Current Projects

Fall 2018 Projects

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

Company Name ProjecttTitle Faculty Contact BME CHE CMPEN CMPSC ED EE ESC IE MATSE ME NUCE
API Technologies Inc Banding Machine Setup Improvement (SMED) Joshi, Sanjay 0 0 0 0 3 0 0 1 3 2 0

Non-Disclosure Agreement: NO

Intellectual Property: NO

Our main product is a tubular ceramic capacitor that requires an epoxy ink band to be applied to each end. We produce about 1 million units and changeover machines about 300 times each month. The equipment is very old and takes a long time to setup and calibrate. A lot of labor is wasted in setting up the machines so we would like engineers to analyze the setup process and recommend ways reduce waste. Our goal is to go from 38 minutes to 9 minutes to achieve Single Minute Exchange of Dies (SMED.)
Company Name ProjecttTitle Faculty Contact BME CHE CMPEN CMPSC ED EE ESC IE MATSE ME NUCE
Armstrong World Industries Test Fixture to Make Airflow Resistance Measurements in XYZ Direction Wang, Donghai 0 0 0 0 3 2 0 0 0 1 0

Non-Disclosure Agreement: YES

Intellectual Property: YES

Overview:

Airflow resistance of a porous board is an important property affecting the acoustical performance of a ceiling panel. Typically, airflow resistance is measured in the through thickness direction ZZ using ASTM C-522 Airflow Resistance Test. We would like to also measure airflow resistance in the lateral directions XX and YY of a given sample.

Deliverables:

Patent search results.

Technology search results.

At least 3 concepts explored.

Bench top prototype of one system that can measure airflow resistance in XX, YY, and ZZ directions.

Measurement of airflow resistance using the technique.
Company Name ProjecttTitle Faculty Contact BME CHE CMPEN CMPSC ED EE ESC IE MATSE ME NUCE
B. Braun Medical SECUREMENT DEVICE Wheeler, Timothy 3 0 3 0 0 1 0 0 0 2 0

Non-Disclosure Agreement: YES

Intellectual Property: YES

PROBLEM
Most hospital patients have an IV Catheter placed during a stay. IV Catheters are essential for hydration and drug delivery. But to a patient, they can be an irritant. Having something piercing your skin/vein isn’t natural. And many patients, whether consciously or not, try to remove the IV catheter. For patients that have compromised veins this can cause issues as the availability of insertion points can be limited and placing the catheter can be difficult. Hence, once a catheter is placed it should remain until the procedure is complete. Securement devices are available, but patients can still remove the IV catheter.

PROJECT
Design and prototype a securement device that has a sensor based warning system that alerts hospital staff that a patient is attempting to remove their IV catheter.

PROJECT REQUIREMENTS
1) Understanding of the project goals.
2) Concept generation and selection.
3) Prototype construction and testing.

CONSIDERATIONS
• Patient safety
• Patient comfort
• Cost
• Disposable/reusable
• Intuitiveness
• Ease of use
• Effectiveness of the device

REFERENCES
• TBD

DELIVERABLES:
• Documented user requirements
• Concept generation
• Neutral concept selection method
• Prototype construction
• Prototype testing
Company Name ProjecttTitle Faculty Contact BME CHE CMPEN CMPSC ED EE ESC IE MATSE ME NUCE
Bechtel Power Corporation Fusion Reactor Lithium Blanket Knecht, Sean 0 0 0 0 1 0 0 0 3 2 0

Non-Disclosure Agreement: NO

Intellectual Property: YES

Bechtel is one of world’s oldest and largest Engineering, Procurement and Construction (EPC) companies. In addition to being the contractor of choice for a wide variety of power generation facilities for more than 60 years, Bechtel has led the emerging nuclear technology markets. Examples include the design and construction of the first U.S. reactor, EBR-1 (Experimental Breeder Reactor); the world’s first commercial nuclear power plant, Dresden; the world’s first HTGR (High Temperature Gas-Cooled Reactor), Peach Bottom; Canada’s first nuclear plant, NPO; and the first U.S. nuclear plant in 25 years, Watts Bar Unit 2. The latest and most prominent examples are the management and operation of Lawrence Livermore National Laboratory’s National Ignition Facility, construction of Vogtle Units 3 & 4, and fusion reactor power plant capital cost estimates for DOE’s Advanced Research Projects Agency – Energy Program.

As advanced nuclear reactor technology (Generation IV) designs continue to evolve, the reality of commercial compact fusion power generation appears closer than ever. There are various compact fusion reactor designs in different stages of development today. Each of these designs must achieve the same result to be viable in a commercial power application, namely extracting energy produced by fusion reactions and turning it into usable electricity. A common approach is to use a lithium blanket enclosing the fusion reactor core to trap high energy neutrons produced by the fusion reaction and then convert these high energies into electricity. The lithium blanket also provides radiation shielding to prevent these high energy neutrons from damaging instrumentation and equipment and facilitates the regeneration of tritium fuel for operational uses.

This proposed project is to develop a conceptual design for a lithium blanket that can be used by a compact fusion reactor power plant design (e.g., tokamak) to harvest neutron energies and to produce tritium as fuel for fusion reactor operation. The project team will perform the following tasks:

• Understand the concepts of various fusion reactor designs;
• Select a fusion reactor design (e.g., tokomak) as a base for the lithium blanket design; and
• Design a conceptual fusion lithium blanket.

The project will culminate in a presentation of the group’s conceptual design to Bechtel senior management. Stretch goals include scalability and clear identification of design challenges. The final design can be enhanced by 3D CAD and 3D printed models if time allows.
Company Name ProjecttTitle Faculty Contact BME CHE CMPEN CMPSC ED EE ESC IE MATSE ME NUCE
Brembo 1 3D Printing Solutions for Rapid Prototyping Manogharan, Guha 0 0 0 0 3 0 0 3 2 1 0

Non-Disclosure Agreement: YES

Intellectual Property: YES

3D printing technologies are starting to become the norm for many manufacturing and production environments. It is a fast, cheap and reliable process for rapid manufacturing. Many small companies today rely on 3D printing for all manufacturing needs and larger companies implement 3D printing as a supplemental technology. Turbo Laces, a very small company out of Kennet Square, PA, uses 3D printing for all prototyping and product development. On the other end of the spectrum, Bugatti is 3D printing vehicle components out of titanium. The possibilities are truly endless and with this idea in mind, Brembo would like to start researching 3D printing technologies.

The goal of this project is to identify if 3D printing will be a viable solution for foundry tooling prototyping. Tooling to be 3D printed consists of gating systems for pattern plates, pattern plate inserts, sand core box inserts, and risers. The idea is to have the ability to rapidly manufacture tooling in order to reduce the external supplier dependence.
In order to quantify these results, Brembo would like to work very closely with the university and students. Brembo would like to test prototypes provided by student engineers, provide feedback and give the engineers a chance to revise their product before the final release. This is similar to how the real world process works.

Brembo would like to be provided with two prototypes throughout the duration of the semester. The first prototype is to be designed, manufactured and shipped to Brembo North America for internal testing. Once tested, results and feedback will be provided to the student engineering team in order to create revisions if need be.

The final prototype must be free of defects and failures present in the primary prototype. Brembo will test the final prototype and share the results with the student engineering team. In addition to internal testing, some external testing will be required from the student engineering team.

With both prototypes, it is imperative to understand how the geometry is affected after production time. One way to analyze this is with a blue laser scanner. The scanner will provide feedback relating to surface imperfections, geometry inconsistencies and dimensional inconsistencies. Ultimately, this feedback will allow Brembo and the student engineering team to identify if the material chosen was effective.
Company Name ProjecttTitle Faculty Contact BME CHE CMPEN CMPSC ED EE ESC IE MATSE ME NUCE
Brembo 2 3D Printing Solutions for Rapid Prototyping Manogharan, Guha 0 0 0 0 3 0 0 3 2 1 0

Non-Disclosure Agreement: YES

Intellectual Property: YES

3D printing technologies are starting to become the norm for many manufacturing and production environments. It is a fast, cheap and reliable process for rapid manufacturing. Many small companies today rely on 3D printing for all manufacturing needs and larger companies implement 3D printing as a supplemental technology. Turbo Laces, a very small company out of Kennet Square, PA, uses 3D printing for all prototyping and product development. On the other end of the spectrum, Bugatti is 3D printing vehicle components out of titanium. The possibilities are truly endless and with this idea in mind, Brembo would like to start researching 3D printing technologies.

The goal of this project is to identify if 3D printing will be a viable solution for foundry tooling prototyping. Tooling to be 3D printed consists of gating systems for pattern plates, pattern plate inserts, sand core box inserts, and risers. The idea is to have the ability to rapidly manufacture tooling in order to reduce the external supplier dependence.
In order to quantify these results, Brembo would like to work very closely with the university and students. Brembo would like to test prototypes provided by student engineers, provide feedback and give the engineers a chance to revise their product before the final release. This is similar to how the real world process works.

Brembo would like to be provided with two prototypes throughout the duration of the semester. The first prototype is to be designed, manufactured and shipped to Brembo North America for internal testing. Once tested, results and feedback will be provided to the student engineering team in order to create revisions if need be.

The final prototype must be free of defects and failures present in the primary prototype. Brembo will test the final prototype and share the results with the student engineering team. In addition to internal testing, some external testing will be required from the student engineering team.

With both prototypes, it is imperative to understand how the geometry is affected after production time. One way to analyze this is with a blue laser scanner. The scanner will provide feedback relating to surface imperfections, geometry inconsistencies and dimensional inconsistencies. Ultimately, this feedback will allow Brembo and the student engineering team to identify if the material chosen was effective.
Company Name ProjecttTitle Faculty Contact BME CHE CMPEN CMPSC ED EE ESC IE MATSE ME NUCE
Cameron, A Schlumberger Company Development of an Ultrasonic Imaging System for Industrial Applications Wheeler, Timothy 0 0 2 3 0 1 0 0 0 0 0

Non-Disclosure Agreement: YES

Intellectual Property: YES

The Advances in integrated circuits has led to a reduction in the number of system components necessary to design an ultrasound imaging system. The main system components include the Transmit circuity, Receive circuity, Beamformer, Transmit Receive Switch, FPGA and Microprocessor (see system diagram). The purpose of this project is to design an ultrasound imaging system using integrated circuity components. The designers will pick all the necessary components for designing a 64 channel system. Using these components the Capstone Group can simulate the performance of such circuits in the CADANCE ELECTRICAL design software. Fabricate prototype electronics or demo board.
Company Name ProjecttTitle Faculty Contact BME CHE CMPEN CMPSC ED EE ESC IE MATSE ME NUCE
Capital One Money Management Verbanec, Alan 0 0 2 1 3 0 0 0 0 0 0

Non-Disclosure Agreement: NO

Intellectual Property: NO

Capital One focuses on leveraging new technology to create helpful tools for our customers. As a financial services corporation, we continue to focus on our customers and how we can improve their lives financially. A huge problem that people have with finances is dealing with how and when to spend their money, and what to spend their money on. This is because people often do not understand how their spending today affects them in the future.

We want you to solve this problem by creating a financial management service for our customers. We challenge you to create a full stack web application that tracks an individual’s expenses, budgets how they should use their money, and predicts how it will affect them in the near and long-term future.
The team will leverage Machine Learning technology to predict behavior. We would like the team to present the Money Management tool in a customer-friendly way powered by APIs. We’ll utilize the first meeting to provide requirements, mock-up UI designs, discuss database structures, etc.
Company Name ProjecttTitle Faculty Contact BME CHE CMPEN CMPSC ED EE ESC IE MATSE ME NUCE
Carlisle Construction Materials, LLC Attachment Design for Roofing Equipment Accesories Knecht, Sean 0 0 0 0 3 0 0 3 2 1 0

Non-Disclosure Agreement: YES

Intellectual Property: YES

This project will focus on creating accessories for power tools used on commercial roofing projects. The objective would be to design supports that would decrease fatigue on the operator and improve quality in critical weld areas. The project will cover two main accessory options. The design could include robotic applications and will be targeted for two different welding types and welding situations. The deliverable we anticipate are two prototypes that can be 3D printed using heat resistant materials, due to the high temperature of the welders. We also expect to test the prototypes to receive customer feedback.
Company Name ProjecttTitle Faculty Contact BME CHE CMPEN CMPSC ED EE ESC IE MATSE ME NUCE
Central PA SCI Modified Playstation for young man with brachial plexus injury Hayes, Daniel 3 0 2 0 0 1 0 0 0 3 0

Non-Disclosure Agreement: NO

Intellectual Property: NO

Devin is a 19 year old male injured in a motorcycle accident almost 2 years ago where he sustained a mild brain injury, a spinal cord injury and a complete shearing of his brachial plexus on the left side. He now ambulates short distances with use of a hemi-walker and minimum to moderate assistance. He performs all his activities of daily living [ADLs] with set up to minimum assistance because he has no use of his left arm secondary to brachial plexus injury. Prior to accident he was enlisted in the Navy with aspirations to become a Navy SEAL. He was very active and enjoyed video gaming prior to accident. Now he is unable to play. Devin desires to be able to interact and play with friends.
Company Name ProjecttTitle Faculty Contact BME CHE CMPEN CMPSC ED EE ESC IE MATSE ME NUCE
Corning Incorporated Proof of concept: High temperature water leak arrestor Kimel, Allen 0 0 0 0 0 0 0 3 1 2 0

Non-Disclosure Agreement: YES

Intellectual Property: YES

Background: This project will attempt to address an issue with a critical piece of Corning equiment, referred to as a "HT machine". This machine contains a high temperature process zone surrounded by insulating materials. Some critical components are located inside the insulating material, between the outer cover and process zone, and must be kept cool by water circulating though metal tubes. In some cases, these metal tubes will begin to leak over time, leaking water into the insulation and towards the process zone. This causes severe heat loss and negatively affects the process. The theory behind this project is that in the event of a leak, the water source could be switched to another liquid, which will stop the water leak.

Objective: Recommend one or more liquid formulas and remedial procedure to arrest water leaks in the HT machine. The liquid must not contaminate or damage surrounding material (details given later), must stop a leak in a reasonable time and with a simple procedure, and the procedure must not risk clogging the cooling tube.

Requirements and Expectations:
Access to a high temperature oven or furnace which can be modified for this experiment will be required. Special materials like the cooling tubing and insulating material will be provided. Team members are expected to develop and produce a test apparatus to evaluate candidate solutions. The team will develop a list of potential leak arrestor formulas and test them. The team must deliver a detailed written report documenting the test method, results, scientific hypothesis of why each experiment failed/succeeded, and recommendations to Corning regarding next steps. The team will also deliver regular updates to the sponsor through regular meetings. The sponsor will be available for discussion of any questions or technical issues.
Company Name ProjecttTitle Faculty Contact BME CHE CMPEN CMPSC ED EE ESC IE MATSE ME NUCE
Covestro LLC Solid Polymer Additive for improving concrete formulations Kimel, Allen 0 3 0 0 3 0 3 0 1 2 0

Non-Disclosure Agreement: YES

Intellectual Property: YES

Objective of this project is to devise and evaluate concrete cement formulations which incorporate, in addition to normal components, various levels of a company-supplied granular solid polymer additive. Potential applications of the resulting concrete formulations should include: roadway pavement, curbs, sidewalks, water drainage vessels; synthetic paving stones or decorative articles for lawn and garden.
Suggested physical testing on concrete samples are: measure of ease of concrete processing, e.g. slump test, or similar; compressive strength; characterization of surface visual appearance, e.g., beige color shade, and colorfastness on exposure to sunlight and other weather related factors; measure of sound dampening or resistance to transmission of vibration or mechanical durability in vibration service; resistance of surface to "spalling" or other degradation due to repeated freeze-thaw cycles in use phase; any other characteristics the student team determines to be interesting and may offer benefits as compared to conventional concrete for said applications.
Company Name ProjecttTitle Faculty Contact BME CHE CMPEN CMPSC ED EE ESC IE MATSE ME NUCE
EDRO Specialty Steels, Inc Corrosion Analysis and Comparison of Stainless Steels for Plastic Injection Molding and Tooling Kimel, Allen 0 0 0 0 0 0 0 3 1 2 0

Non-Disclosure Agreement: NO

Intellectual Property: NO

EDRO Specialty Steels is based in Conshohocken PA and provides steel and machining services for the plastic injection molding industry. EDRO developed a stainless holder grade called RoyAlloy over 20 years ago and has been extremely successful in the plastic tooling market in the US and around the world. RoyAlloy is a modified 410 stainless steel with excellent machinability and very high dimensional stability due to its unique chemical composition and microstructure. It contains a very inhomogeneous microstructure with a high concentration of sulfides in the material. RoyAlloy has also been introduced in other applications including food processing. In the past, there has been some corrosion data collected but this has been very limited and does not reflect improvements made in the production of RoyAlloy over the years. Students should study/observe the corrosion behavior by designing an experiment that best simulates the operating and service conditions that RoyAlloy and other comparable grades will be subjected to in these applications. We would like to quantify the corrosion behavior by obtaining practical corrosion values such as mass loss rate and pitting potential, as well as micrographs and pictures of the material at various point of the project. At the end of the project students should be able to compare and quantify the corrosion resistance of RoyAlloy to other grades such as, 1.2085, 420, and possibly other similar stainless holder grades.
Company Name ProjecttTitle Faculty Contact BME CHE CMPEN CMPSC ED EE ESC IE MATSE ME NUCE
Envinity, Inc Commercial HVAC Freeze Stat Tester Wang, Donghai 0 0 3 0 0 2 0 0 0 1 0

Non-Disclosure Agreement: NO

Intellectual Property: NO

The Problem: In a commercial HVAC system, if the air handling unit’s cooling coils freeze, they can rupture and cause extensive flooding and damage to facilities and equipment. The freeze stat is a device that is tripped when it detects air that is too cold and sends a signal to the air handler to protect the coils from freezing. The current means of testing and calibrating these freeze stats are not adequate to confirm they will protect the air handling unit when needed. Sometimes, canned air or bags of ice are used to trip the freeze stat, but this is not precise and can result in damaging the freeze stat.

