should allow for start and stop of infusion, include a visual representation of dose delivery, and provide an indicator when the infusion is complete. The design should be scalable for high volume, low cost manufacture.

Deliverables include:
• concept design: sketches, drawings, CAD models
• description of delivery mechanism including pros and cons for use with target product or patient groups

Lead design will be selected for progression to a second semester for further design refinement, and proof of principal prototyping.
Company Name Project Title Faculty Contact BME CHE CMPEN CMPSC DS ED EE EGEE ESC IE MATSE ME NUCE
Digital Inventors Group Inc The Game of College Verbanec, Al 0 0 0 1 0 0 0 0 0 0 0 0 0

Non-Disclosure Agreement: NO

Intellectual Property: YES

Physical Prototype or On-Campus Equipment: NO

Using the Unity engine and any appropriate back-end software (web/database access), the game will be a fun, interactive experience with the opportunity to earn tokens with continued play and "leveling up". It will also provide my company the opportunity to load dynamic, current content that is designed to help college students become smarter, richer, healthier, and happier. Some of the content itself will be interactive and will include surveys and possibly interactive stories. The game will be tailored to the student, including, hopefully, content/news that is specific to their campus, but also tailored to their year in school, prior knowledge about certain learning objectives, and other ways. If the design (and time) allows, the app itself will load multiple 2D and 3D games to be played at different times and will allow future games to be installed as revisions of the app.

For background, I have prior experience designing and producing both educational games and educational animations. I've won over 2 dozen national awards in media production and feel very confident this product will get finished and will help thousands of students in the coming years. I've included artwork from a couple of prior projects since I don't have any artwork from this project yet.
Company Name Project Title Faculty Contact BME CHE CMPEN CMPSC DS ED EE EGEE ESC IE MATSE ME NUCE
Electric Power Research Institute (EPRI) 1 The Cinnamon List - Crowdsourcing an NLP energy dictionary Verbanec, Al 0 0 0 1 0 0 0 3 0 0 0 0 0

Non-Disclosure Agreement: NO

Intellectual Property: YES

Physical Prototype or On-Campus Equipment: NO

The need for natural language processing (NLP) applications in the energy industry is constantly rising. It is already in use for customer interactions, but power generation applications for on-site communications and automated information extraction from all the asset documents are still missing. During the first research projects in this space, EPRI researchers found the lack of industry-specific terms in standard dictionaries to be a significant hurdle in NLP adoption for the power industry.

This project aims at creating a large database of industry terms and synonyms through a crowdsourcing approach, enabling industry experts worldwide to add their vocabulary to the database. The first results can be implemented in an existing EPRI tool for comparison.
The desired deliverables are a website or phone app that allows structured entries and a technical report.
Company Name Project Title Faculty Contact BME CHE CMPEN CMPSC DS ED EE EGEE ESC IE MATSE ME NUCE
Electric Power Research Institute (EPRI) 2 Verification of Continuous Online Monitoring (COLM) Quick Guides (QGs) via laboratory experiments Choi, Kyusun 0 0 1 0 0 0 2 0 3 0 0 3 0

Non-Disclosure Agreement: YES

Intellectual Property: YES

Physical Prototype or On-Campus Equipment: YES

Many of the electricity generation plants are installing additional sensors and instrumentation to support continuous online monitoring (COLM) of the asset. The COLM helps in reducing number of manual preventive maintenance tasks while keeping the power plant asset reliability same or higher. EPRI has been developing equipment specific COLM quick guides (QGs) to provide guidance for sensor selection. The development of COLM QG is based on subject matter experts’ knowledge and experience with sensors to detect various failure modes associated with that asset.

The goal of this project is to verify selection of sensors based on actual failures simulated in the laboratory environment. The desired deliverables are failure data collected via sensors, and report including detailed information regarding laboratory setup (equipment setup, and sensor installation procedure), failure simulation/emulation procedure, analysis procedure and results.
Company Name Project Title Faculty Contact BME CHE CMPEN CMPSC DS ED EE EGEE ESC IE MATSE ME NUCE
Exacta Global Smart Solutions Cellular based IoT using oneM2M Choi, Kyusun 0 0 1 0 0 0 2 0 0 0 0 0 0

Non-Disclosure Agreement: NO

Intellectual Property: NO

Physical Prototype or On-Campus Equipment: YES

An IOT device that operates far from power and communications infrastructure requires power efficient implementations, reduced complexity and sustainability. This can be achieved by using components that are already known and verified to work so that a developer can quickly bring a new product to market. Cellular devices are an example where the radio module components are formally certified to operate according to specific cellular radio standards. oneM2M is a global standard that serves to make developing IoT applications that can be formally certified as well. This project will build a oneM2M compliant sensor device and actuator device using the Thingy 91. The project team will be exposed to a global IoT standard and have the potential to contribute to an open source software project.

The team will learn oneM2M application development and embedded device programing using the Nordic Thingy 91 and Zephyr RTOS. The main deliverables will be:
Sample oneM2M compliant Sensor application hosted on a Nordic Thingy 91 using the Zephyr RTOS
Sample oneM2M compliant Actuator application hosted on a Nordic Thingy 91 using the Zephyr RTOS
Company Name Project Title Faculty Contact BME CHE CMPEN CMPSC DS ED EE EGEE ESC IE MATSE ME NUCE
Exelon Generation Company, LLC Nuclear Test Loop Fast-Exchange Design Knecht, Sean 0 0 0 0 0 0 0 0 1 0 3 2 3

Non-Disclosure Agreement: NO

Intellectual Property: YES

Physical Prototype or On-Campus Equipment: YES

For the Nuclear Test Loop (NTL) to capture significant value, efficient exchange of samples post-irradiation run is essential. This Project “Fast-Exchange” targets only the mechanical design that facilitates safe and efficient sample transfer to minimize dose to operators/ technicians, does not introduce a new nuclear safety hazard, minimizes contamination and is quick and easy to remove and re-install to minimize the ‘down-time’ between sample runs.
Technical Specifications
This Project shall:
1. Ensure the nuclear fuel clad barrier is never challenged.
2. Maintain Nuclear Safety by ensuring a reliable Loop Pressure Boundary (LPB) during operation at design pressure 3000 psig and temperature 600 degF (max).
a. This specification defines the requirement that this “fast exchange concept” which requires breaking the LPB must not cause excessive wear or damage to surfaces or components in that action.
b. Stud and Bolting can be used however quick install and removal must be considered as well as any Foreign Material Exclusion (FME) method to prevent dropping materials into the reactor pool and challenging nuclear fuel cladding.
c. Specifically, mating surfaces which form the LPB components must be robust to resist deformation which would result in a failure at the interface. Temporary devices could also be employed to protect surfaces if needed (but should not substantially impact sample ‘down time’).
d. Alternatively, this can include soft-parts or other consumables so long as the expense is not beyond reason.
3. Provide Operator/ Technicians with the ability to use ‘simple actions’ for sample removal and re-installation.
a. This specification requests that we keep ‘the number of steps’ to complete at a minimum. There should not be complication regarding what an Operator/ Technician must do to swap samples—while procedures will be written, this should be intuitive, and an Operator/ Technician has no doubt that the LPB is restored when a new sample is loaded.
4. Provide Operator/ Technicians with radiation dose exposures ‘as low as reasonably achievable’.
a. To meet this specification, RSEC Management also imposes a 150 mR/ h dose rate limit. Therefore, shielding may be required in addition to time out of the Loop.

NTL Project Background
Exelon Generation Nuclear Innovation is exploring the potential of a modification to the Penn State Breazeale Reactor (PSBR) at the Radiation Science and Engineering Center (RSEC) at Penn State to add a “Nuclear Test Loop” which creates a nuclear in-core environment to simulate PWR or BWR environments for sample materials. These material samples (0.5 g nominal) are irradiated and ‘stressed’ if needed while subjected to chemistries, temperatures and pressures experienced in a Power Reactor.
The NTL Project would be an investment by Exelon Generation, creating a new revenue stream from customers seeking to perform lower-irradiation materials science investigations (e.g., at the proof-of-concept level to give confidence prior to large-scale costly irradiation). This Project has had favorable verbal support from EPRI and DOE for nuclear testing and analysis.
The NTL would serve a large demand in the nuclear materials science community and support lower-cost research to accelerate nuclear innovation for future nuclear reactors as well as support initiatives for existing LWR. This NTL Project will complete Phase I feasibility and safety simulation work October 2021. Results are as expected and find no significant safety issues.
Company Name Project Title Faculty Contact BME CHE CMPEN CMPSC DS ED EE EGEE ESC IE MATSE ME NUCE
Flowserve Corporation Variable Blade Angle Pump Impeller Rattner, Alex 0 0 0 0 0 0 2 0 0 0 0 1 0

Non-Disclosure Agreement: YES

Intellectual Property: YES

Physical Prototype or On-Campus Equipment: YES

Flowserve Corporation aims to continuously improve its flow control portfolio and provide extraordinary solutions for its customers to make the world better for everyone. Flowserve offers a wide range of pump types that support power, oil, gas, chemical, and general industries.

Flowserve centrifugal pumps use impellers to impart energy into a process fluid to aid in fluid movement or pressurization. Flowserve is interested in studying the feasibility of creating a pump impeller capable of varying its blade angle to adjust overall pump performance. Blade adjustment should be capable of fine adjustment without disassembly of the pump or removal of the process fluid.

Objectives:
Understand pump and impeller fundamentals
Research and study existing adjustable impellers
Create list of Engineering Requirements
Draft/adapt ideas for adjusting mechanism
Create 3D model of proposed adjustable impeller
Create physical prototype
Perform prototype testing
Create a bill of materials for prototypes and the proposed design
Participate in a design review with Flowserve team


Deliverables:
Physical and functioning prototype
CAD package (Includes any simulation work)
Test Report (Prototype Performance Results)
Final Report

Throughout this project students will need to exercise their engineering judgment and intuition as they investigate this technology. The students will present their study, redesign, results, and conclusions to Flowserve.
Company Name Project Title Faculty Contact BME CHE CMPEN CMPSC DS ED EE EGEE ESC IE MATSE ME NUCE
Fresh Start wellness Association LLC Lightweight portable leg press Purdum, Charlie 0 0 0 0 0 0 0 0 0 2 0 3 0

Non-Disclosure Agreement: YES

Intellectual Property: YES

Physical Prototype or On-Campus Equipment: YES

The leg press is a critical component to physical therapy in the lower limbs. The sponsor has developed a new concept for a leg press and needs assistance in getting it ready for the next phase of development. The student team will evaluate the current design of the sponsor’s physical therapy device. The evaluation should include wear testing of all components and consideration of material costs for high volume manufacturing. Deliverables should include material recommendations, degradation test results of all components, and SOLIDWORKS files of device. If time allows. Provide manufacturing connections.
Company Name Project Title Faculty Contact BME CHE CMPEN CMPSC DS ED EE EGEE ESC IE MATSE ME NUCE
GE-Hitachi Nuclear Energy Americas LLC Moon Based Reactor Shielding Design for Personnel Protection Knecht, Sean 0 0 0 0 0 0 0 3 3 0 2 1 0

Non-Disclosure Agreement: YES

Intellectual Property: YES

Physical Prototype or On-Campus Equipment: YES

To provide for sustained human life of the moon, Mars or other planets; reliable and plentiful power will be needed for the habitat, to purify water, to create oxygen, and make propellent and liquid oxygen for a return to earth. One option is using fission surface power to provide electricity. Even when placed a long distance away (1 km), the radiations dose to full time residents can be above mission goals/limits. Solving this challenge is very important. The project the team will determine an optimal shielding solution by performing radiation transport analysis for a surface power space reactor design. Trade-offs studies that potentially include weight, size, geometry, attachment methods, buried excavation, distance, and power cable mass will need to be performed to help make a system that will be able to safely provide power to personnel away from earth. The team will work with GEH and SpaceNukes engineers to plan and execute this study.

GE Hitachi Nuclear Energy (GEH) https://nuclear.gepower.com/
Based in Wilmington, N.C., For more than 60 years, GE and Hitachi have been designing, building, and servicing the world’s safest boiling water reactors (BWRs), including over 80 nuclear power plants globally, providing over 70 GW of electricity. We build on our legacy, boldly innovating to provide reliable carbon free power to the world. Today, GE Hitachi Nuclear Energy (GEH) offers the BWRX-300, a small modular reactor designed to be cost-competitive with other forms of generation, the ESBWR and ABWR. In 2020, GEH and TerraPower introduced the sodium cooled Natrium™ power production and energy storage system. In addition to our technology, we also provide a full range of new nuclear plant services and can tailor each solution to help customers overcome new plant challenges and experience better project development and execution. Global Nuclear Fuel (GNF), GEH’s sister company, provides fuel to these plants.

