Fall 2016 Senior Design Expo

Date Published: 
December 13, 2016

The William States Lee College of Engineering held its fall semester Senior Design Expo on Dec. 9, 2016. Thirty teams presented their completed two-semester projects, and 50 teams presented their first-semester design-concept posters. A photo gallery of the winners and the Expo is here.

The three completed projects judged to be the best were:

First Place - Ingersoll Rand Pneumatic Pump Energy Harvesting Unit
Team Members:
Patrick Dodd (MEGR), Dakota Kiser (ECE), Brian Barefoot (ELET), Corbin Grohol (MEGR), Sam Ludwig (MEGR), and Mitchell Rutledge (MEGR)
Mentor: Dr. Steve Patterson, Mechanical Engineering and Engineering Science
Project Supporter: Ingersoll Rand
Project Overview:
The objective of this project was to design and prototype a muffler for an Ingersoll Rand ARO pneumatic diaphragm pump that contains an energy harvesting, conditioning, and storage system for the purpose of powering an ARO pump controller. The Energy Harvesting Unit (EHU) muffler eliminates the need to run electricity to difficult to reach locations where the ARO pump and controller may be operating. While the pump is in operation, the EHU generates electricity (24 VDC) from the ARO pump compressed air exhaust by spinning a turbine-generator assembly and is capable of producing 30 W of electrical power. When the pump is inactive, the EHU is also capable of storing power to support the ARO controller in standby mode (100 mA) for 30 minutes. The EHU requires 2.5 hours of pump run time to completely recover from 30 minutes of standby mode battery drain. The EHU utilizes a 3D printed housing, exhaust ducting, turbine, and turbine shroud showcasing the capabilities of ABS plastic and Poly Carbonate rapid prototyping technology. The turbine-generator assembly reaches speeds up to 12,000 rpm and the EHU incorporates a control system to maintain turbine speed by adjusting the battery charge current, modifying the electrical load on the generator.

Second Place - Production of Tool Post for Diamond Micro-Chiseling of Retroreflectors
Team Members:
Nicholas Sizemore (ME), Dustin Gurganus (ME), Joshua Conde (ME), Pierre Jean (EET)
Mentors: Dr. Matthew Davies and Dr. Joseph Owen, Mechanical Engineering and Engineering Science
Project Supporter: ORAFOL
Project Overview:
The objective of this project was to design and manufacture a multi-axis rotational diamond micro-chiseling (DMC) tool-post with on-machine metrological capabilities. This on-machine metrological system comprises of a removable microscopy system and a dynamic force measurement system. The work associated with this project includes initial research, CAD modeling, structural analysis, vibrational analysis, and fabrication of the tool-post. The tool-posts capabilities are tested on the Moore Nanotechnology 350FG machine, which validates the functionality of the dynamic force measurement system, and its ability to produce diamond micro-chiseled microstructures. DMC is a non-traditional method of tool path operations that require high precision movements and multi-axis control. The purpose of constructing this tool-post for DMC is to produce retroreflective microstructures for light management.

Third Place - Sealed Air Box Scanner
Team Members:
Wissam Bawab (MEGR), John Hickner (MEGR), Jose Munoz (MEET) and Jeremy Nelson (EEGR)
Mentor: Dr. Steven Patterson, Mechanical Engineering
Project Supporter: Sealed Air
Project Overview:
The goal of this project was to find the optimum method of scanning packages to calculate the non-occupied volume by objects within a package. Currently there’s no economical method of scanning a package to calculate the void volume. Sealed Air asked the team to develop a way to scan the void volume in packages ranging from 8”x 8”x 8” to 20” x 20” x 20” and capable at a speed of 65fpm. The UNC Charlotte team used an IFM O3D Smart Sensor (photonic mixer device) as the scanner and used of software development kits to developed an algorithm in Linux system to calculate void volume. Testing consisted of testing various size packages, non-orthogonal packages, and passing packages under scanner. A fully functional scanner will display the void volume on a display and will be delivered to Sealed Air at the completion of the project.