The Objective: Envinity would like students to design and build a test device that clamps around a 1 foot section of the freeze stat and decreases the temperature in a controlled and measurable way so the freeze stat’s actual trip temperature can be measured and the freeze stat certified to be working correctly. This also will allow adjustable freeze stats to be adjusted to the correct setting.
Company Name ProjecttTitle Faculty Contact BME CHE CMPEN CMPSC ED EE ESC IE MATSE ME NUCE
FedEx Services In-facility Geo Positioning Verbanec, Alan 0 0 1 2 0 3 3 0 0 0 0

Non-Disclosure Agreement: YES

Intellectual Property: YES

FedEx would like to sponsor a group of students to continue the work of a team from last semester. The goal of the project is to use Bluetooth Low Energy (BLE) beacons to provide precise location of Android based wearable scanning devices within a facility. The team will take over the code created last semester and develop a service that FedEx production applications can call for location specific information that can be passed to the user. For example if the user is performing a scanning operation checking for miss-loaded packages the location service will provide the user with which dock door they are at and what the trailer number is at that dock door. The team will be developing Java based code running native on an Andriod device.
To help the team understand the business problem being solved they will need to travel to a local FedEx hub (2.5 hours drive) for a tour and operations overview. The team may also choose to travel to Memphis to meet and spend a day working on their solution at the FedEx R&D center with engineers building advanced Internet of Things (IOT) devices leveraging BLE.

Documentation from last semester attached.
Company Name ProjecttTitle Faculty Contact BME CHE CMPEN CMPSC ED EE ESC IE MATSE ME NUCE
Flowserve Corporation Development and Testing of Induced Swirl on Pipe Wear Wang, Donghai 0 0 0 0 3 0 0 0 2 1 0

Non-Disclosure Agreement: YES

Intellectual Property: YES

Flowserve is continuously seeking ways to improve the products that are provided to our customers and remain competitive in a very aggressive market. Flowserve offers a wide range of pump types supporting power, oil, gas, chemical, and general industries; which include aggressive fluids, slurries, and solids handling applications. To reduce total life cycle costs, improve productivity, profitability, and pumping system reliability; Flowserve is interested in investigating how inducing swirl to a fluid might reduce wear within piping systems.

The concept is similar to that of flow in a pipe bend. The flow spiraling along the longest path – around the outside of the pipe – will have the highest pressure and lowest velocity.
Whereas, the flow spiraling along the center of the pipe will have lower pressure and higher velocity. This pressure differential could work to keep particles in the center of the pipe; reducing wear.

To obtain greater insight into the properties of this phenomenon, a team of students will be required to develop a method to generate swirl, investigate the flow characteristics, and quantify resulting wear.

This one semester project will require the students to use both an experimental and a theoretical approach.

- Objectives
* Perform a literature survey on this concept, specifically in slurry pipelines, to develop theoretical base for the project.
* Perform theoretical calculations for the effects of swirl on fluid pressure and velocity.
* Develop a mechanism to induce the optimal swirl angle and pressure necessary to suspend solids in the center of a pipe system.
* Design a test loop to evaluate and quantify wear on piping.
* Manufacture the test rig that will be used to perform the experiments.
* Test various designs for inducing swirl and flow velocities to minimize pipe wear.
* Create a final report detailing the results of the tests, and the design and manufacture of the test rig.
Company Name ProjecttTitle Faculty Contact BME CHE CMPEN CMPSC ED EE ESC IE MATSE ME NUCE
Ford Motor Company Mobility as a Service Seat Design Optimization Cannon, Dave 3 0 0 0 3 0 0 1 3 2 0

Non-Disclosure Agreement: YES

Intellectual Property: YES

Penn State Capstone students on the Ford team this term will be joining the seat engineering development team to be an integral part of the creation of a new standard for seats used in mobility as a service applications. Below are some items the team will be leading, and a few open ended questions we will want to answer together.
Clinic, ideate, iterate
What does the MaaS customer need
What does the MaaS customer expect/like/want
Seat Design Reviews
Engineering constraints, customer concerns, and design proposals
Students iterate with feedback loop from multiple seat clinics on campus
Understand both youth and elderly users
What direction do we want the seat to face?
Are there ways to offer privacy in this space?

The final product goal will be a physical seat (base starting point will be provided) that includes specifications on engineering metrics of the seat. The team will study how their design will be acceptable to all occupants, and then show with subjective data that this seat had the highest comfort and accommodation out of a competitive set of seats.
Company Name ProjecttTitle Faculty Contact BME CHE CMPEN CMPSC ED EE ESC IE MATSE ME NUCE
General Motors 1 Machine system data integrity improvement by Nonstandard condition identification Using Machine state Data logs Verbanec, Alan 0 0 0 1 3 0 0 2 0 0 0

Non-Disclosure Agreement: YES

Intellectual Property: YES

Description:
Develop an IT software tool that will apply Machine Learning/Neural Networks or other AI approaches to learn patterns in data flow streams from Machining Systems and then detect and alert on nonstandard conditions and patterns

Benefit:
Support detection of extraordinary signal behaviors and help tag and deep-dive outlier conditions on machines
Apply learning to develop rules not comprehended by current rule sets and improve outlier detection.

Deliverable:
Develop the following functionality:
Accept machine state log files as inputs for learning.
Apply learning techniques to new input logs stream and identify outliers
Output outlier conditions detected along with rationale on why an event is tagged as an outlier.
Company Name ProjecttTitle Faculty Contact BME CHE CMPEN CMPSC ED EE ESC IE MATSE ME NUCE
General Motors 2 Machine Gauge Heartbeat and Dataflow Integrity tracking Verbanec, Alan 0 0 3 1 0 0 0 2 0 0 0

Non-Disclosure Agreement: YES

Intellectual Property: YES

Description:
Develop a standalone IT software tool that will track heartbeats across hundreds of plant floor gauges and alert when a gauge heartbeat is lost. The software will also need to track data transfers from Gauge to IT system and alert if data is not being transferred per expectation.

Benefit:
Improve reliability of Gauge data collection from Plant floor
Improve response times when gauge data collection stops

Deliverable:
Develop the following functionality:
Ability to import flat files with lists of gauges that need to be monitored. Ability to edit list after import.
Interface and monitor heartbeat and file transfer activity across the configured gauges.
Interface to alert when the heartbeat rules or gauge transfer rules are not met.
Company Name ProjecttTitle Faculty Contact BME CHE CMPEN CMPSC ED EE ESC IE MATSE ME NUCE
Halosil International, Inc. Create an Inexpensive Device to Remove Hydrogen Peroxide Vapor from Air Kimel, Allen 2 0 0 0 3 0 0 0 1 0 0

Non-Disclosure Agreement: YES

Intellectual Property: YES

Halosil manufactures and sells the Halo Disinfection System to fog hospitals, long-term care facilities, medical research labs, schools, and athletic facilities world-wide to eliminate pathogens that cause infections in humans and animals. In hospitals, for instance, we prevent the spread of C. difficile bacteria that otherwise cause Healthcare-Acquired Infections (HAIs) that kill about 30,000 a year in U.S. hospitals alone. In another example, the U.S. military academies use the system to fog their football and wrestling locker and equipment rooms to greatly reduce the risk of MRSA and other infections among their athletes. In medical research labs, the system is used to protect the animals in their vivariums and to disinfect biological safety cabinets.

The advantage of the hydrogen peroxide-based fog is that it goes everywhere in a space, killing 99.9999% of pathogens in all the nooks and crannies of complex rooms. As H2O2 ultimately breaks down into oxygen and water, the process is both effective and leaves no detectable residues or odors. Halosil was the first company (in 2013) to gain an EPA registration (a legally required validation) to make "kill claims" using an aerosolized disinfectant.

The biggest impediment to the expansion of the approach in hospitals is the time required to allow the hydrogen peroxide vapor to fall from a peak of about 120 ppm to less than 1 ppm, an OSHA and EPA requirement. An average patient room in a hospital, for instance, requires about 2 hours to turn a cleaned room over to the next patient who needs to be in that room. Of that 2 hours, only about the first 30 minutes are required to kill the pathogens of all surfaces; the remaining 90 minutes is simply to wait for the H2O2 vapor to decompose naturally.

We need a device that will be activated after the killing time has elapsed that will, in turn, take the remaining H2O2 vapor out of the air quickly. This device must be relatively inexpensive to manufacture, easy to operate and cheap to run.

For comparison, the complete HDS with which it would be sold costs us less than $4,000 and which sells for about $14,000 once it gets through our distribution channels. A completely disinfected patient room costs the customer about $25 in consumables (our HaloMist disinfectant). Realistically, therefore, we need an "air scrubber" that would cost us less than about $1,500 to manufacture and would add less than, say, $5-$10 per room to run - assuming we can cut at least 50% off the waiting time after the fog has completed its killing process.

In previous efforts, we have found that simple dehumidifiers can reduce the overall room turnaround time by about 10% if started after active fogging has stopped but before the killing process has stopped. We did not have any luck with either hepa filters or activated charcoal filters. We know that the chemical catalase decomposes H2O2 quite effectively in nature, but have not been able to test whether or not it could be stabilized to work as part of an air filtration system. And others have suggested that certain bandwidths of ultraviolet light might be able to decompose H2O2 vapor in entire room, with or without an air re-circulation mechanism.

We have ideas and experience, but we have not had the resources (and creativity, perhaps) to find a solution. When we find one, we can save more lives from unnecessary infections, family suffering and, too often, death. HAIs in the U.S. kill upwards of 75,000 people a year, the equivalent of a commercial airliner crash a day.
Company Name ProjecttTitle Faculty Contact BME CHE CMPEN CMPSC ED EE ESC IE MATSE ME NUCE
High Concrete Group LLC, d/b/a StructureCare Site Inspection Automation Bilen, Lennart 0 0 1 3 0 0 0 3 0 2 0

Non-Disclosure Agreement: YES

Intellectual Property: YES

StructureCare, a division of High Concrete Group, provides customers with solutions to existing and developing conditions on their parking structures. A Field Engineer will provide a detailed inspection by performing a walkthrough of the structure documenting and mapping areas of concern while including photos of current conditions. Tools used during this inspection currently include a wireless tablet with a pdf copy of the blueprint / drawing of the structure, hammer, and chain. This includes visual inspections of all floor level, vertical, and overhead conditions. These conditions could include cracking, spalls, water leakage, and movement. Acoustic testing is also performed, sounding of the concrete surface with a hammer or chain drag while listening for changes in sound signifying unsound or delaminated concrete. Load testing, driving over floor members while looking for movements between concrete joints. Material testing, performing Chloride-Ion testing related to chloride penetration which leads to steel reinforcement corrosion and concrete failure. During the inspection the Field Engineer is looking for signs of loose or cracked concrete, rusted steel, worn paint and coatings, aged waterproofing, exposed connections, line stripping conditions, general housekeeping within the structure, bearing pad placement and conditions, and properly installed lifting caps.

The project objectives are to utilize technology to enhance data collection, reduce the need for an on-site engineer, facilitate remote evaluation of gathered data, and improve the overall effectiveness of the inspection process by lowering cost, reducing duration, increasing accuracy and increasing consistency. Additionally, automating the data reporting (photos and mapped observation locations) for use with completed inspection reporting should be included.
Company Name ProjecttTitle Faculty Contact BME CHE CMPEN CMPSC ED EE ESC IE MATSE ME NUCE
High Steel Structures LLC Improve "Pack to Ship" Process for Bridge Crossframe Members Voigt, Robert 0 0 0 0 0 0 3 1 0 2 0

Non-Disclosure Agreement: NO

Intellectual Property: YES

Overview
? High Steel Structures takes pride in our reputation for producing bridge steel which is consistently superior in quality and fit. Proper project coordination and efficient delivery of the structural steel to bridge project is a key factor in its ultimate success. This is what gives High Steel the leading edge.
? The scope of this project is our assembly, packing and skidding of crossframe members in our Lancaster facility. Crossframes are welded pieces (typically angle, channel and plate) that are cross braces for bridge girder beams.
? The objective of this project is to develop a more streamlined and cost effective process to secure these pieces together for over the road shipping to the job site. The current process is a labor intensive and tedious manual operation utilizing overhead cranes and/or forklifts, threaded rod, bolts and nuts, etc.

Deliverables & Design Elements
? A Simpler and quicker assembly and packing process for crossframe members (labor reduction).
? Hardware component improvements (material savings) that also support various crossframe sizes, configurations and loads.
? Documented Standard Work for assembly, packing and skidding of crossframes that highlight repeatable, streamlined steps to complete the work.
? The new process must have the necessary controls in place to deliver a safe process for the operator and secure package for transportation.
? Supporting information (i.e. load analysis, material specifications, etc.) to show the packing method/hardware provide a safe alternative to current methods
? A cost analysis that documents the savings that the new assembly/packing process delivers.

Support
? Involvement and guidance from High Steel Continuous Improvement and Fabrication resources
? High Steel Structures will perform tests/trials to support the project research. We request that at least 2 weeks are allowed for the turnaround of requests.
Company Name ProjecttTitle Faculty Contact BME CHE CMPEN CMPSC ED EE ESC IE MATSE ME NUCE
Impulse Technology LLC Manufacturing & Testing of a 3D Joint Hayes, Daniel 3 0 0 0 0 0 0 1 3 2 0

Non-Disclosure Agreement: YES

Intellectual Property: NO

Overview: A human ankle is essentially a 3D joint that is controlled by non-linear muscle actuation. Impulse Technology is developing products that mimic functions of normal knee, ankle and foot. Manufacturing is a concern from both cost and performance perspectives. The objective of this project is to explore strategies for manufacturing and assembly of a design assigned by Impulse Technology. The team will analyze each components of the 3D joint design for manufacturability and recommend an optimal production plan. The team will manufacture a full-size prototype using techniques available at Penn State (for example manual or CNC machines) and perform mechanical testing to demonstrate the functionality.
Approach: The team will be given a design developed by Impulse Technology. It will study the design for functionality and manufacturability. The team will then manufacture a prototype using commercially available metallic alloy material and techniques available at Penn State. The next step will be to test the prototype under uniaxial compression and bending loading – typical in bio-mechanics of walking. Finally, the team will optimize the design and the manufacturing techniques to recommend a path towards mass production. They do not need to demonstrate or implement this recommended production plan.

The ME 440 team will work very closely with Professor Aman Haque, who is a co-founder of the startup company Impulse Technology. This project will provide useful experience for the would-be engineers on how the bio-mechanics of walking is mimicked in machine design and how manufacturing techniques govern the design to product transformation.