Space Nuclear Power Corporation (SpaceNukes) https://www.spacenukes.com/
SpaceNukes was founded on two fundamental beliefs: 1) the future of humankind is inexorably linked to our exploration and expansion into space, and 2) nuclear power is essential to our future, on Earth and in space. Our goal is to enable the successful deployment of space nuclear systems on the Moon, Mars, outer planets, or anywhere solar power or other sources are not practical. Progress in space fission reactors was stagnant for 50+ years, until our founders as key players of the Los Alamos National Laboratory team envisioned, formulated, designed, and successfully executed the DUFF and KRUSTY projects. This team combined unparalleled technical expertise, innovative thinking, and unabashed enthusiasm to end decades of failed advanced reactor programs, for both space and terrestrial application.

Note: Attached pictures courtesy of SpaceNukes and NASA
Company Name Project Title Faculty Contact BME CHE CMPEN CMPSC DS ED EE EGEE ESC IE MATSE ME NUCE
Green Garden Products Company, LLC 1 K-1 lawn and garden sprayer assembly process Purdum, Charlie 0 0 0 0 0 0 3 0 0 1 0 2 0

Non-Disclosure Agreement: NO

Intellectual Property: NO

Physical Prototype or On-Campus Equipment: YES

Green Garden Products Company, LLC
Project Proposal 1
K1 Assembly Process

Currently Green Garden Products Company injection molds and assembles products on a twenty-four hour per day basis five or six days weekly. The assembly of most products is manually, assisted by one or more pneumatic cylinders. To produce in this manner requires one full time person per assembly cell being operated on each shift. The ideal production level in this manner is 2,000 pieces per operator per shift, however, a number of our operators are only achieving in the neighborhood of 1,100 per shift. This situation coupled with the inability to fill some positions on all shifts, due to the current labor shortage, has become very costly and inefficient to Green Garden.

When personnel were abundant and wages were lower, we tended to overlook the advantages of automating projects such as this. Currently we feel this is an ideal function to automate with robotics. We could robotically pick and place parts and place the finished units in cartons for shipment to customers.

Currently we can produce 24,000 K-1 sprayers per day and our annual volume is approximately 5,000,000 units. The objective of this project is to identify opportunities for improving and automating the production process and demonstrate a "proof of concept" intervention. This will allow us to reassign the personnel to more technical functions where we are most impacted by the labor shortage.
Company Name Project Title Faculty Contact BME CHE CMPEN CMPSC DS ED EE EGEE ESC IE MATSE ME NUCE
Green Garden Products Company, LLC 2 K-3 lawn and garden sprayer assembly process Purdum, Charlie 0 0 0 0 0 0 3 0 0 1 0 2 0

Non-Disclosure Agreement: NO

Intellectual Property: NO

Physical Prototype or On-Campus Equipment: YES

Green Garden Products Company, LLC
Project Proposal 2
K3 Assembly Process

Currently Green Garden Products Company injection molds and assembles products on a twenty-four hour per day basis five or six days weekly. The final assembly of our K-3 product is manual. To produce in this manner requires three full time personnel per shift. It is accomplished by pulling people from their normal job assignments to form the pack out team. One of the employees assembles the right-side plate to the interior sprayer body, the second the left side plate and the third puts on the nozzle at which point the assembly is complete. This situation has been created by the inability to fill some positions on all shifts which has made it very costly and inefficient for Green Garden.

When personnel were abundant and wages were lower, we tended to overlook the advantages of automating projects such as this. Currently we feel this is an ideal function to automate with robotics. We could robotically pick and place parts and place the finished units in cartons for shipment to customers.

Currently we can produce 20,000 K-3 sprayers per week with an annual volume of approximately 1,000,000 units. The objective of this project is to identify opportunities for improving and automating the production process and demonstrate a "proof of concept" intervention. By automating these processes, we could avoid reassigning personnel from their normal assignments thus making the entire process significantly more efficient and increase output substantially.
Company Name Project Title Faculty Contact BME CHE CMPEN CMPSC DS ED EE EGEE ESC IE MATSE ME NUCE
Iridium Satellite LLC Realtime Graphical view of Command & TLM status for each Iridium Satellite Verbanec, Al 0 0 0 1 0 0 0 0 0 0 0 0 0

Non-Disclosure Agreement: YES

Intellectual Property: YES

Physical Prototype or On-Campus Equipment: NO

Iridium operates the world's largest constellation of satellites with complete global coverage. Operations requires real-time situational awareness of satellite information. This project involves the creation of a real-time display for use in operations to provide insight into each satellite's command and telemetry paths to/from the satellite operations center in Virginia.
Company Name Project Title Faculty Contact BME CHE CMPEN CMPSC DS ED EE EGEE ESC IE MATSE ME NUCE
Johns Hopkins Medicine - Department of Otolaryngology Our Bast Effort - 3D Computational and Physical Modeling Hylbert, Lyndsey 1 0 0 3 0 0 0 0 0 0 3 2 0

Non-Disclosure Agreement: NO

Intellectual Property: NO

Physical Prototype or On-Campus Equipment: YES

This semester we plan to Expand our 3-D Histological model for COMSOL computational analysis of Steady State IE Flow between the ED, Saccule and Utricle, in a healthy patient. The team will develop a 3-D model of the utriculo-endolymphatic valve (Bast valve) based on healthy human inner ear anatomy for computaional analysis of steady stead flow between the inner ear's utricle and endolymphatic duct. We aim to 3-D print a scaled up physical model to allow for pressure and flow validation of our steady-state model. The physical model will be dynamically similar to a healthy patient, allowing steady state pressure and flow validation.

You can view last semester's award winning project here: https://sites.psu.edu/lfshowcasesp21/2021/04/29/modelling-the-role-of-the-basts-valve-in-menieres-disease/
Company Name Project Title Faculty Contact BME CHE CMPEN CMPSC DS ED EE EGEE ESC IE MATSE ME NUCE
KCF Technologies Design and Fabrication of a Smart Flange with Embedded Sensors to Measure Temperature and Pressure in a Moving Fluid Using Additive Manufacturing Techniques Wang, Chao-Yang 0 0 2 0 0 0 3 0 3 0 0 1 0

Non-Disclosure Agreement: NO

Intellectual Property: NO

Physical Prototype or On-Campus Equipment: NO

Design and Fabrication of a Smart Flange with Embedded Sensors to Measure Temperature and Pressure in a Moving Fluid Using Additive Manufacturing Techniques

Sponsor – KCF Technologies (kcftech.com), State College, PA 16801
Industrial Mentors – Dr. Gary Koopmann, Senior Technologist, Co-Founder, KCF Technologies, garykoopmann@gmail.com
Dr. Micah Gregory, Senior Electrical Engineer, KCF Technologies, mgregory@kcftech.com

An emerging technology at KCF Technology is the remote monitoring of pump efficiency using wireless communication. The method involves measuring pressure and temperature differentials across a pump during its duty cycle. Presently, the temperature is measured with long probes (usually thermistors) that protrude into flow. However, when measuring with such a probe in contaminated fluids (think sewage treatment plants), the probe often gets covered with the contaminants, thus adversely affecting its accuracy. What is needed is a device that will avoid the contamination problem, i.e., one with no protrusions in the flow. Your team will be designing such a device that we call a ‘smart flange’.

In this design project, your team will design, fabricate (using additive manufacturing) and test a ‘smart’ flange (see above graphic) that provides an accurate measure of the moving fluid’s temperature and pressure even when the fluid is contaminated.

Steps in the design process

1) Become conversant with methods for measuring temperatures/pressures in fluids
2) To design the smart flange, begin with selecting a thin, robust liner material with high thermal conductivity (to rapidly take on temperature of the fluid)
3) Next, select a material for the flange with a low thermal conductivity to insolate the liner from ambient temperature of the surroundings. This part of the flange also must have adequate structural strength to withstand high internal pressures, e.g., 100 psi.
4) Choose devices and a method to measure the temperature of and pressure on the inner liner. (Suggestion: KCF will provide thermistors for the embedded temperature sensors). Miniature pressure sensors will be selected and purchased by the team. KCF will also provide details on the power and output requirement of the thermistors, pressure transducers to be compatible with KCF’s wireless system

Steps in the additive manufacturing fabrication process

1) Fabricate the inner liner with embedded thermistors and pressure sensors
integrated with outer insulating layer, both with embedded wires that lead to the external electrical connector.

Steps in the testing process

1) Install smart flange in a closed pumping system (provided by KCF at State College facility)
2) Connect thermistor and pressure sensor outputs to KCF’s wireless transmitter.
3) With pump operating, compare temperature/pressure of smart flange outputs measured remotely with that of KCF’s in-house temperature and pressure probes.

Throughout all three of the above stages of the project, KCF engineers will be available for consultation as to specifics of design requirements and compatibility with existing pumping system

Recommended disciplines: Mechanical Engineering, Engineering Science, Materials Engineering, Electrical Engineering, and Industrial Engineering
Company Name Project Title Faculty Contact BME CHE CMPEN CMPSC DS ED EE EGEE ESC IE MATSE ME NUCE
Listrak, Inc. An evaluation of email subject line content on predicting customer engagement. Verbanec, Al 0 0 0 1 0 0 0 0 0 0 0 0 0

Non-Disclosure Agreement: YES

Intellectual Property: YES

Physical Prototype or On-Campus Equipment: NO

Project Summary
Does email subject line content matter in driving customer engagement?

Project Context
Listrak is a leading digital marketing platform trusted by 1,000+ top retailers and brands for email, text message marketing, identity resolution, behavioral triggers and cross-channel orchestration. Listrak is focused on delivering maximum digital marketing ROI to customers by leveraging its AI-driven data platform to optimize customer marketing strategies. Listrak seeks to explore and quantify the impact of email subject line content on engagement (i.e. interaction with the email).

Project Purpose
While email is the most powerful form of digital marketing, recipients are often inundated with promotional content, causing them to ignore messages. Listrak clients sends over 70B billion marketing emails annually with little insight on whether the subject line contains engaging enough terminology to capture the subscribers’ limited attention.
By leveraging historical subject lines and respective open rates to identify common characteristics that result in subscriber engagement, customers would gain insight into the potential strength of a subject line prior to launching a campaign. This would assist customers in creating engaging subject lines resulting in increased subscriber open rates and customer satisfaction.

Project Pitch
Listrak is successful when their customers are successful and remains laser focused on delivering solutions and strategies that deliver meaningful results year-over-year.
Students will work with the analysts and engineers from Listrak to understand the workings of eCommerce shopping patterns by using modern, applied machine learning techniques to help make an impact on the success of Listrak and its 1,000+ customers.

Project Skills
The student team should have familiarity with predictive analytics using R or Python on a Windows operating system. The team should also have basic SQL knowledge and the ability to translate technical results into common business terminology.

Project Data
The data set includes email records from 2020 – 2021. The data model will be provided during kickoff.
Data description – Randomly selected email content and engagement data over the last two years will be provided. All data is de-identified according to Safe Harbor standards.
Data access and resources – Data will be stored in a relational database on Amazon Web Services infrastructure. Windows virtual machines will be available in AWS with both R and Python for the students to query and analyze the data. Students will be provided the necessary credentials.

Other details – No data will be allowed to leave the AWS network.
Company Name Project Title Faculty Contact BME CHE CMPEN CMPSC DS ED EE EGEE ESC IE MATSE ME NUCE
Lockheed Martin 1 Modular Hybrid Power System for UAVs Wang, Donghai 0 0 0 3 0 0 2 0 0 0 0 1 0

Non-Disclosure Agreement: NO

Intellectual Property: NO

Physical Prototype or On-Campus Equipment: YES

Current electric VTOL drones typically are limited to an endurance of 1 hour or less due to the weight of state of the are batteries. Hydrogen fuel cell powered UAV’s are starting to increase vehicle endurance, but are slow to gain entrance into the market due to the challenges of supplying hydrogen. A hybrid propulsion pack would enable current UAV’s to have extended mission endurance, while minimizing impact to the supply chain and user experience (some hybrid drones are coming to market with 4-5 hour endurance).

The team will design, build, and test a hybrid power system for a specified UAV (Multicopter). Design scope includes determining system power, voltage, and endurance while designing to size and weight requirements. The final unit should be a modular design, capable of interfacing with multiple UAVs with similar power ratings. The team will be expected to design and fabricate the test hardware to create the motor generator unit. They will then quantity the performance of the system (specific fuel consumption across a range of output powers) which they will be able to use to show the performance change of the UAV when switching from battery to hybrid power. After quantifying the performance of the system the team will power a representative UAV thruster with the system to show the unit is capable of providing stable and sustained power.

This project will be a mix of:
ME-mechanical design and analysis of the unit
EE-design and analysis of the power electronics
CS-design of the engine control system
Company Name Project Title Faculty Contact BME CHE CMPEN CMPSC DS ED EE EGEE ESC IE MATSE ME NUCE
Lockheed Martin 2 AI/ML – Artificial Intelligence & Machine Learning Tuft Data Processing Choi, Kyusun 0 0 1 3 0 0 0 0 0 0 0 2 0

Non-Disclosure Agreement: NO

Intellectual Property: NO

Physical Prototype or On-Campus Equipment: YES

Lockheed Martin has been a global leader in innovation and technology in the aerospace and defense field for over 100 years. Technology has been transforming how humans and machines work together. Lockheed Martin is focused on the development of key technologies such as Artificial Intelligence and Machine Learning to serve as a capability multiplier on our unmanned systems. People are relying on machines to help make more informed decisions, expand reach and access, and increase safety and productivity. This new era of human-machine collaboration depends on trust and understanding—allowing each component of the team to do what it does best. In an AI-enhanced future, humans will become better at everything; they’ll also become safer and less vulnerable to danger. AI-enabled autonomous systems are changing the way militaries operate and protect their forces, the way first responders fight fires, how researchers explore the far reaches of space and the ocean’s depths.