Requirement: The team skillset should include manufacturing (machine shop techniques) as well as machine design (modeling and finite element analysis). Gait mechanics is a plus but not required.
Company Name ProjecttTitle Faculty Contact BME CHE CMPEN CMPSC ED EE ESC IE MATSE ME NUCE
InnoH2O Solutions, LLC Small-Scale, Low-Energy Desalinating Water Purification System Kimel, Allen 0 0 0 0 0 3 0 0 1 2 0

Non-Disclosure Agreement: NO

Intellectual Property: YES

Background:

InnoH2O seeks to develop a small-scale, low-energy desalination water purification system. It is conceived that this system would provide a small group of people drinking water in a disaster relief situation or be deployed to developing countries to purify drinking water.

InnoH2O has performed research, in the past, that has determined that a system of this type must be easy to use, operate on as minimal of energy as realistically possible, and ensure the safety of people consuming the water being produced by the system. This leads to a select few technologies that may be utilized to build the system including reverse osmosis, vapor compression distillation, distillation and/or forward osmosis. While these technologies are not meant to be fully inclusive of new advancements, they represent the current state-of-the-art in small-scale desalination activities.

Desired System Characteristics:

The conceived system would have the following characteristics:
• Daily Volumetric Capacity – 6 to 10 gallons of purified water per hour
• System Weight – no more than 40 pounds
• System Volume – no more than 16 cubic feet
• Energy Consumption – less than 10 watt-hours per gallon
• Water Types – fresh, brackish and saltwater purification
• Prefiltration – gravity fed or low-pressure process
• Power Source – solar, wind, batteries, generator (ideally system is DC and not AC)

Project Tasks:

• Task 1 – Research and Preliminary Design
o Research and determine the correct filtration selection
o Perform preliminary process and mechanical development
o Perform preliminary electrical development
o Develop preliminary 3-D models of system and packaging
• Task 2 – Detailed Design
o Finalize filtration selection
o Finalize filtration process design
o Finalize electrical and mechanical design
o Finalize 3-D models of system and confirm packaging size
• Task 3 – Prototype Build
o Assembly of all components
o Ensuring that all pieces/parts fit in the selected packaging
o Ensuring that all components function as deemed necessary
• Task 4 – Prototype System Testing
o Test prototype system to validate filtration capacity (to NSF P248 standard)
o Test prototype system to validate energy consumption
Company Name ProjecttTitle Faculty Contact BME CHE CMPEN CMPSC ED EE ESC IE MATSE ME NUCE
John Deere Commercial Products Low Cost Self-Centering Spring Damper Control Improvement Belegundu, Ashok 0 0 0 0 3 0 2 3 0 1 0

Non-Disclosure Agreement: YES

Intellectual Property: YES

A self-centering spring damper motion control device is currently used on mechanical hydrostatic transmission designs to modulate the system response and dampen environmental feedback to achieve peak levels of system response and optimal operator comfort.

The current self-centering spring damper is comprised of an external steel tube that captures subsystem components including a common oil motion damper, with two opposed centering springs. One end of the assembly contains an eccentric that is used to compensate for system tolerance stack up and set a neutral position.
When an external force is applied, the self-centering spring damper opposes the force in accordance with the static linear compression of one of the centering springs and a dynamic force from the oil damper that varies with the rate of change of linear position. When the external force is removed, the self-centering spring damper will drive the system to a centered equilibrium position of the centering springs with the rate of motion controlled by the dynamic force from the oil damper.

The cost of the self-centering spring damper is disproportionally high, when viewed from the simplistic components it is comprised of and the other parts that make up the hydrostatic control system. The current eccentric neutral adjustment is also more complex than may be needed.

John Deere will provide the student design team with physical parts of the current setup. The goal of this project is to characterize the performance of the current self-centering spring damper and eccentric adjustment and develop alternate concepts that replicate the performance with the goal of reducing the cost of the system and improving the ease of assembly and adjustment.

PDF of project with illustrations of components is available upon request.

Confidentiality Agreements will be needed for this project.
Company Name ProjecttTitle Faculty Contact BME CHE CMPEN CMPSC ED EE ESC IE MATSE ME NUCE
John Deere Turf Human Centered Operator Control Design for Walk-Behind Mowers Rothrock, Ling 0 0 0 0 0 2 0 1 0 3 0

Non-Disclosure Agreement: YES

Intellectual Property: YES

Background:
Operator presence and steer control on a walk-behind mower today is performed by four mechanically operated levers. Two levers have to be squeezed against a stationary handle as they detect operator presence and the other two levers, one on each side, are pulled up towards the stationary handle to dictate the steering and speed of the machine.

During spring 2018 semester, a CAPSTONE team at Penn State worked to lead the development of a new operator interface to deliver excellent ergonomic value for walk-behind mowers. The team used Force Sensing Resistors (FSR) to deliver operator presence and joysticks along with linear actuators to control speed and direction of the mower.

Project Objective:
The goal of this project is to build upon work that was performed during spring 2018 semester and deliver an operator interface design that is inspired from an everyday object as simple as a grocery store shopping cart. The solution would need to decipher operator’s desired speed and direction command despite changing terrain pitch and slope coupled with mechanical (vibration/shock) disturbances coming from the ground, engine and mower deck. It may be possible to use tactile sensing to achieve this objective but that is only one idea to how this can be executed.

Deliverables:
•System block diagram, system calculations, electrical schematics, design, and installation drawings. Installation drawings shall include any relevant assembly instructions and a parts list of commercially and custom designed available parts to create a working prototype. Custom parts shall be fully detailed in drawings meeting ANSIY14.5 drawing standards.
•Bill of materials with part numbers and cost estimates.
•Working physical demonstration prototype.
•Documented source code for all software components.
Company Name ProjecttTitle Faculty Contact BME CHE CMPEN CMPSC ED EE ESC IE MATSE ME NUCE
Johnson Doll Baby Doll with Multiple Functions Erdman, Michael 3 0 1 0 3 2 3 0 0 0 0

Non-Disclosure Agreement: NO

Intellectual Property: NO

Baby Doll: Press button on baby doll's hand to make a whistle sound, press button for the baby doll to shake a little bit, and press button for the head to go back and fourth. Also, press button to play a Christmas song (Blake Shelton's "Let It Snow" or Mickey Mouse kid song "Deck the Halls") and a button to press that says "Hi Lauren." The three most important are the first three listed: whistle sound, doll to shake, and the head to go back and fourth.
Company Name ProjecttTitle Faculty Contact BME CHE CMPEN CMPSC ED EE ESC IE MATSE ME NUCE
KCF Technologies, Inc. 1 Smart Flange for Measuring Temperatures of a Moving Fluid Remotely Wang, Donghai 0 0 0 0 0 2 0 3 3 1 0

Non-Disclosure Agreement: NO

Intellectual Property: NO

KCF Technologies is a State College-based technology company founded by three Penn State researchers in 2000 whose mission is to optimize American manufacturing. Our team develops and commercializes products and solutions for industry and the military and specializes in wireless sensors, energy harvesting, underwater navigation and smart material devices. Our passion is bringing the latest technologies to life to make the things we work and live with Smarter!

An emerging technology at KCF 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. 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 will call a ‘smart flange’.

In this design project, your team will design, fabricate and test a ‘smart’ flange (see accompanying graphics below) that provides an accurate measure of the moving fluid’s temperature even when the fluid is contaminated.
Steps in the design process:
1) Become conversant with methods for measuring temperatures 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 with a low thermal conductivity to insolate the liner from the flange material (the flange could be steel or PVC)
4) Choose a device(s) and a method to measure the temperature of the inner liner. (Suggestion: thermistors are a good choice) KCF will provide details on the power and output requirement of the thermistors to be compatible with KCF’s wireless sensors
Steps in the fabrication process:
1) Fabricate the inner liner with attached thermistors
2) Fabricate the insulating annulus
3) Assemble the three components, (liner, insulator, flange)
4) Provide connecting ports for thermistor cables
Steps in the testing process
1) Install smart flange in a closed pumping system (provided by KCF)
2) Connect thermistor probes to KCF’s agnostic sensor.
3) With pump operating, compare temperature of smart flange measured remotely with that of KCF’s adjacent thermistor 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
Company Name ProjecttTitle Faculty Contact BME CHE CMPEN CMPSC ED EE ESC IE MATSE ME NUCE
KCF Technologies, Inc. 2 Quieting Quadcopters Wang, Qian 0 0 0 0 2 0 3 3 0 1 0

Non-Disclosure Agreement: NO

Intellectual Property: NO

KCF Technologies is a State College-based technology company founded by three Penn State researchers in 2000 whose mission is to optimize American manufacturing. Our team develops and commercializes products and solutions for industry and the military and specializes in wireless sensors, energy harvesting, underwater navigation and smart material devices. Our passion is bringing the latest technologies to life to make the things we work and live with Smarter!

This project focuses on making quadcopters quieter, particularly at cruising speeds.
As drones become more common place in our society, their acceptance, as package delivery systems for example, will require that they do not disturb the peace and quiet of a community and consequently become a noise nuisance.

KCF has developed a technology for quieting propeller-driven UAV’s, and in this project your design team will be transitioning this technology to treat quadcopter propeller noise. You will be using anti-sound methods, i.e., canceling sound with sound. This method involves placing a tuned resonator near the blade tips of a propeller (say in a shroud around the propeller) in such a way that when driven into resonance by the propeller, the resonator generates anti-phase sound that cancels the propeller noise.

This project will begin with conducting research on quadcopters to understand their control mechanism and operating procedures. For this step, you will purchase a shrouded quadcopter and learn how to fly it. During this phase, you will also need to learn how to measure noise of the quadcopter and particularly, its spectrum. KCF engineers will help you with this effort to identify the quadcopters’ blade tone frequencies.

The design steps of the project are as follows:
• First, design and integrate a small Helmholtz resonator (think blowing over the neck of a bottle to get a sound) in the shroud of each propeller by fabricating a new one with a 3-D printer. The resonator’s tone is dependent only on it volume and neck opening size. Tuning the integrated resonator to the match the dominant propeller tone is part this design step.
• Once the resonator/shrouds are fabricated and mounted to the supporting structure of the quadcopter, the next step involves flying the quadcopter in an open field and measuring its noise (spectrum) as the RPM changes. When the propeller RPM is such that it is an antiphase to the resonator’s tone, the quadcopter will become much quieter. This process may take several design iterations. A measureable noise reduction will signal success of the project.
• Throughout the project, KCF engineers will provide guidance on implementing the anti-sound technology.
Company Name ProjecttTitle Faculty Contact BME CHE CMPEN CMPSC ED EE ESC IE MATSE ME NUCE
Laboratory Testing Inc. Round Test Specimen Automated Polisher Neal, Gary 0 0 0 0 0 2 0 0 0 1 0

Non-Disclosure Agreement: NO

Intellectual Property: NO

Our company has recently purchased an automated round test specimen longitudinal polisher. This polisher can longitudinally polish the reduced test section of round test specimens in a variety of different sizes for Mechanical Testing such as high cycle fatigue, low cycle fatigue, fatigue crack growth, creep and stress rupture. As part of this project, we are looking to reverse engineer our current polishing machine. We will be physically providing you with our polishing machine at the Learning Factory. This will allow you to create SolidWorks drawings of our current products parts, and if achievable, create an assembly in SolidWorks of the system. The end goal of this project is to create a prototype of a new design of the polisher with enhancements in design but also that meet the requirements for automatic polishing set forth by NADCAP. Whether this means making the polisher more compact, lighter, enhanced design, that is up to you. Objectives of this project would be: 1. Create 3D SolidWorks parts of all components of the polisher in current state. 2. Create an assembly of our polisher in current state. 3. Design and develop a prototype for a new design of the polisher with design enhancements and improvements.
Company Name ProjecttTitle Faculty Contact BME CHE CMPEN CMPSC ED EE ESC IE MATSE ME NUCE
Lockheed Martin 1 Search and Rescue System Design Project Wang, Qian 0 0 0 0 0 2 3 0 0 1 0

Non-Disclosure Agreement: NO

Intellectual Property: NO

The Boeing Company and Sikorsky, a Lockheed Martin Company, will partner to challenge four teams composed of Mechanical, Electrical, and Computer Engineers to design, build, and test unmanned vehicles capable of interfacing to complete a simulated search and rescue mission. The goal of this project is to demonstrate the power of collaboration at industry, workforce, and system levels.
Over the past ten years, the National Park Service has reported search and rescue missions numbering anywhere from 2430 to 5761 missions per year with 119 to 244 associated fatalities. Each year, the majority of these missions are to retrieve hikers. As a result, the National Park Service has invested in unmanned-vehicle technology to help find and rescue those lost or hurt in the wilderness. Additionally, unmanned systems are used after natural disasters to aid disaster relief and emergency response (DRER) services, such as Search and Rescue (SAR) operations. Unmanned systems can increase mission success by providing rapid deployment, access to human denied environments, and increased situational awareness to SAR operators.
By leveraging their expertise, the aerospace industry is helping to develop optimized systems focused on pairing unmanned air and ground vehicles. For example, a long-range drone is often incapable of navigating areas an all-terrain rover is better suited for, and vice-versa. Interfacing these vehicles into a collaborative system has proven to extend rescue capabilities.
Additionally valuable to system interoperability is workforce collaboration. In the current industrial environment, it is becoming an increasingly common industry practice for companies to partner and leverage complementing skills for a competitive advantage. For example, the Sikorsky-Boeing SB-1 Defiant is a medium-lift-sized aircraft entry for the United States Army’s Future Vertical Lift program. Given their large industrial base and their track-record in transport helicopter designs, this joint team is seen to have an advantage over other submissions. By combining “the best of both worlds,” Boeing and Sikorsky can offer a very impressive solution.
Similarly, two teams of students will work collaboratively to design, build, test, and demonstrate an unmanned search and rescue system consisting of an aerial vehicle (UAV) and a ground vehicle (UGV). One team will develop the unmanned aerial vehicle (UAV), responsible for delivering the UGV to the mission site, providing aerial surveillance of the UGV, and retrieving the UGV to return to base. Another team will develop the deployable, unmanned ground vehicle (UGV), responsible for navigating the search site, rescuing survivors, and returning to the extraction site for UAV extract. By employing systems engineering principles, both teams will collectively design the interfacing components and functions to produce a fully integrated solution. These two teams will collaborate to compete against another UGV+UAV two-team pairing.
Sikorsky, a Lockheed Martin Company, will employ a team of electrical and mechanical engineers to develop a UAV capable of delivering the UGV to the mission site and providing sensor data to the operator. Mechanical engineers will be responsible for the structural components of the UAV, including frame, flight components, and UGV delivery mechanism. Electrical engineers will focus on the software and programming, including flight controls, sensor integration, and pilot interface development. To complete the mission system, the Sikorsky UAV team will partner with a Boeing UGV team. This pairing will compete against another UAV+UGV two-team pairing.

The Boeing Company will employ three teams of electrical and mechanical engineers to develop two UGV’s and one UAV. The mechanical engineers will be responsible for structural, dynamic, and functional components, whereas the electrical engineers will focus on the power, programming, and piloting of the vehicles. One of the Boeing UGV teams will partner with the Sikorsky UAV team to compete against the remaining Boeing UAV and UGV teams.

The teams will demonstrate their systems capabilities to Boeing and Sikorsky sponsors at the end of the semester, on the day of the Learning Factory Showcase, by completing a mock Search and Rescue (SAR) mission. The Sikorsky + Boeing pairing will compete against the Boeing + Boeing pairing to determine which teams have developed the best system for the intended mission.
Company Name ProjecttTitle Faculty Contact BME CHE CMPEN CMPSC ED EE ESC IE MATSE ME NUCE
Lockheed Martin 2 Real-Time Modeling of Aerodynamic Moments on Rotary Actuators at Mach Speeds Wheeler, Timothy 0 0 3 0 0 1 0 0 0 2 0

Non-Disclosure Agreement: YES

Intellectual Property: YES

The goal of this project is to research, design, and fabricate a test fixture that can accurately model the torque created by the atmosphere on the control system of a gravity released munition. With the advancement of munitions guidance algorithms, there is a growing need for simulation/test environments to model the control systems with extreme precision. When munitions are released at speeds near-to, or exceeding Mach one, the aerodynamic drag forces on an actuation surface can cause the actuation system to perform significantly different than at rest. Engineers on this project must perform research and CFD analysis on the related aerodynamics of the system. It is expected the students will understand all contributing factors, including speed, altitude, temperature, humidity, etc. after this project concludes. Engineering students will design and fabricate a test fixture that will supply precisely modeled rotational forces in a real-time test bench. The test fixture will accept control parameters from the weapon’s software simulation, and report both performance and feedback via an electronic interface governed by a microcontroller. The students will define their embedded communications protocol and message structure in an interface control document (ICD). The device should contain power electronics including AC to DC voltage conversion and voltage regulation to allow it to be directly plugged into a standard 120V wall socket. The final design will be accurate, robust, maintainable and cost effective. Once the design is prototyped and proven as a viable solution, the engineering students can have an opportunity to help integrate their design into Lockheed Martin’s Hardware in the Loop (HWIL) simulation lab.
Company Name ProjecttTitle Faculty Contact BME CHE CMPEN CMPSC ED EE ESC IE MATSE ME NUCE
Lockheed Martin 3 Simulation Scripting Language Verbanec, Alan 0 0 2 1 0 0 0 0 0 0 0

Non-Disclosure Agreement: NO

Intellectual Property: NO

Lockheed Martin’s avionics simulation environment allows users to interact with the application in two forms: They can control the application via the Graphical User Interface or they can use DCFs (Dynamic Control Files). DCFs use a custom home-grown programming language. In the current implementation, lexical analysis and parsing of output is performed in the Ada language using nonstandard and sub-optimal algorithms. Lockheed Martin seeks to upgrade this solution to more current technologies and robust algorithms. This project shall task the team of students to write a lexical analyzer and parser for Linux using common tools such as flex and bison. Focus shall be on ease-of-use to improve productivity and incorporation of automation wherever possible. Additionally, if time allows, the team shall create a reference implementation of a graphical user interface that an end-user could use to validate their DCFs. This reference implementation can be a simple webpage front-end or a more complex desktop application.
Company Name ProjecttTitle Faculty Contact BME CHE CMPEN CMPSC ED EE ESC IE MATSE ME NUCE
Lockheed Martin 4 Model Based Engineering Design of a Smart System Knecht, Sean 0 0 0 0 1 0 2 0 0 0 0

Non-Disclosure Agreement: NO

Intellectual Property: NO

This project is about design and model a smart and reliable alert system using Model Based System Engineering (MBSE) and Model Based Engineering (MBE) methodology. The smart system will automatically alert damage suing sensor technology. By the end of this project effort, the models of the designed system and a project summary including discussions about the advantages of using MBSE/MBE methodology, potential benefits of the designed system, and next steps are expected.
Company Name ProjecttTitle Faculty Contact BME CHE CMPEN CMPSC ED EE ESC IE MATSE ME NUCE
Lycoming Engines Turbocharger Bracket Design and Analysis Belegundu, Ashok 0 0 0 0 2 0 0 0 0 1 0

Non-Disclosure Agreement: YES

Intellectual Property: YES

Lycoming Engines manufactures air-cooled piston engines for general aviation aircraft, ranging from 4 to 400 horsepower. Some turbocharged legacy engine models utilize a rear mounted bracket to support the turbocharger system. Lycoming is seeking to improve the design of this current turbocharger support bracket.

The current bracket is fabricated from steel components with corrosion resistant coating and plating. Due to high amounts of thermal cycling, the protectant coating and plating can flake off leaving exposed material. The team will first create an analysis and research the current design as preliminary baseline for comparison. The team will then design a new bracket considering material selection, corrosion resistance, manufacturability, cost, and weight. To aide in the design process, students are expected to use a finite element analysis software package to provide a strength comparison between the new and current design. Primary deliverables will then include a detailed report and presentation to Lycoming.

Requirements:
-Analysis of the current bracket
-Research on available materials and anti-corrosion techniques to compare their impacts on component strength, weight, and cost
-Analysis of the recommended bracket design
-Detailed technical report

Provided Materials/Information:
-Bracket supported component specifications
-Available drawings and CAD models of current bracket
Company Name ProjecttTitle Faculty Contact BME CHE CMPEN CMPSC ED EE ESC IE MATSE ME NUCE
McLanahan Corporation Scheduling Visibility for Manufacturing and Beyond Shanbhag, Uday 0 0 0 2 0 0 0 1 0 0 0

Non-Disclosure Agreement: NO

Intellectual Property: NO

This project is an opportunity for a dedicated team to design a functional process that supports job scheduling within our manufacturing environment. We design and produce equipment and parts for many industries worldwide. Our facility in Hollidaysburg includes plate cutting and forming, welding, machining, with a blasting and coating application. We also must include our Foundry which is the oldest, family owned, operating Foundry in the U.S.
We currently use Epicor’s E9 ERP software to manage our sales, inventory, and subsequent production jobs. We will be updating our ERP with the implementation of Epicor’s E10 version 1/1/2019. While the software includes a scheduling module, we have not been successful in developing accurate information to support procurement of materials and production planning without manually manipulating Epicor’s output. We also lack the ability to provide a snapshot in time to other stakeholders with a clear view of current work requirements.
The deliverables would include a process that supports accurate scheduling analysis starting with the individual part structure, through procurement and manufacture. This would also include visibility to stakeholders in the form of electronic documents showing the current and projected state of each required job.
Company Name ProjecttTitle Faculty Contact BME CHE CMPEN CMPSC ED EE ESC IE MATSE ME NUCE
Pennsylvania Insulating Glass Corp Custom Glass Auto Loader Erdman, Michael 0 0 0 3 3 0 1 0 0 2 0

Non-Disclosure Agreement: NO

Intellectual Property: NO

Design and prototype a safe and reliable device to automatically transfer cut pieces of glass from a vertical harp rack to a horizontal conveyor.

Glass is cut per customer's size requirements and then placed into an individual vertical slot of a 100-slot harp rack. Currently, this glass is then removed by hand and placed horizontally onto load caster tables.

I need to design a machine that will:
1) Index the piece of glass out of the harp storage rack onto an existing tilting table.
2) Transfer the glass from the vertical position to the horizontal position.
3) Convey the glass onto the caster tables.
Company Name ProjecttTitle Faculty Contact BME CHE CMPEN CMPSC ED EE ESC IE MATSE ME NUCE
Philips Ultrasound Ultrasound Lens Reliability Test Lehtihet, Amine 3 0 0 0 0 3 0 1 0 2 0

Non-Disclosure Agreement: NO

Intellectual Property: NO

Philips Ultrasound designs and builds market leading medical ultrasound transducers. Lens Rub testing is a key part of our reliability demonstration test capability. Our current Lens Rub test machine is old and uses outdated controls. The project will be to improve our Lens Rub test fixture with new hardware and control method.
Company Name ProjecttTitle Faculty Contact BME CHE CMPEN CMPSC ED EE ESC IE MATSE ME NUCE
PMG-Pennsylvania LLC ASSET MANAGEMENT AND MATERIAL HANDLING IMPROVEMENT Purdum, Charlie 0 0 0 0 3 0 0 1 0 2 0

Non-Disclosure Agreement: YES

Intellectual Property: YES

Objective:
Create a detailed layout of the facility automation with accurate component designations and drawing definition. This will require the use of drawing software to update the current layout and define all of the material handling conveyors with a systematic approach and define the critical failure components. An analysis of the critical components based on a detailed risk analysis model will be required to prioritize the need for spare components and potential replacement of existing systems.

Deliverables and Project Plan:
Phase I
• Review the current plant layout and develop a numbering system for the material handling conveyors. Report #1 week 2/3

Phase II
• Identify the material handling conveyors on the current PMG layout and update according to the developed system. Report #2 week 6/7

Phase III
• Identify and design/draft the critical components for each conveyor. Report #3 week 10

Phase IV
• Develop a critical spare parts plan with risk levels and cost and present to the maintenance and procurement group. Report #4 week 13

Phase V
• Summarize all activities and report results to the President and Chief Financial Officer. Report #5 week 14
Company Name ProjecttTitle Faculty Contact BME CHE CMPEN CMPSC ED EE ESC IE MATSE ME NUCE
Princeton Leadership Services, LLC Basketball bench time-out buffer Belegundu, Ashok 0 0 0 0 2 0 0 0 0 1 0

Non-Disclosure Agreement: NO

Intellectual Property: YES

During college basketball games, timeouts are called at least four times per half for media purposes. In this situation, the team’s managers run onto the floor with tiny stools for the coach and players to sit on. This is done to escape the crowd noise and prevent people from seeing or hearing what is happeing. To reduce distraction all the remaining players and coaches stand around trying to block out tv cameras, cheerleaders, promotional games, etc. Unfortunately this is not very effective and is particularly challenging when playing away from home where opposing fans, bands and cheerleaders do their best to distract the visiting team.

We seek to work with a team of engineers to develop a buffer or shield that surrounds the team’s bench to block out distractions and noise during time outs. The structure should have the following features -
It must be able to be deployed in seconds, and stored in a similarly short time frame
It should be able to surround 5 to 6 chairs each approximately 18-22” wide and should be able to and adjust to the varying bench configurations and sizes.
It must be portable, lightweight, and easily stored and transported on a bus or plane
It must be collapsable
It must be opaque, so you can’t see through it.
It should significantly reduce crowd and band noise as much as possible
It must be sturdy and anchored in some manner.
The ability to include university logo or corporate advertising on the screening is desirable.

We have other ideas to share but want to keep them in reserve until we meet as a team and so to avoid influencing the design ideas of the engineers.

The leadership on this project are two straight-A high school brothers at St. Joseph’s Catholic Academy in Boalsburg who play basketball and will be mentored by their father. We plan to be actively involved in the development and meet frequently.

The desired deliverable is a working prototype of the above described concept.

The team would like to meet weekly to discuss materials, development, and overall progress of the project throughout the semester.
Company Name ProjecttTitle Faculty Contact BME CHE CMPEN CMPSC ED EE ESC IE MATSE ME NUCE
Propter Hoc Imaging LLC Development of Prototype Housing for Proprietary Lens System Knecht, Sean 0 0 0 0 2 0 0 0 0 1 0

Non-Disclosure Agreement: YES

Intellectual Property: YES

We are commercializing a lens technology that was developed as a spinoff of the development of a telescope for finding extrasolar planets by researchers in the PSU Department of Astronomy. The lens can be coupled to commercially available digital camera systems (e.g. cell phone cameras) to produce very small, high magnification microscopes (>800x). The lens itself requires precise alignment for optimal performance, the specifics of which vary as a function of the materials and other optical components in play (e.g. the digital camera system). The goal and deliverable of this project is the construction of a prototype mount that holds the lens and other optical elements in the correct orientation and with the correct spacing from the imaging object to achieve optimal magnification.
Company Name ProjecttTitle Faculty Contact BME CHE CMPEN CMPSC ED EE ESC IE MATSE ME NUCE
PSU Athletics Development of a hockey puck launching/passing machine Manogharan, Guha 0 0 2 3 0 3 3 0 0 1 0

Non-Disclosure Agreement: NO

Intellectual Property: YES

During the Spring 2018 semester we worked with a group of students through the learning factory to develop a prototype of machine designed to pass hockey pucks. The team was able to develop a workable machine, but it faced a number of problems that need to be improved upon in order to make it usable on daily basis. The needed improvements include -

1) Reduction/elimination of vibrations from motor used to launch the puck.

2) Improved puck storage capacity

3) Improved functionality related to puck speed, display and other electrical components.

4) The overall size, weight and portability of the machine is prohibitive for regular use or development into a viable product and needs to be reduced significantly.

5) Significant on-ice testing is needed, which did not occur during last semester's project.

Project sponsor is retaining the IP rights, but is willing to share those rights with the student team.
Company Name ProjecttTitle Faculty Contact BME CHE CMPEN CMPSC ED EE ESC IE MATSE ME NUCE
PSU Beaver Stadium Improving Customer Service at Beaver Stadium Concession Stands Purdum, Charlie 0 0 2 3 0 0 0 1 0 0 0

Non-Disclosure Agreement: NO

Intellectual Property: NO

Introduction: the purpose of this project is to improve customer service at Beaver Stadium concession stands. Nice opportunity to adapt the SERVQUAL instrument for this service (covered in IE460). The project has two main goals:
1. Improve waiting lines in front of concession stands;
2. The stands currently staffed by volunteers who may not have much training or experience. Standardized processes need to be developed to ensure that customer service is consistent, reliable, and high quality.
Task 1.1: Estimating arrival rates, service rates, and abandon rates of sampled concessions.
Task 1.2: Building a SIMIO model for the queueing networks.
Task 1.3: Studying the current process configurations, steps, and times
Task 1.4: Suggesting standardized work instructions and developing cheat sheets, education videos, skill test, and SOP documents.
Company Name ProjecttTitle Faculty Contact BME CHE CMPEN CMPSC ED EE ESC IE MATSE ME NUCE
PSU BME Design of Rolling Cane to Assist Independent Living Hayes, Daniel 1 0 0 0 0 0 0 2 0 3 0

Non-Disclosure Agreement: NO

Intellectual Property: NO

Falls are the leading cause of fatal injury and the most common cause of nonfatal trauma-related hospital admissions among older adults resulting in $50 billion in healthcare costs per year. In addition to the elderly, many individuals with physical disabilities (e.g., cerebral palsy) have difficulty walking and are at risk for fall-related injuries. Current stability devices, like walkers, work well for outdoor activities but are too bulky for indoor use. Canes can provide additional support in living spaces; however, traditional canes need to be lifted off the ground during walking, which may actually increase a person's falling risk. Therefore, the objective of this project is to design an ergonomic and safe rolling cane that can move with the user and provide continuous walking support. This will reduce fall-related deaths and injuries, enable greater independence in the elderly and disabled, and potentially offer significant commercial opportunities.
Company Name ProjecttTitle Faculty Contact BME CHE CMPEN CMPSC ED EE ESC IE MATSE ME NUCE
PSU College of Medicine 1 Process Optimization for Clinical Trials Initiation Yang, Hui 0 0 3 2 0 0 0 1 0 0 0

Non-Disclosure Agreement: NO

Intellectual Property: NO

The Associate Dean for Clinical Research at the Penn State College of Medicine has requested process time metrics for the purpose of optimizing the administrative processes required to initiate a clinical trial. Process metrics from the Award Management System (SIMS), the Institutional Review Board System (CATS IRB), and the Clinical Research Management System (STAR) are available, but are not easily combined or available for process analysis across all three systems. While each office has worked diligently to optimize their processes, we have little to no insight into how the three processes and systems interact in terms of their impact of the overall time it takes to initiate a clinical trial and what opportunities there may be to optimize the overall efficiency of the process. Process data from all three systems is already being collected and can be exported. Ideally, the team would use the process data from all three systems to model the process to identify current issues and to project anticipated higher volumes to identify where challenges are likely to arise as the number of clinical trials increases. In addition, the team should establish or recommend tools that could be used for ongoing analysis.
Company Name ProjecttTitle Faculty Contact BME CHE CMPEN CMPSC ED EE ESC IE MATSE ME NUCE
PSU College of Medicine 2 Self Retaining Surgical Retractor Hayes, Daniel 1 0 0 0 0 0 0 0 2 3 0

Non-Disclosure Agreement: NO

Intellectual Property: YES

Surgical technology can evolve at lightning speed or stagnate with something that "gets the job done." Imagine spending hours operating and at the penultimate portion of the procedure - sewing two blood vessels together with suture as thin as hair - the suture snags on a cumbersome retractor and snaps. In an elective surgery, the work has to be redone. In an emergency, the patient may not survive. The retractors we currently use for most vascular surgery cases are versatile but awkward. The handles often jut into the surgical field. Senior, skilled operators can make it work either by elaborate draping the instruments with sterile towels or by having an assistant "follow" the suture. The assistant's sole task is to hold the suture and make sure it doesn't wrap around a knob or handle. This is a waste of resources and a cause of undue stress. It slows the pace of a procedure and worsens patient outcomes, since they are negatively correlated with operative time. There is ample opportunity to design a lower-profile retractor that is sleek, innovative, and blissfully utilitarian. My challenge to the students is to find a design that is unique and can easily be assembled, disassembled, and maintain structural integrity with repeated sterilization.
Company Name ProjecttTitle Faculty Contact BME CHE CMPEN CMPSC ED EE ESC IE MATSE ME NUCE
PSU EDSGN 1 Residual Limb Standard Scanning Method Hayes, Daniel 2 0 0 3 3 3 0 0 0 1 0