The goal of this project is to take in video data of tuft testing which captures airflow vector fields along the surface of a body, and then map that data to the UV coordinates of a 3D model. Tufts are small pieces of string or yarn installed on bodies in a moving fluid which assist in visualizing flow patterns at the surface of that body. Tufts help identify areas of steady and turbulent flow such as when a wing transitions into a stalled condition. Tufts can also identify periodic steady buffeting as can be seen on helicopter fuselages in rotor downwash field.

A series of 3D shapes should be tested with goal of providing the associated UV maps for each object. Students will need to 3D print the objects, add tufts in both even and randomly distributed positions and densities across the surface, place objects in a wind tunnel, and record video of how the tufts move. The video data will then need to be reviewed by students to manually identify the 2D vectors of every tuft in the camera’s coordinate system. The 2D camera space vectors will then need to be projected on the surface of the model by aligning the associated 3D model in the same relative position to the camera as the physical test article (recommend Unity software be considered). The surface vectors would then need be converted to UV coordinates using the UV mapping provided to align them to a 2D texture of the object.

At this point you would have a sparce distribution of airflow vectors across the UV texture map, this sparse vector field can then be fed into a deep learning model (Tensorflow / Keras / PyTorch) to learn to implicitly interpolate the vector field across the entire texture. This continuous vector field across the UV texture can then be re-applied to the 3D model to provide a full solution of airflow over the model in 3D space.

A stretch goal students can pursue would be to repeat this testing virtually within a CFD environment (such as Ansys / SimFlow / FreeCAD) and train the deep learning model on the “true” full airflow vector field as predicted by the CFD simulation.
Evaluation of aerodynamics using tufts is a common industry practice that provides a simple and cheap solution for understanding complex airflows on fixed wing and rotorcraft. This project will enhance the engineering data which can be extracted from such techniques and provide students the opportunity to learn and develop critical skills directly applicable to real world Lockheed Martin products and systems.

Key Project Deliverables Include
• A matrix of relevant test 3D objects and tuft distribution fields that effectively demonstrate the robustness of the final model
• A trained Deep Learning model capable of autonomously producing a vector field from 2D video data and mapping that data in 3D space
• Weekly Status Meetings with LM Advisor
• Design reviews and corresponding documentation such as a report and lessons learned
Company Name Project Title Faculty Contact BME CHE CMPEN CMPSC DS ED EE EGEE ESC IE MATSE ME NUCE
Logyard Brewing Create a New and Exciting Way to Package a "Variety" 4-pack for breweries of all sizes Purdum, Charlie 0 0 0 0 0 0 0 0 0 1 0 2 0

Non-Disclosure Agreement: NO

Intellectual Property: YES

Physical Prototype or On-Campus Equipment: YES

At this time, Logyard Brewing packages 4 16-oz cans together with plastic snap lid covers. This is a manual process where a person connects the cans to the lid covers. The cans can spin freely when snapped in place which means that the labels of the can may not be visible in a display case for a potential customer to read. Also, when the 4-pack is in a display case, 1) the 4-pack could be set in the display case [by the retailer] in any facing direction, 2) although it is a 4-pack, the display case will only show the two frontward facing can, therefore a customer will not be able to see the two cans in the back of the pack, 3) the labeling process much be customizable for Logyard Brewing to put any combination of cans together in the 4-pack and be easily viewed in the display case, 4) the shipping crates are a standard size and may restrict design if the packaging material is too thick, 5) the retailer is not responsible to ‘make sure’ all packs are facing the ‘right way’ and a customer is not responsible for spinning the cans or digging through a case to see if what they would like is in stock.

Logyard Brewing works hard to conserve resources and takes pride in using locally sourced materials. This mission would need to be a consideration in this project.

Logyard Brewing is looking for a creative team of students who will design, test, and evaluate different packaging and labeling options for the variety packs. Logyard Brewing requires the packing and labeling to be cost effective, easy to implement, and sustainable.

Logyard Brewing requires the project to include drawings to support design, a cost and risk matrix to support a business decision, and a final report. A prototype is also highly desirable so that we can work with our largest clients to get feedback and roll out this concept at a few select locations to test its effectiveness. Weekly meetings and progress reports are necessary to complete this project.
Company Name Project Title Faculty Contact BME CHE CMPEN CMPSC DS ED EE EGEE ESC IE MATSE ME NUCE
Mack Trucks Computer Vision and AI on Raspberry Pi Mittan, Paul 0 0 2 1 0 0 0 0 0 0 0 0 0

Non-Disclosure Agreement: NO

Intellectual Property: NO

Physical Prototype or On-Campus Equipment: YES

The team will be trained on the existing module and familiarize themselves with the current hardware, code and graphic user interface. The module contains a raspberry pi, pi camera, touchscreen display, docker capabilities, source code and is connected to a network. Deliverables is as follows: Creating an application and Optimization of GUI (auto launch upon start-up of raspberry pi, improved visuals and interface), capturing and processing pictures using Azure Custom Vision (adjusting white balance, camera settings, improving speed), and training the module to perform with repeatability and accuracy (increases accuracy of object detection model).
Company Name Project Title Faculty Contact BME CHE CMPEN CMPSC DS ED EE EGEE ESC IE MATSE ME NUCE
Mainstream Engineering Corporation 1 Low-cost Remote Monitoring System (RMS) - Hardware Mittan, Paul 0 0 2 0 0 0 1 0 0 0 0 0 0

Non-Disclosure Agreement: NO

Intellectual Property: NO

Physical Prototype or On-Campus Equipment: YES

Two Engineering teams from the Penn State Learning Factory will be developing the electronic hardware and software necessary to implement a low-cost Remote Monitoring System (RMS) with Fault Detection and Diagnosis capability. In a typical residential home, one of the largest sources of energy consumption is the air conditioning or heat pump system (AC). The AC units that traditionally “break on the hottest day of the year” actually have been operating at reduced capacity for some time, wasting energy. These units are typically operating with degraded capacity and operating for longer periods to compensate for their poor performance. When the first hot day arrives, the unit’s degraded capacity becomes apparent and the homeowner will probably call a technician for emergency service.

What is especially unique about the RMS system is that it can predict many common faults including: low refrigerant charge, degraded run or start capacitor, faulty relay, contactor pitting, faulty condenser fan, faulty evaporator blower, badly fouled or blocked condenser, and badly fouled or blocked evaporator or filter (reduced evaporator air flow).

The challenge to the engineering students at the Learning Factory is to develop the prototype of a low-cost implementation of the necessary electronics (Hardware Team) and to develop the user interface to be used by the homeowner and AC professional (Software Team).
Company Name Project Title Faculty Contact BME CHE CMPEN CMPSC DS ED EE EGEE ESC IE MATSE ME NUCE
Mainstream Engineering Corporation 2 Low-cost Remote Monitoring System (RMS) - Software Mittan, Paul 0 0 2 1 0 0 0 0 0 0 0 0 0

Non-Disclosure Agreement: NO

Intellectual Property: NO

Physical Prototype or On-Campus Equipment: NO

Two Engineering teams from the Penn State Learning Factory will be developing the electronic hardware and software necessary to implement a low-cost Remote Monitoring System (RMS) with Fault Detection and Diagnosis capability. In a typical residential home, one of the largest sources of energy consumption is the air conditioning or heat pump system (AC). The AC units that traditionally “break on the hottest day of the year” actually have been operating at reduced capacity for some time, wasting energy. These units are typically operating with degraded capacity and operating for longer periods to compensate for their poor performance. When the first hot day arrives, the unit’s degraded capacity becomes apparent and the homeowner will probably call a technician for emergency service.

What is especially unique about the RMS system is that it can predict many common faults including: low refrigerant charge, degraded run or start capacitor, faulty relay, contactor pitting, faulty condenser fan, faulty evaporator blower, badly fouled or blocked condenser, and badly fouled or blocked evaporator or filter (reduced evaporator air flow).

The challenge to the engineering students at the Learning Factory is to develop the prototype of a low-cost implementation of the necessary electronics (Hardware Team) and to develop the user interface to be used by the homeowner and AC professional (Software Team).
Company Name Project Title Faculty Contact BME CHE CMPEN CMPSC DS ED EE EGEE ESC IE MATSE ME NUCE
Mainstream Engineering Corporation 3 Advanced Air-Coupled Heat Exchanger for Mobile Battery Thermal Management System Rattner, Alex 0 0 0 0 0 0 0 0 0 3 2 1 0

Non-Disclosure Agreement: NO

Intellectual Property: NO

Physical Prototype or On-Campus Equipment: YES

Background: In most cooling applications, heat rejection to ambient air remains a system level constraint of aggressive size, weight, and power (SWaP). Military mobile applications have long been SWaP sensitive. Increasingly, commercial applications are SWaP sensitive also. For example, electric car battery thermal management systems require significant heat rejection capabilities in SWaP efficient packages that are also cost-effective. Traditional rectilinear heat exchanger geometries are simple and low cost to fabricate but SWaP inefficient. For applications like residential air conditioners, a fan produces a low-pressure region in a void space to uniformly move air across a heat exchanger surfaces. Close coupling of the fan to the heat exchanger minimizes size but introduces flow uniformity challenges.

Overview of Program: We would like to leverage advances in 3-D printing capabilities to maximize total heat rejection by specifically designing the heat exchanger to closely couple with a fan (provided). In this project, we would like the team to evaluate designs of conventional heat exchangers geometries (baseline) and alternate heat exchanger geometries (improved) to model, analyze (thermal and mechanical), design, fabricate, and demonstrate an improved geometry. Due to time and cost, the initial demonstration will likely be with a high thermal conductivity plastic. At the conclusion of the project, we would like a summary of the SWAP improvement the teams design achieved and a cost comparison between the baseline and improved design.

Design space:
Cooling Fluid: Water or glycol/water mixture
Fluid temperature: 50 DEGC
Air Temperature: 35 DEGC
Fan and Pump are specified

Deliverables:
Thermal and mechanical analysis results
Prototype
Experimental test results
Mechanical drawings
Cost analysis
Company Name Project Title Faculty Contact BME CHE CMPEN CMPSC DS ED EE EGEE ESC IE MATSE ME NUCE
Medtronic, plc Mobile App Development for a Custom Motion Capture System Verbanec, Al 3 0 2 1 0 0 0 0 0 0 0 0 0

Non-Disclosure Agreement: YES

Intellectual Property: YES

Physical Prototype or On-Campus Equipment: YES

Quantifying human body motion outside the laboratory, in a real world ambulatory environment is important for various research application. There are some commercial systems capable of collecting such data, however are typically designed for specific applications, and no designed for use with mobile devices. Small wireless Inertial Measurement Units (IMUs) that can connect to mobile devices exist, and can record accelerations and rotations. However, multiple sensors need be to used and synced to collect appropriate motion data.

The objective of this project is to develop a mobile app to connect to multiple (minimum 3) wireless sensors using existing APIs. The mobile app would allow for custom calibrations, as well as real time calculations to relate the sensors. The real time calculations and display of data will inform user of appropriate calibrations which is a crucial step of the data collection. The mobile app should also be able to alert the user when any sensor disconnects from the mobile device, or otherwise fails to record data. The output of the project would be the mobile app, along with sample data collection as proof of concept.
Company Name Project Title Faculty Contact BME CHE CMPEN CMPSC DS ED EE EGEE ESC IE MATSE ME NUCE
Meerya LLC Automatic Warning/Communicating System Design for Industrial & Construction Spaces at Blind Corners, Isles & Doors Mittan, Paul 0 0 1 0 0 0 2 0 0 0 0 3 0

Non-Disclosure Agreement: NO

Intellectual Property: NO

Physical Prototype or On-Campus Equipment: YES

Design a cost-effective platform that is reliable & that can be installed in industrial spaces where high risk occurs of collision is present. For example, end of aisles or blind corners. The design of the system will trigger the industrial vehicle's horn when the vehicle is approaching the checkpoint. The project variables will consist of determining the optimal design that uses readily available technology; such as, RFID, ultra sonic sensors, Bluetooth/WiFi, etc that will be able to command the vehicle's horn to trigger at the high danger areas automatically. One of the givens is that the horn will consist of Meerya's smart horn design that has the ability to integrate with various sensors. The team will be tasked with determining the right hardware required to automatically trigger Meerya's smart horn, & a proof of concept will help validate the thinking. Things to note when selecting the right hardware will be how fast a vehicle is approaching & in which direction.
Company Name Project Title Faculty Contact BME CHE CMPEN CMPSC DS ED EE EGEE ESC IE MATSE ME NUCE
Modern Industries, Inc Design and Prototype a 5 station Lathe ToolHolder that can be indexed using the lathes live tool station. Purdum, Charlie 0 0 0 0 0 0 0 0 0 1 3 2 0

Non-Disclosure Agreement: YES

Intellectual Property: YES

Physical Prototype or On-Campus Equipment: YES

Modern is looking to advance design and prototyping of a patented tool holder. The lathe toolholder houses 5 pockets(for 5 similar or varying geometry inserts). A prototype of the tool has been produced and placed into a test/display stand with an integrated motor and PLC for testing purposes. Through testing in this stand, we have identified some design modification that are needed. We want to incorporate these and other design ideas derived by the capstone team into a working prototype and test the prototype in the fame lab haas live tool St-20 lathe. This may require modification to the current prototype housing and drive systems to work with the Haas.