Non-Disclosure Agreement: NO

Intellectual Property: NO

There are an estimated 2 million people in the U.S. living with lower limb amputations. In order to regain mobility, many rely on prosthetic devices to go about their normal, everyday activities. With recent advances in bio-reverse engineering and digital fabrication techniques, it may be possible to streamline the process of prosthetic design and fabrication, saving time and money for these patients. The capstone team will be responsible for the design and implementation of a standardized scanning technique for residual limbs, using inexpensive off-the-shelf 3D Scanners. This may involve mechanical design, fabrication, and testing of an automated jig to assure quality scans, and scans produced using jig will be assessed against baseline models produced from higher fidelity methods. The team will adhere to IRB standards while working with patients to take scans and gather anthropometric data, and adhere to HIPPA regulations when handling and storing private and sensitive information. The team will have a unique opportunity to create a design and be part of its implementation. The project requires not only talented engineers but empathetic engineers, who can create a system for scanning residual limbs and interact with TTA patients with care and respect.
Company Name ProjecttTitle Faculty Contact BME CHE CMPEN CMPSC ED EE ESC IE MATSE ME NUCE
PSU EDSGN 2 Automated 3D-Scanned Pointcloud Cleaning Workflow Verbanec, Alan 3 0 2 1 0 0 0 0 0 3 0

Non-Disclosure Agreement: NO

Intellectual Property: NO

Following a Trans-Tibial amputation, the road through rehabilitation to recovery is long and involves the creation of a prosthetic socket to perfectly match the residual limb. The creation of a digital clone of the limb is an important step in creating a design for digital fabrication. The capstone team will be responsible for the creation and implementation of a workflow for cleaning a 3D scan (input for workflow will be a point cloud and expected output can be either mesh, cleaned point cloud, etc). This will involve de-noising a raw point cloud while preserving the underlying geometry. Solutions may include traditional statistical-based methods of point cloud de-noising or machine learning algorithms. The work will generate knowledge important to improving the lives of patients following any amputation, and requires students dedicated to producing quality work quickly. The work may result in co-authorship in a peer-review journal article.
Company Name ProjecttTitle Faculty Contact BME CHE CMPEN CMPSC ED EE ESC IE MATSE ME NUCE
PSU EE Concentrating photovoltaic windows Wheeler, Timothy 0 0 3 0 0 1 0 0 0 2 0

Non-Disclosure Agreement: NO

Intellectual Property: NO

Goal:
The team will build a window that selectively generates power from the direct beam component of sunlight while letting the diffuse solar component through for lighting.

Overview:
Buildings that are energy efficient and even generate power are becoming requirements for new construction, while natural lighting from glass rooftops and large windows are expensive to cool during the summer and prevent the installation of solar panels on the rooftops.
Windows that could collect the more intense direct light from the sun can capture much of the solar energy available for solar cells while letting less intense diffuse light in for natural lighting. Companies such as Ubiquitous Energy and SolarWindow are pursuing solutions such as semitransparent organic photovoltaic windows but these are extremely inefficient (see, e.g. https://spectrum.ieee.org/energy/renewables/the-dawn-of-solar-windows).
Focusing the direct sunlight onto existing silicon solar cells (20% efficiency) with an array of lenslets could in principal capture all of the intense direct sunlight for power generation while leaving the diffuse light (from clouds and the sky) for natural lighting, thus achieving both high efficiency and lighting functionality. The goal of this project is to develop and test such a prototype system based on a Fresnel lenslet array and integrated mechanical tracking system.

Deliverables:
• Design of mechanical tracking system
• Optical design using commercial lenses for prototype system
• Prototype system with integrated tracking
• Power efficiency measurements
• Qualitative analysis of lighting quality
• Simple model for reduction of room heating from sunlight compared to a standard window
Company Name ProjecttTitle Faculty Contact BME CHE CMPEN CMPSC ED EE ESC IE MATSE ME NUCE
PSU ELD CHILL - when is your shower ready for you? Erdman, Michael 0 0 2 0 0 3 1 0 0 3 0

Non-Disclosure Agreement: NO

Intellectual Property: NO

Yeow! It is the middle of January, and you are late for class. You are trying to save money, so your apartment is chilly. You just stepped into the shower, and the water is FREEZING COLD, the hot water has not yet reached the shower head. Talk about a bad start to your day!

Every day, electricity and water are wasted as people estimate when their shower will hit the right temperature. This project is designed to determine when that temperature has been achieved and to give a notification, both with a soft beep from the shower head (in case you are in the bathroom) and with a message to your smart phone (in case you are not nearby). In addition, an alarm function can be set to sound after a set elapsed time to remind slow-pokes to finish their shower.

A simple device should be included to convert some of the energy from the flowing water into power for the unit, so that replacing batteries is not needed. Easy installation and low price are crucial elements of the design.
Company Name ProjecttTitle Faculty Contact BME CHE CMPEN CMPSC ED EE ESC IE MATSE ME NUCE
PSU Human Powered Vehicle (HPV) Human Powered Vehicle Neal, Gary 3 0 0 0 2 0 3 0 0 1 0

Non-Disclosure Agreement: NO

Intellectual Property: NO

The team will revise the design of last year's vehicle to improve performance. In general, human powered vehicles (HPV) are recumbent bikes or tricycles. The vehicle will compete in the ASME HPV competition in the spring. The fall Capstone team will be responsible for re-designing the major components and ensuring that they meet the safety standards through stress analysis. They will also be responsible for writing the relevant parts of the competition report and clearly documenting their work. Students who wish to see the overall project through to its end and participate in the competition are welcome to continue working with the spring Capstone team.
Company Name ProjecttTitle Faculty Contact BME CHE CMPEN CMPSC ED EE ESC IE MATSE ME NUCE
PSU Industrial & Manufacturing Engineering IME Capstone Business Development Purdum, Charlie 0 0 3 2 0 0 0 1 0 0 0

Non-Disclosure Agreement: NO

Intellectual Property: NO

Develop a robust business development process to identify projects and industry partners for the IME Capstone program (IE 480W). This project will involve COE and Smeal students as well (marketing, market research, sales, etc.) as part of SCM 496 (course number to be confirmed). As a starting point materials from the national Capstone Program conference (91 schools in attendance) will be used along with other materials to guide the team (Smeal's SCM program resources).
Company Name ProjecttTitle Faculty Contact BME CHE CMPEN CMPSC ED EE ESC IE MATSE ME NUCE
PSU Kerchinski Blade Edge Damage Analysis Verbanec, Alan 0 0 2 1 0 0 0 0 0 3 0

Non-Disclosure Agreement: YES

Intellectual Property: YES

The objective of the project is to identify and measure razor blade edge damage. The focus will be analyzing the mechanical damage using machine vision systems or microscopy and developing a software.

Deliverables: Developing a methodology and software to identify and analyze the mechanical edge damage of razor blades.
Company Name ProjecttTitle Faculty Contact BME CHE CMPEN CMPSC ED EE ESC IE MATSE ME NUCE
PSU Learning Factory 1 Redesign of the Capstone Project and Poster Judging System Verbanec, Alan 0 0 2 1 0 0 0 0 0 0 0

Non-Disclosure Agreement: NO

Intellectual Property: NO

The objective of this project is to redesign the project and poster evaluation system for the Learning Factory Project Showcase. The new system will be web-based and feature improved evaluation and reporting functionality. Students will have access to the existing system, which they can either build upon or scrap entirely.

The present Engineering Showcase Capstone Design Voting System is a web based system written in PHP and is made accessible through the Apache web server. Configuration data and scoring records are collected into a MYSQL database. The purpose of the system is to provide a quick and efficient means of selecting a team and providing scores for the semester Engineering Showcase. Two primary modes of scoring are an ”official judging mode” and a “public people’s choice” mode.

The system was developed and designed in 2010 and requires an update to its web based and database operating systems.

The scoring data output only provides a listing of total votes from the judges on projects. There is a requirement to take this data and weight scores of judges using results from specific questions to minimize and break tied scores. The output should be a listing of actual judge’s numbers and an output of the final weighted scores. These scores must be formatted into an easy to read printed output.

The present system provides for 6 sets of judging pairs on technical and two sets of judges on posters. There is a requirement to add additional sets of judges especially two additional poster sets of judges in this project.

The new system program must be web based, able to operate a standalone network that is transmitted to iPads for judges to enter their scores to specific questions and to laptops for the public to select their People’s choice.

A copy of the present system will be provided as a starting point. The team will evaluate the present program, determine what updated web based operating system to convert the program to, make the system easy to configure for data and scoring records, provide operating instructions and a weighted output that can be sent in a format easy to read and print.

The program requires that the team document the program, provide a copy of the program and provide instructions for loading on any laptop and using.
Company Name ProjecttTitle Faculty Contact BME CHE CMPEN CMPSC ED EE ESC IE MATSE ME NUCE
PSU Learning Factory 2 Redesign of the Capstone Project and Poster Judging System Verbanec, Alan 0 0 2 1 0 0 0 0 0 0 0

Non-Disclosure Agreement: NO

Intellectual Property: NO

The objective of this project is to redesign the project and poster evaluation system for the Learning Factory Project Showcase. The new system will be web-based and feature improved evaluation and reporting functionality. Students will have access to the existing system, which they can either build upon or scrap entirely.

The present Engineering Showcase Capstone Design Voting System is a web based system written in PHP and is made accessible through the Apache web server. Configuration data and scoring records are collected into a MYSQL database. The purpose of the system is to provide a quick and efficient means of selecting a team and providing scores for the semester Engineering Showcase. Two primary modes of scoring are an ”official judging mode” and a “public people’s choice” mode.

The system was developed and designed in 2010 and requires an update to its web based and database operating systems.

The scoring data output only provides a listing of total votes from the judges on projects. There is a requirement to take this data and weight scores of judges using results from specific questions to minimize and break tied scores. The output should be a listing of actual judge’s numbers and an output of the final weighted scores. These scores must be formatted into an easy to read printed output.

The present system provides for 6 sets of judging pairs on technical and two sets of judges on posters. There is a requirement to add additional sets of judges especially two additional poster sets of judges in this project.

The new system program must be web based, able to operate a standalone network that is transmitted to iPads for judges to enter their scores to specific questions and to laptops for the public to select their People’s choice.

A copy of the present system will be provided as a starting point. The team will evaluate the present program, determine what updated web based operating system to convert the program to, make the system easy to configure for data and scoring records, provide operating instructions and a weighted output that can be sent in a format easy to read and print.

The program requires that the team document the program, provide a copy of the program and provide instructions for loading on any laptop and using.
Company Name ProjecttTitle Faculty Contact BME CHE CMPEN CMPSC ED EE ESC IE MATSE ME NUCE
PSU Learning Factory 3 Redesign of the Capstone Project and Poster Judging System Verbanec, Alan 0 0 2 1 0 0 0 0 0 0 0

Non-Disclosure Agreement: NO

Intellectual Property: NO

The objective of this project is to redesign the project and poster evaluation system for the Learning Factory Project Showcase. The new system will be web-based and feature improved evaluation and reporting functionality. Students will have access to the existing system, which they can either build upon or scrap entirely.

The present Engineering Showcase Capstone Design Voting System is a web based system written in PHP and is made accessible through the Apache web server. Configuration data and scoring records are collected into a MYSQL database. The purpose of the system is to provide a quick and efficient means of selecting a team and providing scores for the semester Engineering Showcase. Two primary modes of scoring are an ”official judging mode” and a “public people’s choice” mode.

The system was developed and designed in 2010 and requires an update to its web based and database operating systems.

The scoring data output only provides a listing of total votes from the judges on projects. There is a requirement to take this data and weight scores of judges using results from specific questions to minimize and break tied scores. The output should be a listing of actual judge’s numbers and an output of the final weighted scores. These scores must be formatted into an easy to read printed output.

The present system provides for 6 sets of judging pairs on technical and two sets of judges on posters. There is a requirement to add additional sets of judges especially two additional poster sets of judges in this project.

The new system program must be web based, able to operate a standalone network that is transmitted to iPads for judges to enter their scores to specific questions and to laptops for the public to select their People’s choice.

A copy of the present system will be provided as a starting point. The team will evaluate the present program, determine what updated web based operating system to convert the program to, make the system easy to configure for data and scoring records, provide operating instructions and a weighted output that can be sent in a format easy to read and print.

The program requires that the team document the program, provide a copy of the program and provide instructions for loading on any laptop and using.
Company Name ProjecttTitle Faculty Contact BME CHE CMPEN CMPSC ED EE ESC IE MATSE ME NUCE
PSU Marshal Corps Graduation Ceremony Efficiency Shanbhag, Uday 0 0 0 2 3 0 0 1 0 0 0

Non-Disclosure Agreement: NO

Intellectual Property: NO

The Penn State University Marshal Corps is responsible for all graduation ceremonies on the University Park campus. As college enrollments increase and subsequent graduating classes increase in size, graduation ceremonies are becoming longer. This project's goal is to study different possible formats for conducting graduation ceremonies in order to improve efficiency and shorten the overall time of the ceremony.

The project outcome requires that every name of every graduating student be read as the student is crossing the stage and that the entire ceremony takes less than two hours. The team will also be asked to look at the processional of PhD candidates and their advisors and the overall efficiency of the graduate ceremony. The team should plan for a maximum number of students in one ceremony to be on the order of 1600 to 1800 graduates.

The team will be provided graduation ceremony scripts, video of previous ceremonies and access to the University Marshal, Bob Melton, as well as the University Office of Strategic Communictions, which oversees graduation ceremonies.
Company Name ProjecttTitle Faculty Contact BME CHE CMPEN CMPSC ED EE ESC IE MATSE ME NUCE
PSU MNE 1 Demonstration of a Self-Balancing PV Energy Storage System Wheeler, Timothy 0 0 3 0 0 1 0 0 0 2 0

Non-Disclosure Agreement: NO

Intellectual Property: YES

Research at Penn State has already resulted in the invention of a new photovoltaic energy storage system such that the batteries used in this system are automatically self-balancing by design, without needing balancing power electronics. This can reduce the cost of PV energy storage integration significantly. The theory behind this self-balancing behavior is now well-developed, and there is a significant body of both simulation-based results and laboratory experiments verifying this behavior. The next step - the focus of this project - will be the demonstration of this behavior using an outdoor prototype. This would involve comparing the proposed technology to current PV energy storage integration methods. This demonstration is important for the ultimate commercialization of the technology. This capstone project is intended to support this outdoor prototyping/demonstration effort. Please note that participants in this capstone effort will be expected to release their IP back to the Penn State inventors of the self-balancing PV technology. The fee structure associated with such IP release is appropriate.
Company Name ProjecttTitle Faculty Contact BME CHE CMPEN CMPSC ED EE ESC IE MATSE ME NUCE
PSU MNE 2 Development of a Tensile Testing Machine for Thin Film Specimens Belegundu, Ashok 0 0 0 0 0 0 2 0 3 1 0

Non-Disclosure Agreement: NO

Intellectual Property: NO

The objective of this project is to design and build a uni-axial tensile testing machine that can accommodate specimens that are less than 50 microns thick, 500 microns wide and 5 mm long. Such a tool will be invaluable for nuclear materials, where radiation hazard exponentially decreases with specimen size. It will also be important to test next generation combinatorial alloys, which are synthesized in small amounts.

The ME 440 team will work very closely with Professor Aman Haque, whose research is on nanoscale materials behavior, microscopy and nanofabrication. The team should have at least one member with experience or interest in 'data acquisition and processing' from force and displacement sensors.

Professor Haque will provide the preliminary design and participate/guide through the brainstorming and development phases. His group routinely nanofabricates test chips that accept 1-200 nm thick specimens. The students will learn about the challenges in micro/nanoscale testing. These are (1) gripping the specimen (2) eliminating mis-alignment in the applied force, (3) measuring the force and displacement.

The outcome of this project will be design and manufacture of a testbed assembled with commercially available force and displacement sensors. The team will demonstrate this testbed by performing tensile testing of microscale specimens and compare the data with the literature. Completion of this project will enrich the teams experience in design, manufacture, data acquisition and well as understanding in the fundamentals of engineering materials behavior.
Company Name ProjecttTitle Faculty Contact BME CHE CMPEN CMPSC ED EE ESC IE MATSE ME NUCE
PSU MNE 3 Demonstration of a Self-Balancing PV Energy Storage System Wheeler, Timothy 0 0 3 0 0 1 0 0 0 2 0

Non-Disclosure Agreement: NO

Intellectual Property: YES

Research at Penn State has already resulted in the invention of a new photovoltaic energy storage system such that the batteries used in this system are automatically self-balancing by design, without needing balancing power electronics. This can reduce the cost of PV energy storage integration significantly. The theory behind this self-balancing behavior is now well-developed, and there is a significant body of both simulation-based results and laboratory experiments verifying this behavior. The next step - the focus of this project - will be the demonstration of this behavior using an outdoor prototype. This would involve comparing the proposed technology to current PV energy storage integration methods. This demonstration is important for the ultimate commercialization of the technology. This capstone project is intended to support this outdoor prototyping/demonstration effort. Please note that participants in this capstone effort will be expected to release their IP back to the Penn State inventors of the self-balancing PV technology. The fee structure associated with such IP release is appropriate.
Company Name ProjecttTitle Faculty Contact BME CHE CMPEN CMPSC ED EE ESC IE MATSE ME NUCE
PSU Office of Sponsored Programs (OSP) 1 Refining Subaward Workflow Pang, Gordon 0 0 0 2 0 0 0 1 0 0 0

Non-Disclosure Agreement: NO

Intellectual Property: NO

When faculty members at Penn State receive research grants, they often choose to subcontract some of the funds to collaborators at other institutions. The Penn State Office of Sponsored Programs (OSP) processed 1,389 "subawards" and 62 "subcontracts" between 7/1/17 and 6/30/18. The process for putting these subagreements in place is still relatively manual. Efficiencies could be achieved by further automating the process.

The Office of Research Information Systems (ORIS) is currently mapping the process for automating subaward workflow (replacing our current PDF fill-and-print intake form with a workflow tool). They expect to have mock-ups of possible screen shots by September 2018. A student team could collaborate with the ORIS development team during the fall semester, analyzing the proposed workflow tool and suggesting possible improvements. A student group also could study process data, identifying possible bottlenecks, etc.
Company Name ProjecttTitle Faculty Contact BME CHE CMPEN CMPSC ED EE ESC IE MATSE ME NUCE
PSU Office of Sponsored Programs (OSP) 2 Human Factors: Cultivating working relationships during complex contract negotiations Purdum, Charlie 0 0 0 2 0 0 0 1 0 0 0

Non-Disclosure Agreement: NO

Intellectual Property: NO

A team of Penn State graduate students (Shashank Balasubramanya, Krishna Desai, and Fengjiao Sun) recently completed a "deep dive" analysis of non-disclosure agreements (NDAs) negotiated by Penn State's Office of Sponsored Programs (OSP). The purpose of this study was to identify factors that might contribute to a lengthy negotiation time. One of the factors they identified is that contract negotiators and faculty members often end up working at cross-purposes on these agreements. The team stated in a PowerPoint presentation that “professors should be made aware to co-operate and advocate/stand behind our negotiators.” In their detailed report, the team stated that “It would be of a great help if we can make our professors advocate for us. Many a times this is not the scenario but if we can make our professors understand and make them advocate for us it would be of a great help to our negotiators.” Could a student group study this problem and propose a transactional approach for building a united team? Is there a model for how negotiators should communicate with faculty members to bring them on board earlier in the process? Are there ways of getting Industrial Partnerships and other offices involved in facilitating a more constructive dialogue?

This project might benefit from the involvement of both Industrial Engineering and Industrial/Organizational Psychology students.
Company Name ProjecttTitle Faculty Contact BME CHE CMPEN CMPSC ED EE ESC IE MATSE ME NUCE
PSU Risk Management Developing Efficient Contract Routing Resources Pang, Gordon 0 0 0 2 0 0 0 1 0 0 0

Non-Disclosure Agreement: NO

Intellectual Property: NO

Researchers and other staff often have a contract they need reviewed and processed by an authorized office, but they are unsure of where to start. These employees typically submit the contract to the office they are most familiar with which in many instances is not the right place. Currently there is no common resource researchers and staff can use to identify the correct office quickly. Similarly, there is no common resource staff in the receiving offices can turn to in deciding where and how best to redirect a contract that the receiving office does not handle. The result can be delays and confusion in the process before an actual contract review even begins. Processing contracts can often be a time-consuming process, but it would be very helpful to eliminate as much lost time as possible due to the contract not getting to the right office. Efforts have been made by all offices to more quickly identify contracts that need to be redirected, but additional efficiencies would be very beneficial and hopefully save researcher/staff time and effort for more important issues.

I am interested in having students review this issue and assist with developing resources to improve speed and accuracy in getting contracts to the correct reviewing office
Company Name ProjecttTitle Faculty Contact BME CHE CMPEN CMPSC ED EE ESC IE MATSE ME NUCE
PSU SEE 360 Beaver Stadium Restroom Service Modeling Purdum, Charlie 0 0 0 2 0 0 0 1 0 0 0

Non-Disclosure Agreement: NO

Intellectual Property: NO

Penn State’s Capstone Design Project program serves as
an intricate part of reaching the goals of SEE 360. Recent service industry related capstone projects include volunteer staffing issues at a film festival, process improvement at a local hospital, ergonomic and safety improvements at a retail factory, and optimization of logistics in transportation. These projects save service enterprise companies thousands of dollars through real-life applications.
In this project we will be looking into a well known problem for female customers at large public venues: long waiting lines for bathrooms. This is the case of football game female attendees at Beaver Stadium, which is the subject of this Capstone Project. The challenge here is to survey customers to estimate the customer service level. A perfect opportunity to adapt the SERVQUAL instrument for this service (covered in IE460).

Task 1: Identifying Beaver stadium restroom capacity and demand.

Task 2: Identifying current service satisfaction and areas for improvements by surveying customers.

Task 3: Building a “AS-IS” and “TO-BE” simulation model for Beaver stadium restroom service system based on collected data.
Company Name ProjecttTitle Faculty Contact BME CHE CMPEN CMPSC ED EE ESC IE MATSE ME NUCE
PSU SPIN SPIN: Tying Penn State's research databases together DeMeter, Ed 0 0 0 2 0 0 0 1 0 0 0

Non-Disclosure Agreement: NO

Intellectual Property: NO

Penn State faculty currently need to consult many different systems to look up information about their funded research projects: proposal databases, contracting systems, financial systems, compliance systems, etc. The systems are currently designed to communicate with each other, at least to a certain extent, but system integration challenges remain.

A SPIN number is a Sponsored Project Identification Number. We don’t currently have such a number in any of our systems, but we believe there would be many efficiencies to be gained by adding something like this to our current databases. A student group could examine the concept and help make a business case for or against this approach. They might also be able to suggest timelines and implementation strategies.

In a nutshell, a SPIN number would allow us to tie together all of the various components of a project into a single integrated whole. We sometimes have multiple accounts with a single project (e.g., when faculty members collaborate with researchers in different colleges). We often have multiple award numbers for a single project (when funding comes in multiple increments). We often have multiple award logs (when various administrative changes are made to a project). We also can have multiple protocols (e.g., human subjects, animal subjects, biosafety, conflict of interest) associated with one project. A SPIN number could tie everything together so our financial system, pre-award system, and compliance systems could all talk to each other. And it would allow us to tie everything together better on the myResearch Portal so faculty members would have a less fragmented view of their projects. This should result in better project management.

The reason we’ve never implemented a SPIN is because other proposed enhancements always take priority. (For example, we are forever responding to new compliance requirements.) If a good business case can be made for developing a SPIN number, it may be possible to muster resources in support of the project.
Company Name ProjecttTitle Faculty Contact BME CHE CMPEN CMPSC ED EE ESC IE MATSE ME NUCE
PTC Inc. ThingWorx and the Internet of Things Bilen, Lennart 0 0 1 2 0 0 0 0 0 0 0

Non-Disclosure Agreement: YES

Intellectual Property: YES

ThingWorx – Project Overview

ThingWorx - The Ideal Platform to Drive Innovation
A complete, end-to-end technology platform, ThingWorx delivers the functionality, flexibility and agility needed to
develop, deploy and extend IoT applications. The platform contains a broad set of features, including multiple connectivity options, application development tools, and analytics – all built around the ThingModel, a single, real-time view of a physical object.

For this new ThingWorx Learning Factory project we are looking for a group of creative Computer Engineering and Computer Science students to dream up an IoT project that will utilize IoT devices, including possibly smart phones, micro-computers, sensors, alarms, etc. and the ThingWorx platform. Specifically, we are imagining an application that will aggregate real-time data reported by users and devices, analyze that data, and deliver value to the end users of the application.

Primary Goals
- Collaborate with our team and build a list of possible projects utilizing ThingWorx and IoT technologies (we have some ideas but we’re also interested in yours!)
- Choose the best project and design an implementation on the ThingWorx platform that will leverage the selected IoT technologies
- Implement a proof-of-concept solution using the ThingWorx platform and examples of selected IoT technologies

Secondary Goals
- Expand proof-of-concept

Hardware may be purchased using the project budget to support the physical/visual demo that will be displayed at the Design Showcase.
Company Name ProjecttTitle Faculty Contact BME CHE CMPEN CMPSC ED EE ESC IE MATSE ME NUCE
Quaker Chemical Corporation Machining of Wear Resistant Materials Used For Engine Cylinder Liners DeMeter, Ed 0 0 0 0 0 0 0 1 2 0 0

Non-Disclosure Agreement: NO

Intellectual Property: YES

There is a current trend in automotive engine manufacturing to utilize hard, thin coatings applied via plasma spray, as engine cylinder liners. Such hard thin coatings show improved wear resistance and increased weight reduction, relative to conventional cast iron cylinder sleeves. This project will focus on the study of the machinability and properties of hard wear resistant materials utilized for this application, as well as the study of the lubrication provided by selected metalworking fluids. Specifically, the project will involve the development of a continuous cutting machining process utilizing a turning operation, which will serve to simulate the fine boring of engine cylinders and cylinder liners and through use of this test, study the machinability of two hard wear resistant materials as well as the machining performance offered by three different metalworking fluids.

Deliverables
1. Establish machining test conditions simulating the continuous cutting performed in fine boring of plasma sprayed cylinder coatings
2. Using two different workpiece materials (Alumina Ceramic & 17-4 PH Stainless Steel) evaluate the machining performance of, and the insert wear occurring during the use of three different metalworking fluids.
3. Investigate the surface quality and microstructural changes occurring with increased machining and increasing tool wear.
Company Name ProjecttTitle Faculty Contact BME CHE CMPEN CMPSC ED EE ESC IE MATSE ME NUCE
Sekisui-SPI Infused Imaging Efficiency Project Cannon, Dave 0 0 0 0 0 0 0 1 0 2 0

Non-Disclosure Agreement: YES

Intellectual Property: YES

SEKISUI SPI, LLC is a division of Sekisui Chemical, an $11 Billion worldwide chemical company. SPI manufactures thermoplastic sheet for the aviation, mass transit, medical device, and wall covering industries at its Bloomsburg, PA and Holland, MI campuses.

The Infused Imaging department is located at our Bloomsburg, PA, South Campus facility. Infused Imaging “infuses” designs in to our thermoplastic sheet (similar to a tattoo) to provide customers with bespoke designs for their finished products.

This project focuses on the current material flow and overall department efficiency. Current workflow has the product travelling and crisscrossing in several directions.

The deliverables would include: improved product workflow and employee efficiency; troubleshooting techniques for processing issues; potential ideas for future department development.
Company Name ProjecttTitle Faculty Contact BME CHE CMPEN CMPSC ED EE ESC IE MATSE ME NUCE
Shell 1 Shell Eco-Marathon Urban Concept Car - Team 1 Neal, Gary 0 0 0 0 0 2 0 0 0 1 0

Non-Disclosure Agreement: NO

Intellectual Property: NO

Join the Shell Eco-Marathon Car Design Team! Learn about fuel efficiency innovation and put those principles into practice as you redesign and build a car of the future. This Urban Concept car will push the limits on weight, aerodynamics, and energy efficient technology, while taking advantage of industry-standard small engine and gear design. Students will be tasked with building a new car body and powertrain. The car will compete in the 2019 Shell Eco-Marathon with over 100 other schools across North and South America held during the spring semester. This project is perfect for those who enjoy working on cars and want to #makethefuture in energy. https://sites.psu.edu/pennstateecomarathon/
Company Name ProjecttTitle Faculty Contact BME CHE CMPEN CMPSC ED EE ESC IE MATSE ME NUCE
Shell 2 Shell Eco-Marathon Urban Concept Car - Team 2 Neal, Gary 0 0 0 0 0 2 0 0 0 1 0

Non-Disclosure Agreement: NO

Intellectual Property: NO

Join the Shell Eco-Marathon Car Design Team! Learn about fuel efficiency innovation and put those principles into practice as you redesign and build a car of the future. This Urban Concept car will push the limits on weight, aerodynamics, and energy efficient technology, while taking advantage of industry-standard small engine and gear design. Students will be tasked with building a new car body and powertrain. The car will compete in the 2019 Shell Eco-Marathon with over 100 other schools across North and South America held during the spring semester. This project is perfect for those who enjoy working on cars and want to #makethefuture in energy. https://sites.psu.edu/pennstateecomarathon/
Company Name ProjecttTitle Faculty Contact BME CHE CMPEN CMPSC ED EE ESC IE MATSE ME NUCE
Siemens Industry, Inc. 1 RFID for Personnel and Asset Management Bilen, Lennart 0 0 1 2 0 3 0 3 0 3 0

Non-Disclosure Agreement: NO

Intellectual Property: NO

Modern manufacturing industry is investing in new technologies such as the Internet of Things (IoT), big data analytics, cloud computing and cybersecurity to cope with system complexity, increase information visibility, improve production performance, and gain competitive advantage in the global market. These advances are rapidly enabling a new generation of smart manufacturing, i.e., a cyber-physical system tightly integrating the manufacturing enterprise in the physical world with the virtual enterprise in cyber space. Smart manufacturing goes beyond the automation of manufacturing shop floors but rather depends on data-driven innovations to realize high levels of autonomy and optimization of manufacturing enterprises. There is an urgent need to digitally integrate the manufacturing enterprise, which can be extended from enterprise resource planning (ERP) to supply chain management (SCM) to manufacturing execution system (MES) to process control systems (PCS), and beyond.

The objective of this project is to develop a RFID personnel and asset management system for the learning factory, which will allow digital tracking of human traffic in each region of the lab, as well as the usage information of asset (tools, materials, etc.). The RFID tags will be associated with each person (or each asset). The measurement data and/or subject-specific properties will be written to the RFID tag. Each time when a subject leaves or enters a specific area of the lab for machining or other processing jobs, it will pass a custom RFID read station at the gate or the ceiling, and the check-in and check-out data are automatically read within the 5-meter range and logged into the cloud database. The RFID system will automatically update the traffic information, synced in the cloud database, and then displayed in the web or mobile app. The final results should include both the system and some preliminary data – the data gathering process should start partway through the semester. Based upon the preliminary data, the teams will iterate and improve upon their design through the following phases, i.e., Design and Spec System, Prototype System, Re-design / Modify System, Install Final System, Evaluate Final System.
Company Name ProjecttTitle Faculty Contact BME CHE CMPEN CMPSC ED EE ESC IE MATSE ME NUCE
Siemens Industry, Inc. 2 Virtual Learning Factory Verbanec, Alan 0 0 3 1 0 3 0 2 0 3 0

Non-Disclosure Agreement: NO

Intellectual Property: NO

Modern manufacturing industry is investing in new technologies such as the Internet of Things (IoT), big data analytics, cloud computing and cybersecurity to cope with system complexity, increase information visibility, improve production performance, and gain competitive advantage in the global market. These advances are rapidly enabling a new generation of smart manufacturing, i.e., a cyber-physical system tightly integrating the manufacturing enterprise in the physical world with the virtual enterprise in cyber space. Smart manufacturing goes beyond the automation of manufacturing shop floors but rather depends on data-driven innovations to realize high levels of autonomy and optimization of manufacturing enterprises. There is an urgent need to digitally integrate the manufacturing enterprise, which can be extended from enterprise resource planning (ERP) to supply chain management (SCM) to manufacturing execution system (MES) to process control systems (PCS), and beyond.