Deliverables include:

1. CAD Models and tolerance prints of the completed assembly (preferably in solidworks), suitable for manufacturing purposes. Create cad assembly drawing foro the 5 manjor lathe manufacturers. Haas, Okuma,Mazak,Doosa, DMG Mori
2. Working prototype for either a Haas or an Okuma lathe. Prototype to be tested in the cut and video taped.
3. Estimated cost to manufacture and assemble the assemble in lots of 5-10-50-100.
4. Various part materials and heat treatments need evaluated with recommendations for improvement if appropriate. Consider metal additive manufacturing for certain components to speed up the prototyping....ex. the upper and lower bodies may need to be modified for the different manufacturers.
Company Name Project Title Faculty Contact BME CHE CMPEN CMPSC DS ED EE EGEE ESC IE MATSE ME NUCE
MSA Company Artificial Intelligence / Image Recognition for Fall Protection Connection Detection Verbanec, Al 0 0 0 1 0 0 0 0 0 0 0 0 0

Non-Disclosure Agreement: YES

Intellectual Property: YES

Physical Prototype or On-Campus Equipment: NO

This project aims to research, understand, and develop prototype image recognition services for Fall Protection compliance management. "Compliance" in this case refers to having all pieces of Personal Protective Equipment (PPE) being worn properly, and connected to each other, such that a user is safely tethered if a slip or fall were to occur. Today, management of this form of PPE Compliance is entirely manual, requiring human oversight and constant training. Image recognition tools offer an opportunity to automate the supervision of these compliance requirements on industrial sites.

MSA is seeking a group of students to understand the environments where MSA is most interested in deploying this technology, draft a system architecture for a low-effort and fast prototype (may include hardware technologies such as the camera and user interface for visual feedback on compliance state, and communication path from camera to the cloud / AWS and back to the user interface / tablet), identify main technical risks (such as can it work offline, are there false positives and what are the probabilities and consequences, and training data and customization ), and complete experimentation (define experiments, scenarios, and result metrics upfront which may include: equipment, environment conditions (light, clothing, ...), trial persons, number of test runs, etc).
Company Name Project Title Faculty Contact BME CHE CMPEN CMPSC DS ED EE EGEE ESC IE MATSE ME NUCE
National Cannabis Risk Protection Services LLC Chronic Risk Score (TM) - Defining a Cannabis Company's Real Risk Verbanec, Al 0 0 0 1 0 0 0 0 0 0 0 0 0

Non-Disclosure Agreement: YES

Intellectual Property: YES

Physical Prototype or On-Campus Equipment: NO

In addition to the internal risks normally associated with running a business, US cannabis companies are also straddled with a number of external risks that place additional pressure on their chances of long-term sustainability.

The creation of the CHRONIC RISK SCORE (TM), in conjunction with the innovative CRP(2) (TM) assessment tool will set the stage for accurate and readily available risk definition, mitigation and transfer in the cannabis market.

Project deliverables:

- Data mining of risk definition and mitigation practices
- Development, creation and testing of algorithms to calculate factors and variables
leading to CHRONIC RISK SCORE (TM)
- Creation of code in the developing improvement of various SaaS platforms
- Tie together of above with applicable insurance underwriting guidelines
- Packaging and testing of the end product
Company Name Project Title Faculty Contact BME CHE CMPEN CMPSC DS ED EE EGEE ESC IE MATSE ME NUCE
NAWCAD Experimentation Office (NEO) 1 Autonomous Search Algorithm for UASs Verbanec, Al 0 0 2 1 0 0 0 0 0 0 0 0 0

Non-Disclosure Agreement: YES

Intellectual Property: YES

Physical Prototype or On-Campus Equipment: NO

The objective of the effort is to develop a programmable and adaptable algorithm that would effectively and efficiently conduct “search” patterns within a given sector based upon various pieces of underlying information (target size, sensor performance, aircraft performance, single/multiple assets, additional environmental data, etc.). This type of capability could be utilized across many platforms and with various types of sensors is crucial to enabling the fleet to complete various missions. As more and more operations are being considered to be conducted on UASs to support naval operations, having the system be based to a given baseline set of conditions plus have the ability to adapt on the fly to allow to maintain/increase effectiveness and efficiency is key to getting the overall mission done faster and with more accuracy.
Company Name Project Title Faculty Contact BME CHE CMPEN CMPSC DS ED EE EGEE ESC IE MATSE ME NUCE
NAWCAD Experimentation Office (NEO) 2 Multi-SDR based Communication System Cubanski, Dave 0 0 2 0 0 0 1 0 0 0 0 0 0

Non-Disclosure Agreement: YES

Intellectual Property: YES

Physical Prototype or On-Campus Equipment: YES

Utilizing basic off the shelf software defined radios (SDRs), model and develop a simple multi-SDR based communication system that will be able to receive and transmit information on a wide range of frequencies. Efforts will include modeling of the system, how to handle the data, how to route, how to store, etc. and how to select and utilize various apertures.
Company Name Project Title Faculty Contact BME CHE CMPEN CMPSC DS ED EE EGEE ESC IE MATSE ME NUCE
NAWCAD Experimentation Office (NEO) 3 Unique material solutions for extending life of structural and electrical parts Kimel, Allen 0 0 0 0 0 0 0 0 2 0 1 0 0

Non-Disclosure Agreement: YES

Intellectual Property: YES

Physical Prototype or On-Campus Equipment: YES

Experiment with various coatings to see how they perform on platform structure/electronics. The team should determine if these unique and cost effective implementations methods can be used to protect and allow components to operate in various environments. Conduct testing to determine overall effectiveness.
Company Name Project Title Faculty Contact BME CHE CMPEN CMPSC DS ED EE EGEE ESC IE MATSE ME NUCE
NAWCAD Experimentation Office (NEO) 4 Phase II AI/ML Development - Team 1 Cubanski, Dave 0 0 0 3 0 0 1 0 0 0 0 0 0

Non-Disclosure Agreement: YES

Intellectual Property: YES

Physical Prototype or On-Campus Equipment: YES

Continue with the development of initial Artificial Intelligence (AI)/Machine Language (ML) efforts completed in Spring 2021 projects to continue to expand the development of algorithm(s) to support various technical aspects of UAS technology development and experimentation.

The Spring 2021 projects targeted the sense and avoid functionality in autonomous drone operation. You can view the projects here:

https://sites.psu.edu/lfshowcasesp21/2021/04/29/uav-sense-and-avoid/

https://sites.psu.edu/lfshowcasesp21/2021/04/28/visual-ai-sense-avoid-system-design-for-group-1-3-uavs/

This sponsor was a "Best Sponsor" winner in Spring 2021.
Company Name Project Title Faculty Contact BME CHE CMPEN CMPSC DS ED EE EGEE ESC IE MATSE ME NUCE
NAWCAD Experimentation Office (NEO) 5 Phase II AI/ML Development - Team 2 Cubanski, Dave 0 0 3 2 0 0 1 0 0 0 0 0 0

Non-Disclosure Agreement: YES

Intellectual Property: YES

Physical Prototype or On-Campus Equipment: YES

Continue with the development of initial Artificial Intelligence (AI)/Machine Language (ML) efforts completed in Spring 2021 projects to continue to expand the development of algorithm(s) to support various technical aspects of UAS technology development and experimentation.

The Spring 2021 projects targeted the sense and avoid functionality in autonomous drone operation. You can view the projects here:

https://sites.psu.edu/lfshowcasesp21/2021/04/29/uav-sense-and-avoid/

https://sites.psu.edu/lfshowcasesp21/2021/04/28/visual-ai-sense-avoid-system-design-for-group-1-3-uavs/

This sponsor was a "Best Sponsor" winner in Spring 2021.
Company Name Project Title Faculty Contact BME CHE CMPEN CMPSC DS ED EE EGEE ESC IE MATSE ME NUCE
Nittany Solutions Group, LLC Infinite Shield - Alpha Design Cubanski, Dave 0 0 3 0 0 0 1 0 3 0 2 3 0

Non-Disclosure Agreement: YES

Intellectual Property: YES

Physical Prototype or On-Campus Equipment: YES

Project Overview:
Enhance last semester's Learning Factory proof of functionality effort on the initial Infinite Shield design.

Deliverables:
Finalize the Alpha prototype design such that field-testing units may be produced.
1. Increase the screen resolution dramatically to meet shield accuracy requirements.
2. Revise object sensing technology to accommodate the new higher resolution design.
3. Finalize material selection for environment compatibility.
4. Add defined design features such as automation functionality, safety measures, and operational status indication for improved overall user experience and protection.

You can view last semester's project here: https://sites.psu.edu/lfshowcasesp21/2021/04/29/infinite-shield/
Company Name Project Title Faculty Contact BME CHE CMPEN CMPSC DS ED EE EGEE ESC IE MATSE ME NUCE
Otis Elevator Company Development of a rope sway sensing system Choi, Kyusun 0 0 2 3 0 0 1 0 0 0 0 3 0

Non-Disclosure Agreement: YES

Intellectual Property: YES

Physical Prototype or On-Campus Equipment: NO

The objective of this project is to define and develop a working prototype of a system to monitor and sense lateral motion of hanging ropes. The project milestones are as listed below:

(a) Sensor Selection
Define sensor requirements & select candidate sensors for evaluation
Perform proof-of-concept tests and select sensor

(b) Mechanical Mounting, Data Acquisition & Test rig Design
Design & fabricate sensor mounting hardware
Design & assemble data acquisition & processing system

(c) Data processing & Test Verification
Design & develop data processing algorithms for rope sway monitoring
Verify DSP logic on a test rig setup

(d) Field Test System at Pilot Sites
Implement system on a pilot site
Log & process data to verify rope sway monitoring operation
Company Name Project Title Faculty Contact BME CHE CMPEN CMPSC DS ED EE EGEE ESC IE MATSE ME NUCE
Penn State Health Milton S. Hershey MC Fair distribution of anesthesiology call hours Verbanec, Al 0 0 0 1 0 0 0 0 0 2 0 0 0

Non-Disclosure Agreement: NO

Intellectual Property: NO

Physical Prototype or On-Campus Equipment: NO

The department of Anesthesiology at the Penn State Milton S. Hershey Medical Center is comprised of over 50 faculty anesthesiologists who care for surgical patients in the hospital. At any point in time, there are at least 2 anesthesiologists in the hospital to ensure patient can undergo surgery at all hours of the day. In addition, there are several subspecialty anesthesiology who are available “on-call” and must be in the hospital within 30 minutes of being notified.

In order to ensure equity in the department, it is important that all faculty have a similar overnight and weekend call resposabilities that is distributed between in-house and home call, clinical subspecialty group, part time employment, etc. The objective of this project is to build an interface which will predict future call requirements and duty hours from historical data. This interface will assist with the identification of an optimal call schedule for the anesthesiologists in the department.
Company Name Project Title Faculty Contact BME CHE CMPEN CMPSC DS ED EE EGEE ESC IE MATSE ME NUCE
PennEngineering Design an Automated Handling Device for Standoffs Rattner, Alex 0 0 3 0 0 0 2 0 0 3 0 1 0

Non-Disclosure Agreement: NO

Intellectual Property: YES

Physical Prototype or On-Campus Equipment: YES

Background: The current method of installing internally threaded standoffs onto PC Boards - called surface mount standoffs - is to apply an adhesive patch to the top of every standoff. This patch allows a vacuum to be generated between the installation tool and the standoff. The standoff is picked up by a machine that uses vacuum pressure and then placed onto the PC Board, where it is soldered into position. After soldering, the patch must be removed by hand from every standoff and discarded.

Project: The team will design and develop a new device that will make the adhesive patch obsolete. This new device will allow a vacuum to pick up and place an internally threaded fastener on a PC Board. The device must then be returned to its original position, in order to pick up the next standoff in line. This cycle will require an innovative design. The team will create prototypes of their best design and test the functionality of the device. The optimal result would reduce waste, cost, and the manual labor required to install these fasteners.