The objective of this project is to develop a virtual learning factory that can track the usage, availability, inventory data and display them on an interactive touchscreen computer. This virtual factory will follow the exact layout of real-world factory with all sections such as warehouse, computer room, lecture room, 3D printer room, and the machining shop. Sensor data from machines, human beings, materials, robots will be displayed on the touchscreen monitor. The dashboard design should include (1) digital performance management, (2) real-time sensing, (3) inventory management, (4) machine management, (5) data analytics and so on. This project will provide a virtual control room for the real-world learning factory. The final results should include both the system and some preliminary data. The data gathering process should start partway through the semester. Based on the preliminary data, the teams will iterate and improve upon their design through the following phases, i.e., Design and Spec System, Prototype System, Re-design / Modify System, Install Final System, Evaluate Final System.
Company Name ProjecttTitle Faculty Contact BME CHE CMPEN CMPSC ED EE ESC IE MATSE ME NUCE
Siemens Industry, Inc. 3 Internet of Things for Operations Management of Additive Manufacturing Lab Bilen, Lennart 0 0 1 2 0 3 0 3 0 3 0

Non-Disclosure Agreement: NO

Intellectual Property: NO

Modern manufacturing industry is investing in new technologies such as the Internet of Things (IoT), big data analytics, cloud computing and cybersecurity to cope with system complexity, increase information visibility, improve production performance, and gain competitive advantage in the global market. These advances are rapidly enabling a new generation of smart manufacturing, i.e., a cyber-physical system tightly integrating the manufacturing enterprise in the physical world with the virtual enterprise in cyber space. Smart manufacturing goes beyond the automation of manufacturing shop floors but rather depends on data-driven innovations to realize high levels of autonomy and optimization of manufacturing enterprises. There is an urgent need to digitally integrate the manufacturing enterprise, which can be extended from enterprise resource planning (ERP) to supply chain management (SCM) to manufacturing execution system (MES) to process control systems (PCS), and beyond.

The objective of this project is to develop an IoT vibration sensing system that can be attached to a 3D printer to monitor the on/off period of the machine. This IoT sensing system will include the vibration sensor module, the Arduino controller board, the Arduino Yun shield, and a cloud platform. When the 3D printer is on for job processing, the vibration sensor module will generate the output of “1”. If the 3D printer is off, it will give an output of “0”. This IoT sensing system will monitor each 3D printer in real time, provide utilization statistics for a specific period (e.g., weekly, monthly, or yearly), and then displayed such information in the web or mobile app upon query. The final results should include both the system and some preliminary data. The data gathering process should start partway through the semester. Based on the preliminary data, the teams will iterate and improve upon their design through the following phases, i.e., Design and Spec System, Prototype System, Re-design / Modify System, Install Final System, Evaluate Final System.
Company Name ProjecttTitle Faculty Contact BME CHE CMPEN CMPSC ED EE ESC IE MATSE ME NUCE
Siemens Industry, Inc. 4 Virtual Learning Factory Verbanec, Alan 0 0 3 1 0 3 0 2 0 3 0

Non-Disclosure Agreement: NO

Intellectual Property: NO

Modern manufacturing industry is investing in new technologies such as the Internet of Things (IoT), big data analytics, cloud computing and cybersecurity to cope with system complexity, increase information visibility, improve production performance, and gain competitive advantage in the global market. These advances are rapidly enabling a new generation of smart manufacturing, i.e., a cyber-physical system tightly integrating the manufacturing enterprise in the physical world with the virtual enterprise in cyber space. Smart manufacturing goes beyond the automation of manufacturing shop floors but rather depends on data-driven innovations to realize high levels of autonomy and optimization of manufacturing enterprises. There is an urgent need to digitally integrate the manufacturing enterprise, which can be extended from enterprise resource planning (ERP) to supply chain management (SCM) to manufacturing execution system (MES) to process control systems (PCS), and beyond.

The objective of this project is to develop a virtual learning factory that can track the usage, availability, inventory data and display them on an interactive touchscreen computer. This virtual factory will follow the exact layout of real-world factory with all sections such as warehouse, computer room, lecture room, 3D printer room, and the machining shop. Sensor data from machines, human beings, materials, robots will be displayed on the touchscreen monitor. The dashboard design should include (1) digital performance management, (2) real-time sensing, (3) inventory management, (4) machine management, (5) data analytics and so on. This project will provide a virtual control room for the real-world learning factory. The final results should include both the system and some preliminary data. The data gathering process should start partway through the semester. Based on the preliminary data, the teams will iterate and improve upon their design through the following phases, i.e., Design and Spec System, Prototype System, Re-design / Modify System, Install Final System, Evaluate Final System.
Company Name ProjecttTitle Faculty Contact BME CHE CMPEN CMPSC ED EE ESC IE MATSE ME NUCE
SPHERES Consulting, LLC Design of an adjustable, offset mass golf swing trainer. Belegundu, Ashok 0 0 0 0 2 0 0 0 0 1 0

Non-Disclosure Agreement: NO

Intellectual Property: YES

Swing Trainer
One of the most critical skills in golf is the ability to hit a golf ball a long distance in the desired direction. This requires a combination of high club speed while maintaining the appropriate orientation of the club face. There is a plethora of swing trainers in the market today that are designed to improve club speed; of those, at least two (http://velocityshaft.com/ and https://superspeedgolf.com/news/) are designed to take advantage of scientifically proven principles to help improve swing speed. Golf instructors have noted that these trainers often do result in an increase in club speed; however, they also tend to result in a decreased ability to control the club face, thereby creating poor direction control and an overall decrease in shot quality.
The likely cause lies in the design of these trainers. The existing trainers on the market have a mass that is centered about the shaft. An actual golf club has a head that is roughly perpendicular to the shaft, thus shifting the center of mass away from the center of the shaft. The goal of this project is to design a swing trainer that better represents the mass properties of a golf club so that it creates increased club speed while maintaining the ability to control the orientation of the club face.
Design specifics:
Previous work has assumed a standard length driver shaft. This project will specifically utilize a shorter shaft so the trainer can be used indoors.
A proposed design is included. The team is encouraged to improve upon that design as needed.
Specific attention must be given to the attachment method (e.g. spring loaded pins) to make for an easy user experience.

Deliverables:
1. Computer design of a swing trainer that fulfills the overall mass requirements while mimicking the offset mass of an actual club.
2. Specifications of design, including dimensions, mass, material, and attachment systems.
3. Working prototype of proposed swing trainer.
Company Name ProjecttTitle Faculty Contact BME CHE CMPEN CMPSC ED EE ESC IE MATSE ME NUCE
Sustainable Health Enterprises (SHE) Banana Fiber Extractor Redesign for Sanitary Napkin Production DeMeter, Ed 3 0 0 0 3 0 0 1 3 2 0

Non-Disclosure Agreement: NO

Intellectual Property: NO

18% of women and girls in Rwanda missed out on work or school last year because they could not afford to buy menstrual pads. The social enterprise SHE (Sustainable Health Enterprises) has developed a patented process to turn banana fiber into absorbent sanitary pads to meet the needs of women and girls in Rwanda and beyond. Many machines exist to extract fibers from banana fibers and all have relatively similar designs and preparation requirements for the stem. While existing machines are generally effective for fibers for crafting or that will see significant chemical or mechanical post processing, extraction of good quality fibers for absorption requires additional, time consuming and resource intensive steps. SHE is in need of a new extractor to design which can process fibers just as quickly, while maintaining the necessary quality. The capstone team will be responsible for the design of a new extractor to increase the output of the machine by 4x, while maintaining quality. Furthermore, the design should be adaptable to enable extraction of fiber from other similarly, sized sources of regional agrowaste (ie Corn stover, Pineapple leaf, Jute, Sisal). The work will inform manufacturing specifications for the new extractor and may be featured a news article on Engineering for Change.
Company Name ProjecttTitle Faculty Contact BME CHE CMPEN CMPSC ED EE ESC IE MATSE ME NUCE
The Boeing Company 1 Search and Rescue System Design Wang, Qian 0 0 3 0 0 2 0 0 0 1 0

Non-Disclosure Agreement: NO

Intellectual Property: NO

The Boeing Company and Sikorsky, a Lockheed Martin Company, will partner to challenge four teams composed of Mechanical, Electrical, and Computer Engineers to design, build, and test unmanned vehicles capable of interfacing to complete a simulated search and rescue mission. The goal of this project is to demonstrate the power of collaboration at industry, workforce, and system levels.

Over the past ten years, the National Park Service has reported search and rescue missions numbering anywhere from 2430 to 5761 missions per year with 119 to 244 associated fatalities. Each year, the majority of these missions are to retrieve hikers. As a result, the National Park Service has invested in unmanned-vehicle technology to help find and rescue those lost or hurt in the wilderness. Additionally, unmanned systems are used after natural disasters to aid disaster relief and emergency response (DRER) services, such as Search and Rescue (SAR) operations. Unmanned systems can increase mission success by providing rapid deployment, access to human denied environments, and increased situational awareness to SAR operators.

By leveraging their expertise, the aerospace industry is helping to develop optimized systems focused on pairing unmanned air and ground vehicles. For example, a long-range drone is often incapable of navigating areas an all-terrain rover is better suited for, and vice-versa. Interfacing these vehicles into a collaborative system has proven to extend rescue capabilities.

Additionally valuable to system interoperability is workforce collaboration. In the current industrial environment, it is becoming an increasingly common industry practice for companies to partner and leverage complementing skills for a competitive advantage. For example, the Sikorsky-Boeing SB-1 Defiant is a medium-lift-sized aircraft entry for the United States Army’s Future Vertical Lift program. Given their large industrial base and their track-record in transport helicopter designs, this joint team is seen to have an advantage over other submissions. By combining “the best of both worlds,” Boeing and Sikorsky can offer a very impressive solution.

Similarly, two teams of students will work collaboratively to design, build, test, and demonstrate an unmanned search and rescue system consisting of an aerial vehicle (UAV) and a ground vehicle (UGV). One team will develop the unmanned aerial vehicle (UAV), responsible for delivering the UGV to the mission site, providing aerial surveillance of the UGV, and retrieving the UGV to return to base. Another team will develop the deployable, unmanned ground vehicle (UGV), responsible for navigating the search site, rescuing survivors, and returning to the extraction site for UAV extract. By employing systems engineering principles, both teams will collectively design the interfacing components and functions to produce a fully integrated solution. These two teams will collaborate to compete against another UGV+UAV two-team pairing.

Sikorsky, a Lockheed Martin Company, will employ a team of electrical and mechanical engineers to develop a UAV capable of delivering the UGV to the mission site and providing sensor data to the operator. Mechanical engineers will be responsible for the structural components of the UAV, including frame, flight components, and UGV delivery mechanism. Electrical engineers will focus on the software and programming, including flight controls, sensor integration, and pilot interface development. To complete the mission system, the Sikorsky UAV team will partner with a Boeing UGV team. This pairing will compete against another UAV+UGV two-team pairing.

The Boeing Company will employ three teams of electrical and mechanical engineers to develop two UGV’s and one UAV. The mechanical engineers will be responsible for structural, dynamic, and functional components, whereas the electrical engineers will focus on the power, programming, and piloting of the vehicles. One of the Boeing UGV teams will partner with the Sikorsky UAV team to compete against the remaining Boeing UAV and UGV teams.

The teams will demonstrate their systems capabilities to Boeing and Sikorsky sponsors at the end of the semester, on the day of the Learning Factory Showcase, by completing a mock Search and Rescue (SAR) mission. The Sikorsky+Boeing pairing will compete against the Boeing+Boeing pairing to determine which teams have developed the best system for the intended mission.

Blue 1 = Sikorsky, Drone
Blue 2 = Boeing, Rover
White 1 = Boeing, Drone
White 2 = Boeing, Rover
Company Name ProjecttTitle Faculty Contact BME CHE CMPEN CMPSC ED EE ESC IE MATSE ME NUCE
The Boeing Company 2 Search and Rescue System Design Wang, Qian 0 0 3 0 0 2 0 0 0 1 0

Non-Disclosure Agreement: NO

Intellectual Property: NO

The Boeing Company and Sikorsky, a Lockheed Martin Company, will partner to challenge four teams composed of Mechanical, Electrical, and Computer Engineers to design, build, and test unmanned vehicles capable of interfacing to complete a simulated search and rescue mission. The goal of this project is to demonstrate the power of collaboration at industry, workforce, and system levels.

Over the past ten years, the National Park Service has reported search and rescue missions numbering anywhere from 2430 to 5761 missions per year with 119 to 244 associated fatalities. Each year, the majority of these missions are to retrieve hikers. As a result, the National Park Service has invested in unmanned-vehicle technology to help find and rescue those lost or hurt in the wilderness. Additionally, unmanned systems are used after natural disasters to aid disaster relief and emergency response (DRER) services, such as Search and Rescue (SAR) operations. Unmanned systems can increase mission success by providing rapid deployment, access to human denied environments, and increased situational awareness to SAR operators.

By leveraging their expertise, the aerospace industry is helping to develop optimized systems focused on pairing unmanned air and ground vehicles. For example, a long-range drone is often incapable of navigating areas an all-terrain rover is better suited for, and vice-versa. Interfacing these vehicles into a collaborative system has proven to extend rescue capabilities.

Additionally valuable to system interoperability is workforce collaboration. In the current industrial environment, it is becoming an increasingly common industry practice for companies to partner and leverage complementing skills for a competitive advantage. For example, the Sikorsky-Boeing SB-1 Defiant is a medium-lift-sized aircraft entry for the United States Army’s Future Vertical Lift program. Given their large industrial base and their track-record in transport helicopter designs, this joint team is seen to have an advantage over other submissions. By combining “the best of both worlds,” Boeing and Sikorsky can offer a very impressive solution.

Similarly, two teams of students will work collaboratively to design, build, test, and demonstrate an unmanned search and rescue system consisting of an aerial vehicle (UAV) and a ground vehicle (UGV). One team will develop the unmanned aerial vehicle (UAV), responsible for delivering the UGV to the mission site, providing aerial surveillance of the UGV, and retrieving the UGV to return to base. Another team will develop the deployable, unmanned ground vehicle (UGV), responsible for navigating the search site, rescuing survivors, and returning to the extraction site for UAV extract. By employing systems engineering principles, both teams will collectively design the interfacing components and functions to produce a fully integrated solution. These two teams will collaborate to compete against another UGV+UAV two-team pairing.

Sikorsky, a Lockheed Martin Company, will employ a team of electrical and mechanical engineers to develop a UAV capable of delivering the UGV to the mission site and providing sensor data to the operator. Mechanical engineers will be responsible for the structural components of the UAV, including frame, flight components, and UGV delivery mechanism. Electrical engineers will focus on the software and programming, including flight controls, sensor integration, and pilot interface development. To complete the mission system, the Sikorsky UAV team will partner with a Boeing UGV team. This pairing will compete against another UAV+UGV two-team pairing.

The Boeing Company will employ three teams of electrical and mechanical engineers to develop two UGV’s and one UAV. The mechanical engineers will be responsible for structural, dynamic, and functional components, whereas the electrical engineers will focus on the power, programming, and piloting of the vehicles. One of the Boeing UGV teams will partner with the Sikorsky UAV team to compete against the remaining Boeing UAV and UGV teams.

The teams will demonstrate their systems capabilities to Boeing and Sikorsky sponsors at the end of the semester, on the day of the Learning Factory Showcase, by completing a mock Search and Rescue (SAR) mission. The Sikorsky+Boeing pairing will compete against the Boeing+Boeing pairing to determine which teams have developed the best system for the intended mission.

Blue 1 = Sikorsky, Drone
Blue 2 = Boeing, Rover
White 1 = Boeing, Drone
White 2 = Boeing, Rover
Company Name ProjecttTitle Faculty Contact BME CHE CMPEN CMPSC ED EE ESC IE MATSE ME NUCE
The Boeing Company 3 Search and Rescue System Design Bilen, Lennart 0 0 3 0 0 2 0 0 0 1 0

Non-Disclosure Agreement: NO

Intellectual Property: NO

The Boeing Company and Sikorsky, a Lockheed Martin Company, will partner to challenge four teams composed of Mechanical, Electrical, and Computer Engineers to design, build, and test unmanned vehicles capable of interfacing to complete a simulated search and rescue mission. The goal of this project is to demonstrate the power of collaboration at industry, workforce, and system levels.

Over the past ten years, the National Park Service has reported search and rescue missions numbering anywhere from 2430 to 5761 missions per year with 119 to 244 associated fatalities. Each year, the majority of these missions are to retrieve hikers. As a result, the National Park Service has invested in unmanned-vehicle technology to help find and rescue those lost or hurt in the wilderness. Additionally, unmanned systems are used after natural disasters to aid disaster relief and emergency response (DRER) services, such as Search and Rescue (SAR) operations. Unmanned systems can increase mission success by providing rapid deployment, access to human denied environments, and increased situational awareness to SAR operators.

By leveraging their expertise, the aerospace industry is helping to develop optimized systems focused on pairing unmanned air and ground vehicles. For example, a long-range drone is often incapable of navigating areas an all-terrain rover is better suited for, and vice-versa. Interfacing these vehicles into a collaborative system has proven to extend rescue capabilities.

Additionally valuable to system interoperability is workforce collaboration. In the current industrial environment, it is becoming an increasingly common industry practice for companies to partner and leverage complementing skills for a competitive advantage. For example, the Sikorsky-Boeing SB-1 Defiant is a medium-lift-sized aircraft entry for the United States Army’s Future Vertical Lift program. Given their large industrial base and their track-record in transport helicopter designs, this joint team is seen to have an advantage over other submissions. By combining “the best of both worlds,” Boeing and Sikorsky can offer a very impressive solution.

Similarly, two teams of students will work collaboratively to design, build, test, and demonstrate an unmanned search and rescue system consisting of an aerial vehicle (UAV) and a ground vehicle (UGV). One team will develop the unmanned aerial vehicle (UAV), responsible for delivering the UGV to the mission site, providing aerial surveillance of the UGV, and retrieving the UGV to return to base. Another team will develop the deployable, unmanned ground vehicle (UGV), responsible for navigating the search site, rescuing survivors, and returning to the extraction site for UAV extract. By employing systems engineering principles, both teams will collectively design the interfacing components and functions to produce a fully integrated solution. These two teams will collaborate to compete against another UGV+UAV two-team pairing.

Sikorsky, a Lockheed Martin Company, will employ a team of electrical and mechanical engineers to develop a UAV capable of delivering the UGV to the mission site and providing sensor data to the operator. Mechanical engineers will be responsible for the structural components of the UAV, including frame, flight components, and UGV delivery mechanism. Electrical engineers will focus on the software and programming, including flight controls, sensor integration, and pilot interface development. To complete the mission system, the Sikorsky UAV team will partner with a Boeing UGV team. This pairing will compete against another UAV+UGV two-team pairing.

The Boeing Company will employ three teams of electrical and mechanical engineers to develop two UGV’s and one UAV. The mechanical engineers will be responsible for structural, dynamic, and functional components, whereas the electrical engineers will focus on the power, programming, and piloting of the vehicles. One of the Boeing UGV teams will partner with the Sikorsky UAV team to compete against the remaining Boeing UAV and UGV teams.

The teams will demonstrate their systems capabilities to Boeing and Sikorsky sponsors at the end of the semester, on the day of the Learning Factory Showcase, by completing a mock Search and Rescue (SAR) mission. The Sikorsky+Boeing pairing will compete against the Boeing+Boeing pairing to determine which teams have developed the best system for the intended mission.

Blue 1 = Sikorsky, Drone
Blue 2 = Boeing, Rover
White 1 = Boeing, Drone
White 2 = Boeing, Rover
Company Name ProjecttTitle Faculty Contact BME CHE CMPEN CMPSC ED EE ESC IE MATSE ME NUCE
The Boeing Company 4 Boeing Commercial Airplanes Additive Manufacturing Crush Cartridge Project Belegundu, Ashok 0 0 0 0 3 0 0 3 2 1 0

Non-Disclosure Agreement: NO

Intellectual Property: YES

Boeing will challenge a team of engineers and material scientists to design and produce a crush cartridge using additive manufacturing (AM).

Commercial airplanes have stretched in length as Boeing stretches to accommodate more passengers and improve efficiency. With the physical length of fuselages increasing, “tail skids” have been added to the longer Boeing variants to keep the tail from striking the ground during takeoff and landing and damaging the structure. Currently, the tail skid assembly has a machined aluminum crush cartridge that must be inspected and replaced after a tail strike occurs. These parts are important, as they react applied load by absorbing energy as they crush, but they are expensive.

The goal of this project is that the team will design, produce, and test an AM part that could replace the traditional expensive machined aluminum crush cartridge. The students will need to educate themselves on lattice structures, crush cartridges, and metallic additive manufacturing to complete this project.

Students will experiment with different lattice structures and materials to create a final product that can absorb large amounts of force.

The students will work with professors and the CIMP-3D lab to design, build, and test their structure.

Intellectual Property will be retained by Boeing.
Company Name ProjecttTitle Faculty Contact BME CHE CMPEN CMPSC ED EE ESC IE MATSE ME NUCE
The Innovation Machine The Productivity Pod Cannon, Dave 0 0 0 2 3 0 0 1 0 0 0

Non-Disclosure Agreement: YES

Intellectual Property: YES

The number of coworking spaces continue to grow exponentially each year. Due to the portability of ‘digital work’, this trend will continue for the foreseeable future. Many coworking spaces and modern workplaces have implemented “open” floor plans that are said to foster collaboration. While fine for collaborative work, the open floor plan is often distracting and unproductive when focused work needs to be accomplished.

Our project team will solve this problem by researching, designing, and manufacturing a portable ‘Productivity Pod’. Ergonomic needs will be researched and implemented to ensure the highest level of productivity for knowledge workers that perform CAD, CAM, or CAE modeling. User testing will be performed in one of Chicago’s largest coworking spaces to elicit user feedback (travel not required). Productivity Pod sensors will provide continuous feedback to improve Productivity Pod design, performance, and user satisfaction.

A project plan, team website, and weekly deliverables be used to reinforce new product development discipline and project deadlines. Student team members will be mentored by experts in new product development, market research, industrial design, CAD modeling, CAE modeling, and IoT app development. Deliverables include:

Competitive Product / IP Review
Requirements Document
Concept Drawings
CAD Model /BOM
CAE (Simulation) Model
PTC Thingworx App
Physical Prototype
User Testing
Company Name ProjecttTitle Faculty Contact BME CHE CMPEN CMPSC ED EE ESC IE MATSE ME NUCE
The Timken Company 1 Design and Development of a Wireless Force Monitoring Device for Hard Turning Tools Manogharan, Guha 0 0 3 0 0 2 0 0 0 1 0

Non-Disclosure Agreement: YES

Intellectual Property: YES

Hard turning refers to finish machining process of axially symmetric components like bearings, shafts, gears, etc. after heat treatment (HRC>50). Hard turning is a process that is commonly adopted in low volume finishing of bearing races.

During hard turning of bearing races, monitoring of the cutting tool for excessive wear or damage is critical as a worn/damaged tool can cause thermal damage leading to early failure of bearings. To hedge against this risk, typically a tool life limit in terms of cutting time/distance is specified after which the tool is pulled out of operation. This cutting time/distance is usually empirically established based on numerous cutting tests in a controlled environment where tool wear characteristics such as cutting forces, flank wear, crater wear, etc are monitored. While this approach safeguards against excessive wear of the tool causing thermal damage, the risk of tool fracture or failure due to defective manufacturing of tools, operational errors or other process variability remains. Often times it is incumbent on the machine operator to monitor for tool failure based on certain telltale signs such as excessive spindle power consumption or rough surface finish on a finished component, etc.

Real-time in-process monitoring of hard turning force would be an ideal diagnostic tool since both tool wear and damage correlates directly with an increase in cutting force and a threshold of cutting force can be established to alert the operator for tool change and prevent part damage. However, current commercially available cutting force monitors are expensive, bulky, hard wired and/or tool specific, thus restricting applications only to laboratory environments for controlled cutting tests.

The challenge for the project team would be to design and develop an economical cutting force monitor that is generic such that it can be interchangeably employed with OD or ID turning tools in real time turning applications. The cutting force monitor has to be compact with capability to transmit data wirelessly to a data acquisition system outside the machine. The components of the wireless force monitor also need to be protected from dust and liquid contamination to a minimum of IP66 rating. The device should be capable of measuring up to a minimum of 5kN force in single or multiple components (Normal, Tangential and Axial Cutting Force) with a minimum response time and data acquisition frequency of 150Hz. The project team will be tasked with the design, development and building a prototype of this wireless force monitor and demonstrating reliable monitoring and data acquisition capability by means of turning trials.
Company Name ProjecttTitle Faculty Contact BME CHE CMPEN CMPSC ED EE ESC IE MATSE ME NUCE
The Timken Company 2 Artificial intelligence approaches as solutions to vision inspection for rollers. Verbanec, Alan 0 0 2 1 0 0 0 0 0 0 0

Non-Disclosure Agreement: NO

Intellectual Property: YES

Explore artificial intelligence approaches as solutions to vision inspection needs for rollers. Specifically, the students will receive tagged images of rollers (both good and bad) and must be able to design, train, and implement a neural network to detect visual defects and identify the type of defect and its location within the image. A metric for success will be achieving greater than 95% accuracy with less than 1 second processing time.

The purpose of this project is to learn whether artificial intelligence methods are usable to enable simpler training approaches and whether they can reduce the need for custom filter development. More details will be provided later.
Company Name ProjecttTitle Faculty Contact BME CHE CMPEN CMPSC ED EE ESC IE MATSE ME NUCE
Tioga Tae Kwon Do Automated Material Recycling Machine Wheeler, Timothy 0 0 3 0 0 1 0 3 0 2 0

Non-Disclosure Agreement: NO

Intellectual Property: NO

Tioga Tae Kwon Do (TTKD) is a small, family-owned martial arts school located in Waverly, NY. In addition to the typical martial arts training, the school focuses on community, character, and education.

Throughout the year, a typical practice in many forms of martial arts is to break boards during demonstrations, test events, and technique training. TTKD breaks on average 4,000 - 5,000 boards per year, which in turn produces a significant amount of "waste" material. In the last couple years, TTKD has started breaking the broken boards into small "sticks" and bundling into bags to be used as kindling. Recycling/reselling these boards as kindling helps in offsetting the costs of the raw materials and increases the overall profitability of major events, specifically fundraisers for the TTKD Academic Excellence Program and TTKD Academic Scholarship Program.

To date, the process of breaking the boards into kindling is done manually using a hatchet. The primary goal of this project is to create an automated machine that will serve three primary purposes:
(1) Improve ergonomics and reduce overall physical activity required for creating kindling
(2) Improve process for bagging kindling as it is created
(3) Improve time required for cutting and bagging kindling

The machine should be portable and desktop operable. It should include safety interlocks where necessary and operate via pneumatic and/or standard 120V, 20A electric. It is preferred that the machine have an auto-feed and auto-bundle mechanism. If an auto-bundle mechanism is designed, it should also display the overall weight of the bundle.
Company Name ProjecttTitle Faculty Contact BME CHE CMPEN CMPSC ED EE ESC IE MATSE ME NUCE
Trinity Capital Ventures, LLC BBQ Caddie Cannon, Dave 0 0 0 0 3 0 0 1 0 2 0

Non-Disclosure Agreement: YES

Intellectual Property: YES

This is a recreational product designed to be a portable stand to be utilized for outdoor grilling (tailgating for all sports) and gardening (patio plant stand for herb pots, etc.). A prototype has been constructed (which will be provided to the students as a starting point), and has received a U.S. Design patent #D785981D. The product should be reviewed to enhance the aesthetics, with the goal of refining the existing product into a high-end product as cost effectively as possible. It should be simple, yet elegant and exquisitely functional, and pleasing to the eye, available in team colors and other unique enhancements (think NASCAR, etc.) attractive to the user.
Company Name ProjecttTitle Faculty Contact BME CHE CMPEN CMPSC ED EE ESC IE MATSE ME NUCE
Volvo Construction Equipment North America, LLC Active Vibration Isolation of a Compactor Erdman, Michael 0 0 0 0 3 3 1 0 0 2 0

Non-Disclosure Agreement: NO

Intellectual Property: YES

Overview:

Ride-On Vibratory Compactors for soil and asphalt are used for road construction and other related construction projects. The large steel drums of these compactors are caused to vibrate via a centrifugal mechanism, resulting in large dynamic forces which greatly enhance the compaction efficiency. Even though the vibrating drums have rubber isolators as the connection to the frame of the compactor, significant cyclic forces are still transmitted to the frame. This results in vibration-related failures of parts of the machine, discomfort for the operator, and excessive noise. Thus, more vibration isolation between the vibrating drums and the frame of the machine is desirable.

The current rubber isolators can be termed a "passive" method of vibration isolation. Volvo has a recent patent (US 9,951,482 B2) for an "active" method to reduce the vibration of the frame. That method is to impose forces on the frame via additional centrifugal mechanisms that offset the forces coming from the vibrating drum through the rubber isolators. The purpose of this Capstone Project is to analytically model and simulate this design to evaluate its effectiveness. (A future Capstone project is planned to take the analysis results and build a bench scale model to obtain test data.)

The main thing to design and simulate is a bench scale model (or models) that could be used to experimentally demonstrate this idea. It is up to the team to pick what analysis method(s) to use. Possibilities are finite element analysis, multibody dynamics, AmeSim-type modeling, hand calculations, other methods, or a combination of these. The simulation would have to show the dynamic behavior. A previous Capstone project designed a scale model of the drum part of the compactor, and that could be used as a starting point for the complete model that includes the frame, mounting system, and eccentric system.

For a stretch goal, an analytical model of a full-scale compactor could be developed, thus predicting the effectiveness of this idea at that level. This could be done “from scratch,” or an existing finite element model from Volvo could be used as a starting point, to which this idea would have to be added.

Deliverables:

• Design of a scale model (or models) of something similar to a compactor that can be used to demonstrate the vibration of the frame both with and without this idea.
• Simulation of the dynamics of the model(s). Simulation method is up to the team, but FEA (finite element analysis) or MBD (multibody dynamics) are suggested.
• A sensitivity study showing which aspects of the design of this idea are more critical to the effectiveness.
• For a stretch goal, create a simulation model of one of Volvo’s compactors that includes this idea. This can be done completely by the team, or they can start with an existing model at Volvo, to which this idea would have to be added.
Company Name ProjecttTitle Faculty Contact BME CHE CMPEN CMPSC ED EE ESC IE MATSE ME NUCE
Washington Suburban Sanitary Commission Wireless Valve Position Indicator Belegundu, Ashok 0 0 0 0 0 2 0 0 0 1 0

Non-Disclosure Agreement: NO

Intellectual Property: YES

The Washington Suburban Sanitary Commission (WSSC) is a bi-county, public utility in Maryland that was established in 1918. For 100 years, WSSC has served the communities of Prince George’s and Montgomery counties providing life-sustaining water and water resource recovery services to individuals, families and businesses.

The WSSC water distribution system is comprised of many pressure zones controlled by isolation valves. Proper positioning of these valves play a critical role in the operation of the distribution system. Isolation valves inadvertently left in an incorrect position can cause issues within the system such as difficulty balancing flow and pressure as well as unwanted draining of water standpipes and towers. Position indication of critical valves such as isolation valves is needed, not only at the valve box but also remotely via wireless communication.

In order to monitor and indicate the position of critical valves, a retrofit valve monitoring devise needed within a valve box. The devise will provide visual indication of the valves position once the valve box cover has been removed. The position of the valve will also interface with WSSC via cellular and SCADA networks. The team will develop the concept, create the design and produce a prototype to fit within a valve box without modification to the existing valve or valve box.
Company Name ProjecttTitle Faculty Contact BME CHE CMPEN CMPSC ED EE ESC IE MATSE ME NUCE
Zero Odor Company, LLC Automatic spray unit Erdman, Michael 0 0 3 0 0 2 1 0 3 0 0

Non-Disclosure Agreement: YES

Intellectual Property: YES

Design and build an automatic spray unit that sprays periodically based upon input/motion (more info will be explained) similar but not the same as products offered by airwick and lysol.
 
 

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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