Goals:
- Design a device to replace an adhesive patch.
- Create prototypes of the device.
- Test device functionality.
- Evaluate cost savings of switching from patch to new method.
- Calculate reduction in waste using new method.
Company Name Project Title Faculty Contact BME CHE CMPEN CMPSC DS ED EE EGEE ESC IE MATSE ME NUCE
Philips Ultrasound Automated R&D In-Process Circuit Check System Cubanski, Dave 0 0 2 0 0 0 1 0 3 3 0 3 0

Non-Disclosure Agreement: YES

Intellectual Property: YES

Physical Prototype or On-Campus Equipment: NO

The Philips Ultrasound Transducer R&D organization team creates some of the most advanced Ultrasound Transducers in the market, and has a strong commitment to our customers, innovation, and quality. In this project, we are seeking a team to support us in meeting those commitments by helping us ensure the highest reliability and quality of flex circuits to be introduced into our new product designs.

Deliverables include:
• Identification of equipment to automate in-process capacitance and resistance measurements.
• Development of mechanical fixturing for circuits to be constrained.
• Development of measurement programs to inspect various flex circuits.
• Establishment of data collection method for analysis and presentation.

In a successful project, the team would identify and evaluate of the best equipment to provide highly accurate and repeatable data, mechanical design of necessary fixtures, development of measurement programs, and data output formatted in a presentable, easy-to-interpret way in which our teams can analyze for reliability and quality improvement efforts.

We are relying on this team to provide confidence in the recommended equipment, fixturing, and data collection. Implementing an automated system and collecting this data will allow our engineers evaluate the health of the signal path within the circuits at various steps in the build process to make informed decisions around the viability of the transducer build. Assessing concerns early in the build will reduce scrap costs by discontinuing effort and material costs associated with continued processing of non-viable components. And doing so in an automated way can reduce the labor investment and potential ergonomic concerns presented by manual checks.
Company Name Project Title Faculty Contact BME CHE CMPEN CMPSC DS ED EE EGEE ESC IE MATSE ME NUCE
PSU Applied Research Laboratory 1 Linear actuator test stand Neal, Gary 0 0 3 0 0 0 2 0 0 3 0 1 0

Non-Disclosure Agreement: NO

Intellectual Property: YES

Physical Prototype or On-Campus Equipment: YES

The test stand shall be able to independently measure the actuator stroke length and vary the load applied to the actuator as a function of stoke length. A data acquisition system (LabView) shall also be design which can record the applied load and stroke length vs. time. If time and circumstances allow the system will be built and demonstrated.
Company Name Project Title Faculty Contact BME CHE CMPEN CMPSC DS ED EE EGEE ESC IE MATSE ME NUCE
PSU Applied Research Laboratory 2 Peristaltic pump Rattner, Alex 0 0 0 0 0 0 2 0 0 0 0 1 0

Non-Disclosure Agreement: NO

Intellectual Property: YES

Physical Prototype or On-Campus Equipment: YES

Design and simulate a simple peristaltic pump that employs an electromagnetic coil and a ferrous ring to move fluid through a tube. A flexible membrane will be wrapped over the ring to provide a more direct analog to biological systems. The concept can be simulated using a combination of analytical computations and multiphysics simulation (COMSOL, SPICE, ABAQUS). After validation, the system should then be built and demonstrated.
Company Name Project Title Faculty Contact BME CHE CMPEN CMPSC DS ED EE EGEE ESC IE MATSE ME NUCE
PSU Applied Research Laboratory 3 Machine Learning (ML) Model Adaptation and Concept Drift Detection Verbanec, Al 0 0 0 1 0 0 0 0 0 0 0 0 0

Non-Disclosure Agreement: NO

Intellectual Property: YES

Physical Prototype or On-Campus Equipment: NO

The Algorithms, Prototyping, and Integration (API) Department within the Communications, Information, and Navigation Office (CINO) at The Applied Research Lab at Penn State (PSU/ARL) specializes in developing models and algorithms that derive information to support decision making. For example, the Iris dataset (1) can support a classification model to predict flower types. This model would enable a novice gardener to decide how to care for each flower. Although these models may perform well when initially deployed, they frequently decay over time. This decay in prediction accuracy may occur due to concept drift. Concept drift is the change in statistical properties of a target variable.

The objective of this project is to develop a classifier that can automatically detect and adapt to concept drift.

There are two main ways that drift is currently detected in models: error-rate based detection and data distribution based detection. Error rate detection studies the number of wrong predictions on new data and flags drift if there is a significant upward shift in errors. Data distribution tracks the statistical distribution of the features in new data and flags when there is a significant change. These definitions and more concepts about Learning Under Drift Detection can be found in a literature review from 2018 by Lu et al. (2)

Members of the project team will use Python and Docker to create and train a machine learning model, simulate new incoming data, detect drift, and adapt the model to that drift. An option available to the team is the Iris dataset. This data can be used to classify flower types using a decision tree. Drift could be induced by a scaling the features for one flower type. Adaptation in the decision tree can be accomplished via pruning. Team members are welcome to use this example for this project, but are encouraged to use a feasible dataset or prediction model that they are passionate about.

Deliverables expected by project end include python code, a docker environment, the data set used, and the model (if the model requires weights or some setting to reproduce). Included should be a report covering all aspects of the project and results including a data dictionary, model visualization, how drift was induced, and how the model responded to the drift to improve results.



(1) UCI Machine Learning Repository: Iris Data Set. (n.d.). UCI Machine Learning Repository. Retrieved July 28, 2021, from https://archive.ics.uci.edu/ml/datasets/iris

(2)  Lu, J., Liu, A., Dong, F., Gu, F., Gama, J., & Zhang, G. (2018). Learning under Concept Drift: A Review. IEEE Transactions on Knowledge and Data Engineering. https://doi.org/10.1109/tkde.2018.2876857
Company Name Project Title Faculty Contact BME CHE CMPEN CMPSC DS ED EE EGEE ESC IE MATSE ME NUCE
PSU Applied Research Laboratory 4 Coordinating Cyber Community Protection Operation (C-3PO) Verbanec, Al 0 0 2 1 0 0 0 0 0 0 0 0 0

Non-Disclosure Agreement: NO

Intellectual Property: NO

Physical Prototype or On-Campus Equipment: NO

The objective of this project is to finalize an Android Application prototype. Four previous capstone teams have designed the prototype of an interactive robot simulator game featuring 4 scenarios. This game is the focus of a public high school cybersecurity course that teaches cybersecurity concepts and programming applications.

Previous teams have set up the development environment, the existing code, developed Scenario 1, in addition to significant portions of Scenarios 2 and 3, and they have also thoroughly documented all aspects of their work.

Next steps for Fall 2021 will be:
(1) coding and modeling to finalize Scenarios 2 and 3
(2) coding and modeling to create and finalize Scenario 4, and
(3) implementing user information storage optimization for cloud deployment.

For this App that will be used in high school cybersecurity courses and associated with a set of learning tasks, specifications include design that is accessible to students who have limited cybersecurity and programming background. The unity-based educational robot simulator enables students to control the robotic system using a bash shell interpreter for completing tasks in scenarios and open worlds. A second user interface enables educators to launch adversarial cyberattacks against the robotic system, and record user data for the teacher to oversee and check student progress.

The scenarios re-orient student learners from cyber security as primarily a reactive self-defense experience to a proactive one focused on ensuring the safety of the individual and the community through consistent and persistent self-regulation and regulation of the cyber environment. Through their engagement with the Android App, students will develop their understanding about the necessity of managing their digital footprints, ethical issues in information technology, and the uses of cryptography for protecting private information in the digital age. Students will explore network and device vulnerabilities, launch attacks in a safe environment and explore the consequences of illegal exploitations.
Company Name Project Title Faculty Contact BME CHE CMPEN CMPSC DS ED EE EGEE ESC IE MATSE ME NUCE
PSU ATOMIC - The Center for Atomically Thin Multifunctional Coatings Design and prototyping readout and communication modules for point-of-care electrochemical biosensors. Cubanski, Dave 3 0 2 3 0 0 1 0 3 0 3 0 0

Non-Disclosure Agreement: NO

Intellectual Property: YES

Physical Prototype or On-Campus Equipment: YES

Develop a circuit prototype and android application to interface or communicate with a smartphone for remote readout of electrochemical signals from an electrochemical biosensor.

TASKS
1. Background and literature review on principles of electrochemical sensors and operation principles of a potentiostat.
2. Basic potentiostat circuit - Simulation (Cyclic voltammetry)
3. Breadboard implementation of the basic design
4. Testing with standard redox solutions to validate the basic design
5. Benchmarking the designed circuit and improvement to include advanced modules (square wave voltammetry, differential pulse voltammetry)
o Depending on the progress of the group, if they achieve milestones, additional design elements will be added to allow students to expand their knowledge.
6. Fabrication of the advanced circuit on breadboard
7. Integration of a WiFi/Bluetooth communication module with the designed circuit
8. Development of a mobile app to control the potentiostat
9. Design of a standard industry PCB design (outsourced to be manufactured)
o Exploring multichannel design for multiplex sensing
10. Validation of the final PCB design

DELIVERABLES
o Breadboard implementation of different design steps noted above under tasks
o Design of PCB and implementation
o App development and successful connection to smart phone
Company Name Project Title Faculty Contact BME CHE CMPEN CMPSC DS ED EE EGEE ESC IE MATSE ME NUCE
PSU CHOT 1 Artificial intelligence and virtual reality for smart health Verbanec, Al 2 0 0 1 0 0 0 0 0 3 0 0 0

Non-Disclosure Agreement: NO

Intellectual Property: NO

Physical Prototype or On-Campus Equipment: NO

This research project is aimed at developing VR/AR models to implement digital twin for the electromechanical function of cardiac myocytes. In the digital world, there will be ions (ca2+, Na+, K+ ...), membranes, ion flows, ionic gates, cell contractions, and action potentials etc. We will use HTC VIVE VR systems to implement the models of a cardiac cell and develop artificial intelligence models to control the moving dynamics of ions.
Company Name Project Title Faculty Contact BME CHE CMPEN CMPSC DS ED EE EGEE ESC IE MATSE ME NUCE
PSU CHOT 2 Healthcare Workforce Productivity Measures Purdum, Charlie 3 0 0 2 0 0 0 0 0 1 0 0 0

Non-Disclosure Agreement: NO

Intellectual Property: NO

Physical Prototype or On-Campus Equipment: NO

One of the APP (advanced practice providers) leaders is looking at developing standards and productivity measures in process for APPs. That is, nurse practitioners, physician assistance and the like have various roles across healthcare. This project requires the use of a lot of data from the EMR, and schedules, to develop metrics of healthcare workforce productivity. To our knowledge, it has not been done before and now that APPs are a large part of the Healthcare workforce, we call for a team of senior students to work and develop data-driven metrics of healthcare workforce productivity.
Company Name Project Title Faculty Contact BME CHE CMPEN CMPSC DS ED EE EGEE ESC IE MATSE ME NUCE
PSU Engineering Leadership Development Program (ELDP) Automated Contact Management Purdum, Charlie 0 0 0 1 0 0 0 0 0 2 0 0 0

Non-Disclosure Agreement: NO

Intellectual Property: NO

Physical Prototype or On-Campus Equipment: NO

The Engineering Leadership Development program at Penn State resides within the School of Engineering Design, Technology, and Professional Programs (SEDTAPP). The school offers numerous undergraduate minors and graduate programs for both technical and professional development. Throughout the year, representatives from the organization attend various events, where students (or potential students) sign up to receive specific program information. Depending on a student's semester standing (freshman, sophomore, etc.), certain programs may be more applicable.

Over time, as a student advances through their academic career, other programs may apply. For example, as sophomores, an undergraduate minor in Engineering Entrepreneurship may be most applicable. However, for a senior, a graduate degree in Engineering Leadership may be more applicable than an undergraduate minor.

The purpose of this project is to develop data sorting algorithms that will track contact information for thousands of contacts, identify applicable SEDTAPP programs based on semester standing, and automate the process of updating each contact's semester standing over time (or remove from database after expected graduation). The algorithms and tools must operate in an MS Office application such as MS Excel and provide a configurable user dashboard for appropriate campaign development.
Company Name Project Title Faculty Contact BME CHE CMPEN CMPSC DS ED EE EGEE ESC IE MATSE ME NUCE
PSU Engineering Science and Mechanics (ESM) Machine-learning-enabled classification of materials defects in transmission electron microscopy images Verbanec, Al 0 0 0 1 0 0 0 0 3 0 2 3 3

Non-Disclosure Agreement: NO

Intellectual Property: NO

Physical Prototype or On-Campus Equipment: NO

Materials science and engineering (MSE) plays a critical role in human society. Almost every modern tool we used today benefited from the advances in materials. The performance of materials is usually decided by the defects in them. Various kinds of defects can exist in materials, including point defects, dislocations, grain boundaries and stacking faults, etc. As many of the defects are too small (ranges from one angstrom to one micrometer), transmission electron microscopy (TEM) is required to image them. Visualizing the defects in materials is a crucial step towards understanding how defects impact materials' performance. The mission of MSE is the fabrication of materials with arbitrary desired properties based on a solid understanding of the materials-defects relationship. To more rapidly reach this goal, strategies must be taken to boost the understanding of defects in materials.

In this project, students will form a team to create TEM image-based datasets and develop machine-learning models to automatically detect various kinds of materials defects in these images. This project, if succeeds, will significantly improve the efficiency of material characterization and greatly facilitate the development of novel materials to enable new engineering systems.

Students will conduct the project under the supervision of two PSU professors: Prof. Yang Yang from engineering science and mechanics, an expert on TEM and materials; and Prof. Mia Jin from nuclear engineering, specializing in computational modeling of materials. This interdisciplinary project offers hands-on experience of research in materials science, computer science, nuclear engineering, and engineering science and engineering. Students will have the opportunity to publish a peer-reviewed scientific journal paper if the project generates convincing results.
Company Name Project Title Faculty Contact BME CHE CMPEN CMPSC DS ED EE EGEE ESC IE MATSE ME NUCE
PSU Human Powered Vehicle (HPV) ASME Human Powered Vehicle Challenge (HPVC) Neal, Gary 0 0 0 0 0 2 0 0 0 0 0 1 0

Non-Disclosure Agreement: NO

Intellectual Property: NO

Physical Prototype or On-Campus Equipment: NO

Overview
HPVC is an engineering design & innovation competition where students can network and apply engineering principles through the design, fabrication, and racing of human powered vehicles.

Objectives
The HPV team's main objective is designing and building a Human Powered Vehicle to compete in the Human Powered Vehicle Challenge (HPVC) at the ASME E-Fest. The vehicle needs to meet all standards set forth by ASME to protect the rider in the event of a crash. The vehicle must also be designed to compete in all portions of the competition, which typically includes an endurance and sprint event.

https://efests.asme.org/competitions/human-powered-vehicle-challenge-(hpvc)
Company Name Project Title Faculty Contact BME CHE CMPEN CMPSC DS ED EE EGEE ESC IE MATSE ME NUCE
PSU Learning Factory 3d-printed balance bike Knecht, Sean 0 0 0 0 0 0 0 0 0 2 0 1 0

Non-Disclosure Agreement: NO

Intellectual Property: NO

Physical Prototype or On-Campus Equipment: YES

Balance bikes are used to help toddlers develop the skills necessary to ride a bike. Although they are not particularly common in the US, they are widely used around the world.

Specialized recently released a carbon fiber balance bike that was simultaneously lauded (it's very cool) and derided (it's very expensive, especially during COVID). You can see it here:

https://www.specialized.com/us/en/hotwalk-carbon/p/188009

Your team will design a more "in touch" balance bike. It should consist exclusively of parts that can be 3d-printed or found in a typical recycling bin (clean materials only, please). We will place the completed design on the LF website in our new "public domain designs" section. Your design will be tested in the field, so it needs to be excellent.
Company Name Project Title Faculty Contact BME CHE CMPEN CMPSC DS ED EE EGEE ESC IE MATSE ME NUCE
PSU Materials Research Institute (MRI) Controlling Magnetic Orientation in the Powder Processing of Soft Magnetic Composites for Electric Vehicle Applications Kimel, Allen 0 0 0 0 0 0 0 0 3 3 1 2 0

Non-Disclosure Agreement: NO

Intellectual Property: NO

Physical Prototype or On-Campus Equipment: YES

The automotive industry is in the process of a rapid and revolutionary switch to hybrid and electric powered vehicles, displacing more than a century of dominance for the internal combustion engine. With this paradigm switch in vehicle propulsion, new material systems and production methodologies are needed. One area involves the transition from traditional electrical steels to the processing and application of low loss materials, typically encompassing a class of materials known as soft magnetic composites (SMC).

Processing of SMC and related material combinations will require changes from the traditional laminated sheet product form common to electric steels. Powder processing, whether through traditional press and sinter powder metallurgy (PM) operations or through emerging additive manufacturing (AM) processing, represents an attractive pathway for processing these unique materials. There are new challenges in the processing of these powders and being able to effectively control the magnetic domain orientations and properties of the powders. Since powders demonstrate random crystallographic and magnetic domain orientations, other means for controlling these orientations during processing need to be developed.

In the proposed program, methodologies and tools for controlling magnetic domain orientations during powder flow operations common to PM and AM processing will be explored. Using both design tools and laboratory scale experiments, a means for using magnetic and other tools for producing specific magnetic domains in powder will be explored. At the completion of the project, the basis for controlling these properties in simple mold shapes or powder beds commonly used in AM processing will be demonstrated.
Company Name Project Title Faculty Contact BME CHE CMPEN CMPSC DS ED EE EGEE ESC IE MATSE ME NUCE
PSU SEDTAPP (Global Building Network) Clean Affordable Cooling for Vulnerable Populations Wang, Chao-Yang 0 0 0 0 0 3 0 2 0 0 0 1 0

Non-Disclosure Agreement: NO

Intellectual Property: NO

Physical Prototype or On-Campus Equipment: NO

Your team will evaluate a solar-powered air conditioner and make improvements to the existing design.

According to the National Oceanic Atmospheric Administration, NOAA, 2020 tied with 2016 as the warmest year on record. As temperatures across the world increase, the need for air conditioning units will also rise. The International Energy Association (IEA) projects in its The Future of Cooling report that the global demand from air conditioners is expected to triple by 2050.

To meet the expected demand for air conditioning, the global electricity capacity for cooling must expand to the current total, combined electricity capacity of the United States, the EU, and Japan. In addition, the IEA expects the global stock of air conditioning will increase by four billion units, the equivalent of “ten new air conditioning units sold every second for the next thirty years,” By 2050 air conditioning units will consume 13% of the global supply of electricity, generating two billion tons of CO2 annually. This amount of CO2 emission is equivalent to the current annually generated emissions in India, the world’s third largest emitter.

The relationship between CO2 emissions and the need for air conditioning units is an “ironic feedback loop”. Greater CO2 emissions leads to a warmer climate and a greater need for air conditioning units. There is a human health challenge associated with a warmer planet. The National Institute of Health (NIH) warns that extreme heat exposure can lead to heat exhaustion, heat cramps, heat stroke, and death. Being exposed to extreme heat can also worsen preexisting chronic conditions, such as various respiratory, cerebral, and cardiovascular diseases and low income populations are vulnerable to these health risks, particularly in large urban centers. The high concentration of buildings in urban areas cause the “urban island effect”, the generation and absorption of heat in buildings cause the urban area to be several degrees warmer than the surrounding area.

With the expected increased need for and environmental impact associated with air conditioning units as well as the health risks related to heat exposure, a student team developed a prototype for affordable, solar-powered air conditioning unit last year. A second team looked at broader systemic factors that can influence the translation of the initial outputs into a viable solution based on local and international case study locations (Pittsburgh, Kilifi (Kenya) and Mexico City.

Your project is to circle back to the original prototype and refine it further with using outcomes of the systemic review based on the requirements of these existing case study locations.
Company Name Project Title Faculty Contact BME CHE CMPEN CMPSC DS ED EE EGEE ESC IE MATSE ME NUCE
PSU SEE 360 1 (Service Enterprise Engineering) AI-aided Robotic Siding Cleaner Choi, Kyusun 0 0 1 2 0 0 3 0 0 3 0 3 0

Non-Disclosure Agreement: NO

Intellectual Property: NO

Physical Prototype or On-Campus Equipment: NO

In this project students will design a low cost, intelligent system to clean sidings with minimal use of water and chemicals. It should be operable by a small crew (e.g., 1 or 2 people). It should be small enough to be transportable in a small truck and quick enough that it can clean a typical single family home in a few hours.

The system should use AI/ML to learn from building plans and photos to plan the path of the robot such as avoiding windows and other obstructions. To minimize water and chemical use, the cleaning fluid should be recirculated and continuously treated and reused.

Compare the productivity and sustainability of the new design with existing methods. Cost should be comparable to yard equipment (riding mowers, snow blowers). Analyze the ROI for new and existing small businesses to offer this service
Company Name Project Title Faculty Contact BME CHE CMPEN CMPSC DS ED EE EGEE ESC IE MATSE ME NUCE
PSU SEE 360 2 (Service Enterprise Engineering) SmartBells Choi, Kyusun 0 0 1 2 0 0 3 0 0 3 0 0 0

Non-Disclosure Agreement: NO

Intellectual Property: NO

Physical Prototype or On-Campus Equipment: YES

Dumb bells with accelerometers and low-power Bluetooth. Develop a smart phone app that logs exercise performance to cloud and provides visualization and performance metrics.
Company Name Project Title Faculty Contact BME CHE CMPEN CMPSC DS ED EE EGEE ESC IE MATSE ME NUCE
PSU The Studio for Sustainability and Social Action "Together, Tacit" Choi, Kyusun 3 0 1 0 0 0 2 0 0 0 3 3 0

Non-Disclosure Agreement: NO

Intellectual Property: NO

Physical Prototype or On-Campus Equipment: YES

Together, Tacit

In May 2018, I participated in a tour at the Palmer Museum with the Sight Loss Support Group of Central PA, stood beside individuals with varying types of sight impairments, and helped guide their hands over two sculptures I had exhibited in the Plastic Entanglements: Ecology, Aesthetics, Materials exhibition. Both of these works were figurative in nature. I participated in the tour was because I was interested in learning how people might imagine the form I built, especially in how they might describe the facial expression. Through my participation in the tour with museum visitors with sight impairments, I became very interested in thinking of a project where students and sight-impaired individuals could work together to build a sculpture inspired by how the visually impaired “see.”

Usually in hands-on museums, another person has already made the form that others are given permission to handle. What if the directionality of the build was different? What if visually impaired people worked with sighted collaborators to create artworks for display and interaction? “Together, Tacit” proposes an inclusive sculptural workshop between the visually impaired and the sighted to situate an exchange of tacit knowledge. Members from The Sight Loss Support Group of Central PA , students from The School of Visual Arts, The Learning Factory, and larger Penn State community would be invited to participate. The workshop would be hosted in The School of Visual Arts, College of Arts and Architecture. The outcome of the workshop collaborations would be exhibited publicly in a University or local gallery.

Utilizing the resources at The Learning Factory, sensors or computational textiles would be designed into a fabric based, glove-like form to serve as an initial tool to be used by the visually impaired to make body movements. These movements would become spatial data of what the visually impaired participants would imagine a sculptural form would look like (i.e. bumpy boxing glove, sorrowful facial expression, elongated shiny curve). This data would be translated into drawings, marks, or directives that engineering, computational, and fine art students could use as a guide to build form. It is very unlikely what would be built would parallel what was explicitly stated by the visually impaired participants or what was transcribed via their movements. At first glance, this may appear to be a failure, yet the iterations between what is produced and what is imagined often lead to new insights. Within these slippages, collaborators begin to negotiate, communicate and experience through the art making process to create a form that neither group, the sighted or visually impaired, could have built without the other. In this way, “Together, Tacit” aims to create a shared language that knits a meeting place between what we see and how we know through acts of knowing together.

Bonnie Collura
Professor of Art (Sculpture)
Sculpture Area Head
Penn State School of Visual Art
Company Name Project Title Faculty Contact BME CHE CMPEN CMPSC DS ED EE EGEE ESC IE MATSE ME NUCE
Quaker Houghton Test Method Design & Metalworking Fluid Performance in the Drilling & Reaming of Cross-Drilled Holes Purdum, Charlie 0 0 0 0 0 0 0 0 0 1 0 2 0

Non-Disclosure Agreement: NO

Intellectual Property: YES

Physical Prototype or On-Campus Equipment: YES

A challenge in industrial machining operations is the drilling, reaming and deburring at the intersection of cross-drilled holes frequently found in engine and transmission components. Minimizing burr formation in the reaming process and effective removing the burrs in subsequent deburring operations is essential for finishing high-quality, precision parts. In many applications, cross-drilled holes act as conduits for fluids, lubricants and gases. Failing to minimize burr formation or remove burrs can cause blockage of these critical passages or create turbulence in the flow. Burrs can also lead to part misalignments, affect dimensional tolerances, and limit the overall efficiency of machined components.

This project will involve the development of a machining test useful for the study of machinability and MW fluid performance in the drilling and reaming of cross-drilled holes in both cast aluminum and gray cast iron. Specifically, the project will involve the following:

a. the design and fabrication of test blocks (both cast aluminum and cast iron) which are designed for the study of cross drill machining
b. development of a method useful for measuring and quantifying the degree of exit burrs that form during machining.
c. using a metalworking fluid supplied by Quaker Houghton, conduct drilling and reaming of the cross drilled holes to validate the method and the performance parameters measured. These including, cutting forces, machined surface roughness, tool wear and built up edge, and exit burr formation.
d. as part of the testing conducted, assess the impact of external flood coolant application versus through tool coolant application, on machinability and burr formation.

The deliverables from the project will be the following:

1. Test method (including test block design) useful for studying drilling and reaming of cross drilled holes.
2. Method useful for quantifying (or semi-quantifying) the degree of exit burrs formed during machining
3. Validation of method via machining using QH metalworking fluid
4. Final report discussing all elements of the method and testing conducted
Company Name Project Title Faculty Contact BME CHE CMPEN CMPSC DS ED EE EGEE ESC IE MATSE ME NUCE
Schlumberger Topology Optimization of PDC Drill Bit for Energy Industry Wang, Chao-Yang 0 0 0 0 0 0 0 0 3 3 2 1 0

Non-Disclosure Agreement: YES

Intellectual Property: YES

Physical Prototype or On-Campus Equipment: YES

PDC drill bit is a rock removing tool widely used in Oil and Gas industry. A traditional downhole PDC bit includes a tool body having a tool axis, and blades extending from the tool body. The blade includes a cutting face, a trailing face, and a top face extending between the cutting face and the trailing face. Cutting elements are attached to the bade along the cutting face. The bit body also includes internal passage for drilling fluid. The traditional PDC bit body is infiltrated with Tungsten carbide powder or milled from steel. The traditional geometry of the PDC bit is constrained by the traditional manufacturing method. With the advanced Additive Manufacturing technology, an innovative geometry can be made to achieve better material usage, optimized stress distribution and better performance.

The project will require students to identify the objective that will drive the optimization process, specify parameters and load cases, generate design alternatives, evaluate benefits and risks, validate the design with FEA and CFD analysis, and make a protype model with 3D printing technology.
Company Name Project Title Faculty Contact BME CHE CMPEN CMPSC DS ED EE EGEE ESC IE MATSE ME NUCE
SEQUIL Systems Inc. Building Vitality Matrix Knecht, Sean 3 0 3 1 0 0 3 2 3 3 3 0 0

Non-Disclosure Agreement: NO

Intellectual Property: NO

Physical Prototype or On-Campus Equipment: NO

Create an architectural design guide integrating collective best practices in sustainability, resilience, wellness, health and safety. This Building Vitality Matrix will consist of numerous elements organized under 6 discrete topics arranged across 6 categories. The overall plan is to create a reference guide focused on building design and functionality elements which will improve and optimize indoor environments for its occupants, environment, site and community. The Building Vitality Matrix will fill in missing links between building codes, design guides, reference manuals, rating systems and traditional means/methods.

The assigned Captstone team will begin to develop the platform and user experience in a Wikipedia style, setting up the input, output, sheet and display format as well as drawing correlations between the numerous elements within and across each of the categories. This work will introduce elements of accessibility, equity, system, atmosphere, siting and accountability not yet addressed in today’s rating systems and industry guidelines. The Building Vitality matrix will be a living document which can be updated in real time by member experts and organizations sharing experiences, testing, results and ideas that may improve the vitality of buildings across the entire architecture/engineering/construction community.

The Capstone team will create the initial platform then flow through iterations based on industry and university feedback, particularly from the architecture and architectural engineering departments. Out of this we expect to begin seeing “stretch” goals that can enhance AE professionals’ industry interaction into new ways of confidently sharing information while maintaining acknowledgement of information provided.

The assigned capstone team will research and define out one sector of the elements matrix so as to establish baseline descriptions and application goals for each element. This sample sector will be utilized to streamline the process and allow input, discussion and edits to flow easily and professionally.
Company Name Project Title Faculty Contact BME CHE CMPEN CMPSC DS ED EE EGEE ESC IE MATSE ME NUCE
Shell 1 Eco-Marathon Urban Concept Car - Team 1 Neal, Gary 0 0 0 0 0 0 2 0 0 0 0 1 0

Non-Disclosure Agreement: NO

Intellectual Property: NO

Physical Prototype or On-Campus Equipment: YES

This semester's Shell Eco-Marathon Project Teams will be tasked with finishing the detailed design of the car and build the car per the design. The plan is for the car to compete in the 2022 Shell Eco-Marathon. Students will be tasked with finishing the design/build of the car body and engine/powertrain. Shell Eco-marathon is a global academic program focused on energy optimization. For over 35 years it has addressed the growing need for more and cleaner energy solutions in the real world, empowering talented and passionate science, technology, engineering and math (STEM) students with a platform to put their own theories and ideas into action.
Company Name Project Title Faculty Contact BME CHE CMPEN CMPSC DS ED EE EGEE ESC IE MATSE ME NUCE
Shell 2 Eco-Marathon Urban Concept Car - Team 2 Neal, Gary 0 0 0 0 0 0 2 0 0 0 0 1 0

Non-Disclosure Agreement: NO

Intellectual Property: NO

Physical Prototype or On-Campus Equipment: YES

This semester's Shell Eco-Marathon Project Teams will be tasked with finishing the detailed design of the car and build the car per the design. The plan is for the car to compete in the 2022 Shell Eco-Marathon. Students will be tasked with finishing the design/build of the car body and engine/powertrain. Shell Eco-marathon is a global academic program focused on energy optimization. For over 35 years it has addressed the growing need for more and cleaner energy solutions in the real world, empowering talented and passionate science, technology, engineering and math (STEM) students with a platform to put their own theories and ideas into action.
Company Name Project Title Faculty Contact BME CHE CMPEN CMPSC DS ED EE EGEE ESC IE MATSE ME NUCE
Stryker Additive Manufactured Hip Broach Instrumentation Hylbert, Lyndsey 1 0 0 0 0 0 0 0 0 0 3 2 0

Non-Disclosure Agreement: YES

Intellectual Property: YES

Physical Prototype or On-Campus Equipment: NO

Additive manufacturing is growing in prevalence in the medical industry and has demonstrated advantages over conventional manufacturing methods in several areas. However, instrumentation for cutting bone and soft tissue are not generally considered appropriate for additive manufacturing given the amount of post-processing necessary to achieve equivalent cutting performance to that of conventionally manufactured cutting instrumentation. The goal of this program is to investigate potential designs of cutting teeth for hip broaches, specific for additive manufacturing, that improve on the as-built sharpness and overall cutting performance. The project team should propose potential solutions, determine appropriate means of screening concepts, and select a final concept and assess its performance.
Company Name Project Title Faculty Contact BME CHE CMPEN CMPSC DS ED EE EGEE ESC IE MATSE ME NUCE
Team Ten LLC Sustainable Use of Reclaimed Fiber Product from Recycled Paper Manufacturing Kimel, Allen 0 0 0 0 0 2 0 0 0 0 1 0 0

Non-Disclosure Agreement: NO

Intellectual Property: NO

Physical Prototype or On-Campus Equipment: YES

American Eagle Paper Mills produces paper using recycled fiber generated in our unique integrated deinking and re-pulping system, giving new life to discarded paper. The recycled papermaking process creates a byproduct referred to as reclaimed fiber product, or RFP. The mill has implemented a new processing plant dedicated to reducing the water content of this material in an effort to decrease transportation costs.

This RFP is used in land application purposes as a soil additive to establish or reestablish agricultural productivity, establish herbaceous wildlife habitat, and facilitate revegetation. Since installing the new processing plant, the reduction in moisture of the RFP has potentially increased the marketability of this material for additional reuse applications in addition to land application. The mill would like to identify other potential uses for the RFP in addition to increasing the range of land application outlets.

Potential deliverables would be informational materials targeted at future land application customers explaining the benefits of RFP, and a technical report identifying potential outlets, their benefits, drawbacks and a cost analysis of these different disposal methods.
Company Name Project Title Faculty Contact BME CHE CMPEN CMPSC DS ED EE EGEE ESC IE MATSE ME NUCE
The Boeing Company Design and Test Multiple Prop Phase Control System Choi, Kyusun 0 0 1 0 0 0 2 0 0 3 0 3 0

Non-Disclosure Agreement: NO

Intellectual Property: NO

Physical Prototype or On-Campus Equipment: YES

With the rise of multi-rotor air vehicles for both manned and unmanned applications, one of the many considerations with increased proliferation of these platforms is noise. While not all noise can be eliminated from a rotor system, one mitigation strategy is to exert control over the directionality of the noise that is produced, so that less noise is generated in specific direction(s), such as away from populated areas. A test setup is desired to demonstrate the ability to control the directionality of rotor/prop noise by controlling the phasing of the individual rotors in a multi-rotor array. This project will include the design and construction of the test model, consisting of multiple electrically driven propellers, whose speed and rotational phasing relative to one another can be precisely controlled. Also included will be the test environment for quantitative measurement of the direction and amplitude, and frequencies of noise generated by the propeller array. The successful project will demonstrate the ability to minimize noise in a chosen direction via propeller phase control.

Deliverables:
1. 3D models
2. System diagram
3. Detailed Specification Report
4. Prototype test rig, to include multi-rotor test vehicle, phase-control system, and noise directionality test apparatus.
5. PDR presentation
6. CDR presentation
Company Name Project Title Faculty Contact BME CHE CMPEN CMPSC DS ED EE EGEE ESC IE MATSE ME NUCE
The Johns Hopkins University Applied Physics Laboratory Bench Test Simulator for a Missile System Deployable Control Surface Assembly Neal, Gary 0 0 3 0 0 0 2 0 0 3 3 1 0

Non-Disclosure Agreement: NO

Intellectual Property: NO

Physical Prototype or On-Campus Equipment: YES

BIG PICTURE

Concept: Stability and maneuverability of a conventional missile is achieved using aerodynamic control surfaces such as fins. Stringent geometric constraints are imposed on control surface assemblies (CSAs) by, for example, an “encanistered” missile or one in “captive carry” on a fixed-wing aircraft. Thus, many CSA designs have foldable fins that rotate into place upon egress from the launch platform (see image). CSA hardware must adhere to strict requirements on deploy time (fractions of a second), which is verified through design, analysis, and test. Factors that affect deploy time include mass properties, stiffness of spring elements used to drive fin deployment, and joint friction mechanisms. A quantitative understanding of these effects on system performance is crucial for a successful CSA design.

Need: Design and prototype a flight-representative deployable CSA with capability to systematically vary key mechanical parameters within prescribed bounds for bench testing.

COMPONENT DESCRIPTION

The deployable CSA simulator will be used by The Johns Hopkins University Applied Physics Laboratory (JHU/APL) to better understand the nature and effects of joint friction on system performance (i.e., deploy time). Data products from CSA bench tests will feed into the development and validation of a fin deploy simulation model to support several missile defense programs. The mock-up hardware will mimic existing CSA designs with a hinge joint and spring-driven outer panel, have mechanisms to release the folded fin and latch it into place in the deployed position, and be capable of varying mechanical properties (e.g., spring and gravimetrics) within prescribed ranges and tolerances. An exceptional design team may also incorporate a sensor suite to directly measure fin angle, but this is not required (indirect measurements will otherwise be incorporated by JHU/APL).

TECHNICAL NEEDS/CHALLENGES

Technical Need: Design, manufacture, and deliver a cost-effective deployable CSA simulator (CAD drawing and prototype hardware) that adheres to a requirements document provided by JHU/APL. At a top level, the simulator will have capability to vary key mechanical properties for bench testing—at a minimum, the spring characteristics (torsional stiffness and applied force). The design shall incorporate features to vary weight and mass moment of inertia, or at least accommodate design modifications by JHU/APL to that end. Nominally, the fin outer panel shall weigh 10 lbf and deploy through an angle of 135 degrees in 100 msec.

Challenge: Balance the desire for systematic and easy adjustment of mechanical properties using a cost-effective and flight-representative fin-flip design (including release and latching mechanisms) that has nominal kinematic performance.
Company Name Project Title Faculty Contact BME CHE CMPEN CMPSC DS ED EE EGEE ESC IE MATSE ME NUCE
The Manitowoc Company Wear Tests on Surface Hardened Steel Pins Kimel, Allen 0 0 3 0 0 0 0 0 0 0 1 2 0

Non-Disclosure Agreement: YES

Intellectual Property: YES

Physical Prototype or On-Campus Equipment: NO

Background: Manitowoc Cranes uses a number of different plating or surface hardening techniques on various parts of a crane, such as nitrocarburizing, electroless nickel, chrome, and yellow zinc plating. Currently, the type of plating that is chosen for a specific part is really just up to the preference of the engineer that designs the part, and there is no uniformity across the various applications. So, Manitowoc has begun a project to go through the different plating techniques and determine each one’s pros and cons. With this information, we plan to create design standards for the engineers that will specify which plating techniques should be used in our various applications.

Project Description: The student team will be tasked with designing and performing an accelerated lifecycle experiment that will be used to analyze the tribological properties of the different surface hardening techniques. A previous student team designed and built a block-on-ring tribometer for this purpose, and the current student team will be given this machine. The tribometer can be updated or tweaked as the team sees fit. The testing output should supply data about the wear scar and estimate the coefficient of friction for varying normal loads on the ring and rotation speeds. Corrosion resistance properties are also of interest to this project, so the test pins will be placed in a salt-fog chamber to determine how the plating’s corrosion resistance changes with wear. The student team will be responsible for developing the salt-fog chamber test procedure as well.
Company Name Project Title Faculty Contact BME CHE CMPEN CMPSC DS ED EE EGEE ESC IE MATSE ME NUCE
Volvo Construction Equipment 1 Soil Compaction Padfoot Drum Performance Improvement Exploration Wang, Donghai 0 0 0 0 0 0 0 0 0 3 2 1 0

Non-Disclosure Agreement: YES

Intellectual Property: YES

Physical Prototype or On-Campus Equipment: NO

Soil Compaction products are used to prepare a solid base of material from which buildings, roads, and other structures can be constructed. The key working implement of a Soil Compactor is a large vibratory drum which operates at specific frequencies and amplitudes to compact the base material. Most applications allow for use of a smooth drum, but in certain cases the material cannot be properly worked by a smooth drum. In these cases, a special padfoot drum is required.

The design of Volvo CE’s padfoot drum has not changed much over the past several decades. As we look to evolve and improve our products overall performance, one area we believe there is opportunity is with the padfoot drum design.

This project would begin with familiarization of the current Volvo design as well as some review of other padfoot designs in the market. The team would then identify areas of padfoot design that they believe are relevant/critical for compaction performance and develop a plan to explore improvement and/or optimization of some or all of the areas. As a starting point, some areas of particular interest have been identified as the following:

- Shape of the pad
o currently rectangular profile, other shapes exist in market
- Angle of the pad
o is there an optimal angle or range?
o is a single angle better than a series of angles or more complex geometry?
- Quantity of pads
- Distribution / pattern of pads

We are very open to the team’s ideas on how best to investigate the technical areas of padfoot design as well as creative ways to validate improvement ideas developed by the team. These may include mathematical/theoretical investigations, 3D modeling and simulation, 3D printing or other physical prototyping, or other methods identified by the team.
Company Name Project Title Faculty Contact BME CHE CMPEN CMPSC DS ED EE EGEE ESC IE MATSE ME NUCE
Volvo Construction Equipment 2 Directional drum vibration control for compactor noise and vibration reduction: Refinement of Rapid Control Prototyping (RCP) Cubanski, Dave 0 0 3 0 0 0 1 0 0 0 0 2 0

Non-Disclosure Agreement: NO

Intellectual Property: NO

Physical Prototype or On-Campus Equipment: YES

This work is a continuation of the investigation into directional drum vibration control. A scale compactor drum model and a preliminary RCP environment have been successfully developed via two Capstone projects in 2017 and 2018 at Penn State University.

The objective of this present project is to refine the previously developed RCP with the following tasks:

1. Create a feedback (PID) controller in the Simulink model to precisely synchronize two electric motors with specified speed and phase relation in real-time.
2. Phase angle differences between the two drums shall be monitored and adjusted in real-time to meet the steady-state error of +/-5 mechanical degrees.
3. Integrate sensors (accelerometers and microphones) to capture the best case scenarios of the noise emitted from the vibrating drum. The accelerations and sound pressures will be monitored and displayed in real-time.
4. Develop a DSP (Digital Signal Process) module for real-time signal analyses (filter, signal detrending, FFT, auto power linear spectrum, PSD, etc.), and add it into the RCP.
5. Optimize the control of speed/phase angle between the two drum models to minimize the overall noise emission of the vibrating drums
Company Name Project Title Faculty Contact BME CHE CMPEN CMPSC DS ED EE EGEE ESC IE MATSE ME NUCE
Volvo Construction Equipment 3 Mobile Li-ion charging module for low-voltage off-highway construction equipment Cubanski, Dave 0 0 0 0 0 0 1 3 0 2 0 0 0

Non-Disclosure Agreement: YES

Intellectual Property: YES

Physical Prototype or On-Campus Equipment: YES

As electrification spreads to off-highway construction equipment, battery life is becoming increasingly important. Contractors are seeking equipment that can at least meet the diesel equivalent machines in power and usage time. Most of these machines, especially, compact units, have space limitations for a variety of reasons and as such the overall machine envelope limits the amount of battery packs that can be installed. In situations where battery space is limited, it becomes more important to be able to recharge these machines as efficiently as possible.

The idea to be researched is the creation of a recharging system that can be mounted/adapted to various types of construction equipment trailers so that the contractors can transport a machine and charging system with an integrated energy storage pack as needed. The contractor can charge the integrated energy storage pack via conventional grid power or optional solar power and then use that stored energy to charge the machine or to have the trailer located on a jobsite for rapid recharging as needed. Several public companies offer battery storage systems for home energy storage and usage and these systems should be investigated and potentially incorporated into the design if feasible. It will be critical to not only investigate and pursue the technical feasibility of such a design but also to understand the cost impacts of the overall system. The machines targeted for such a system would be using low voltage system architectures (~48V) and there are potential applications outside of the United States, so non-US grid power should be factored into the design considerations. The time to recharge the equipment should also be considered and included into the design considerations.
Company Name Project Title Faculty Contact BME CHE CMPEN CMPSC DS ED EE EGEE ESC IE MATSE ME NUCE
Volvo Group Trucks 1 Flexible Pipe Analysis for Heavy Duty Trucks Rattner, Alex 0 0 0 0 0 0 0 0 2 0 0 1 0

Non-Disclosure Agreement: YES

Intellectual Property: YES

Physical Prototype or On-Campus Equipment: NO

Flexible steel corrugated pipes are used for exhaust inlet or outlet routing in heavy duty trucks. These pipes must be resistant to high thermal loads and provide structural rigidity while also being compliant to absorb large motion/vibrations in the system.

In this project current analysis method used for flexible pipes need to be reviewed and updated to improve correlation to measured test data. Analysis method can be simplified hand calculations / Finite Element Method with appropriate boundary conditions applied to capture static and dynamic deflections of the flexible pipe under various loading conditions.

Simulations can be performed using any of the available FEA packages e.g., ANSYS, SOLIDWORKS, Optistruct, NASTRAN etc. Modal analysis, Static stress analysis and frequency response study methods will be required. Improved Fatigue correlation will provide further confidence in method developed.
Company Name Project Title Faculty Contact BME CHE CMPEN CMPSC DS ED EE EGEE ESC IE MATSE ME NUCE
Volvo Group Trucks 2 Structural Design for Ease of Assembly of a Mack Truck Wang, Donghai 0 0 0 0 0 0 0 0 2 0 3 1 0

Non-Disclosure Agreement: YES

Intellectual Property: NO

Physical Prototype or On-Campus Equipment: NO

Class 8 Mack trucks are built on a Frame Rail Structure which requires Easy-Access for the Assembly People to install and Route Lines & Cables & Components inside the frame rails and then later install large/heavy systems along the outside of the frame rail. GeoLock is a Patented Interface Intended to Improve the Assembly Process & Fastener Access at the Frame Rail. This system permits the frame rail and structures to be assembled with plenty of fastener tool access, followed by routing and installation inside the frame rails and then a safe and structural sound “hook & hang” interface for the systems outside of the frame rails.

Focus of this project will be to analyze several version of the GeoLock profile (reference images below) with a “worse case” load condition to do a comparative study (FEA/Von Mises & Modal) to determine optimal feature dimnesions/limits.
GeoLock is an Aluminum Extrusion due to tooling & strength to weight ratio.
Company Name Project Title Faculty Contact BME CHE CMPEN CMPSC DS ED EE EGEE ESC IE MATSE ME NUCE
Volvo Group Trucks 3 Vehicle Configuration Determination Knecht, Sean 0 0 0 1 0 0 0 0 3 3 3 2 0

Non-Disclosure Agreement: YES

Intellectual Property: NO

Physical Prototype or On-Campus Equipment: NO

Goal of this project is to use Data Science to develop a method to determine the optimal vehicle configuration for a customer given all available data.

Currently a customer works with a dealership to determine the specifications for a new truck based on customer verbal input. The customer provides input such as expected load, road grade, duty cycle, etc. Using this data the dealership will determine the best configuration for the truck to achieve the customers requirements(fuel economy, grade start-ability, max cruise speed, etc.)

One option that is currently not available to customers is a tool or process that reviews data from a specific customers truck and determines the optimal configuration based on data from all trucks currently on the road. This will allow the customer to determine the optimal configuration based on actual data.

Basic steps for this project:
1. Students will receive large packet of field data collected from 100,000+ trucks.
-For each truck students will be given Speed/ Torque vs. Time Spent histogram, cruise speed histogram, GVW histogram & 100+ additional parameters.

2. Students will be given truck specifications available.
-Rear end ratio, engine power, transmission type, etc.

3. The goal of the project is to take data from a specific truck and compare it to all trucks on the road to determine if the configuration of the specific truck is optimal. Are there other customers running trucks in a similar manor getting better fuel economy because they are using a different configuration? Should the customer purchase a new truck with the same or different configuration based on the data?

This is an open ended projects. Student need to determine how to process the data. For example, do they start to breakdown the data using clustering? The goal of the project is to develop the best method.
Company Name Project Title Faculty Contact BME CHE CMPEN CMPSC DS ED EE EGEE ESC IE MATSE ME NUCE
Volvo Group Trucks 4 Dynamic Brake Factor for Heavy Duty Trucks Wang, Chao-Yang 0 0 0 0 0 0 0 0 2 0 0 1 0

Non-Disclosure Agreement: YES

Intellectual Property: YES

Physical Prototype or On-Campus Equipment: NO

In this project, a control system will be developed using simple PID controller using Simulink. The plant model will be a vehicle and the braking system associated to the vehicle which would be provided by Volvo. There is a neural network developed by Volvo to estimate braking parameter based on several operating inputs/features such as vehicle speed, brake temperature, brake pressure etc. The output of the neural network is the estimated braking parameter which would act as one of the parameters which is used to determine the reference signal (desired brake pressure) for the control system. Once the control system is developed, we would test the following functions for their performance,
A. Cruise Control
B. Brake Balance Control

The performance of the control system is evaluated by measuring the average error %, overshoot %, settling time and steady state error (if any).
The control system would be compared for relative performance against,
A. Fixed brake parameter value
B. 3-Dimensional table brake parameter value
Example of the control system diagram is shown in the image section below.

Scope
A. Students will build the 1D model, 3D table model and fine tune the neural networks based on the data provided.
B. Students to develop a simple PID control for assessing cruise control and Brake Balance control for different types of brake parameter inputs.
C. Students can also be involved in fine tuning the machine learning model if interested. This would a Physics guided Machine Learning.
Company Name Project Title Faculty Contact BME CHE CMPEN CMPSC DS ED EE EGEE ESC IE MATSE ME NUCE
Volvo Group Trucks 5 Compressor discharge Line and Life of Desiccant Wang, Chao-Yang 0 0 0 0 0 0 0 3 2 3 3 1 0

Non-Disclosure Agreement: YES

Intellectual Property: YES

Physical Prototype or On-Campus Equipment: NO

The Pneumatic installation team is interested in optimizing/redesigning the discharge line system.

Discharge line is the pneumatic line, on a truck pneumatic system, that transfers air from the air compressor to the air dryer.

The pressurized air system is a very important part of the heavy-duty truck. This supplies air to the brake systems and other accessories in the vehicle. The pressurized air is produced by a compressor that is integrated in the engine compartment. Usually the temperature of this high pressure (around 130 Psi) is hot, between 110-130C. Depending on the ambient thin air also carries a considerable amount of Moisture. This moisture is removed by using an air drier with the use of desiccants. This helps prevent freeze-up during the winter and extends the life of air valves.

In order to have an efficient Drying Cycle of this pressurized air it needs to be at a certain optimal temperature (preferably lower than 65°C). Dry and Pressurized air is critical for optimum function of valves and other components in the brake system.
Due to space constraints and high ambient temperatures around the chassis component which is typically on the order
of 40-45% during peak Summer. The vehicle needs a very efficient and optimized heat exchanger.

Problem Statement:
The students are requested to study the different aspects of heat exchangers and propose solutions to drop the temperate of the air between the compressor and the air dryer. Appropriate CAD Models can be provided to define the boundaries and Constraint of the system.

Afew points that can be considered on this project are:
1. Raw material selection
2. Redesign the discharge line
3. Improve the life of the air dryer desiccant
4. Design and build a test bench for SAE J2384 standard
Company Name Project Title Faculty Contact BME CHE CMPEN CMPSC DS ED EE EGEE ESC IE MATSE ME NUCE
Volvo Group Trucks 6 Vehicle field test data visualization and dashboard Verbanec, Al 0 0 0 1 0 0 0 0 0 0 0 0 0

Non-Disclosure Agreement: YES

Intellectual Property: NO

Physical Prototype or On-Campus Equipment: NO

In the development process, Volvo Trucks and Mack Trucks are working with external customers to validate the vehicles in real world applications. The data collected during the field test operations are used to provide feedback to internal and external engineers. To generate the right conclusion, it’s crucial to assess and ensure the data quality generated from the different subsystems in the complete vehicle is of high quality. The project team will have a unique opportunity to work with real customer data and develop a procedure to quantify the data quality and create a dashboard for visualization and tracking of data quality. The project scope includes following:

1) Develop a Python library to determine data quality per internal requirements

2) Data extraction and evaluation of data quality for provided data sets

3) Establish a database for the results

4) Develop a dashboard to visualize data quality for assigned trucks
 
 

About

Our mission is to help bring the real-world into the classroom by providing engineering students with practical hands-on experience through industry-sponsored and client-based capstone design projects. Since its inception, the Learning Factory has completed more than 1,800 projects for more than 500 different sponsors, and nearly 9,000 engineering students at Penn State University Park participated in such a project.

The Learning Factory

The Pennsylvania State University

University Park, PA 16802