Capstone Design Program: Mechanical Engineering

Zero Insertion-Force Contact for a DC/DC Converter

Jeffrey Alvord et al. — Thu, 17 Dec 2009 16:28:46 PST

The purpose of this project is to find a mechanism that will allow for zero, or low, insertion force (ZIF) contact for a DC/DC converter pins into a burn in test board.

Web Handler Project

Jeff Cadle et al. — Thu, 17 Dec 2009 16:28:44 PST

Our group has been chosen to pursue and develop a Tape-Looper project, sponsored by Pr. Sinan Muftu. The goal of this project is to develop a system for experiementally testing recording heads, rollers, and posts, as well as various media types. The expectations for the final deliverable systems include an extensive depth of configurability, a wide rage for web speed and tension, a data acquisition and feedback control system, accommodation for varied web widths, as well as the elimination of any sources of error.

Vision System for Metal Film Metrology Tool

Jason LaTour et al. — Thu, 17 Dec 2009 16:28:44 PST

The integrated circuit fabrication industry requires a nondestructive inspection method that can measure three dimensional features etched in thin metal films on silicon wafers. Accurately measuring the thickness of these metal films to angstrom repeatability was a problem that industry had struggled with for decades. Current processes can only destructively measure blank or unetched wafers. This results in the disposal of millions of dollars worth of blank wafer each year. A thin film metrology tool, known as the Impulse 300 (TM) from Philips Analytical, uses a nondestructive laser based method of measuring thin metal films on blank wafers. The instrument is capable of measuring etched wafers, however it has no way of pinpointing the various features on etched wafers. This report presents a detailed engineering solution for a vision system that has been retrofitted into the existing Impulse 300 (TM).

Usable Cell Phone Design

Michael Jenkins et al. — Thu, 17 Dec 2009 16:28:43 PST

As cellular phone technology rapidly advances, users repeatedly find themselves overwhelmed by features that they never use or even desire. This over-complication frequently occurs because the needs of the end users are often ignored in the early stages of the design process. Through an online survey (N=650+) and usability study (N=17), six distinct user profiles, or archetypes, were developed to represent cellular phone users. These profiles were quantitatively based on comfort with technology, experience with technology, and desire for features. An extensive market study found that most phones on the market today only meet the needs of three user profiles, this project focused on creating a phone to meet the needs of the three unrepresented user profiles. The design solution chosen to accommodate the specific needs of these diverse users was a modular system which utilized a common base chassis and interchangeable keypad and screen modules (see figure below). This system allows users to choose a relevant menu system with an accompanying keypad and screen to meet their needs without overcomplicating the device. The design strived to maximize comfort and performance based on user feedback for features including ease of assembly, hinge force, flip angle, keypad layout, and tactile feedback. These features were then analyzed and optimized for mechanical integrity and production feasibility. Initial user testing on the new menu design showed an average of 45.5% improvement completing basic tasks compared to the menu rated easiest to navigate in the previous usability study.

Transportable Incubator for Cell Culture

Corey T. Lindemann et al. — Thu, 17 Dec 2009 16:28:42 PST

The design team has developed a relatively lightweight mechanical device capable of transporting human cell cultures for multiple hours in a secure, stable environment. The incubator has the capability to constantly monitor and maintain the temperature of the cell culture environment. The system will regulate the proper gas mixture of the environment by adding a calculated amount of air or carbon dioxide, depending on whether the carbon dioxide reading is too high or low. In addition, the humidity of the chamber is kept at around 95 percent, and although this parameter will not be controlled, the user has the capability to monitor the percentage. When completed, the incubator will be able to transport one 24-well multi-well dish. Thus far, the project is in its final design stages and is at a point where the assembly phase will begin shortly. The report will discuss the specifications and beginning stages of the transportable incubator project. Such topics as existing products and patents will be discussed as well as the major challenges which were considered for the design. The final design of the incubator will be discussed in detail, assessing why certain choices were made during the planning stage.

Tree Limb Cutting Device

David Callaghan et al. — Thu, 17 Dec 2009 16:28:42 PST

Pruning tree branches that are higher than twelve feet from the ground is difficult with products available on the market today. Our goal is to create a device that can easily cut a three inch branch positioned 20 feet above ground and can be operated by the residential consumer.

Tissue Loading, Flow-Through Micro-Chamber for High Power Microscopic Observation

Aaron P. Desjarlais et al. — Thu, 17 Dec 2009 16:28:41 PST

Despite its ability to withstand extreme loads, connective collagenous tissue naturally degenerates due to age and pathology. The popularity of advanced modern medical procedures, such as Laser-Assisted in Situ Keratomileusis (LASIK) surgery, has caused a decline in usable corneal tissue. By applying a tensile load to artificial tissue while it is saturated in a sterile and organic environment, it is hypothesized that collagenous cells align and fibroblasts remodel the tissue in order to compensate for the stresses it undergoes. It is projected that the viable cells that are remodeled in this process will continue the advancement of tissue engineering and the availability of these tissues for transplants and other medical services. Due to the close specifications needed for such a sensitive application, and the lack of commercial devices that fall within the given specifications, the purpose of this project is to allow for loading of a tissue specimen while simultaneously viewing under high magnification. Objectives of this project are to avoid over-penetration of the chamber, accurately control the applied load, reduce the chamber volume, and to have a reliable way of heating the media and specimen. A number of approaches to this including a magnetic linear actuator, optical encoders, copper plates and thermocouples were researched and assessed in order to find an ideal design. Currently it has been determined that many off-the-shelf components fall within the given specifications, including a linear actuator, load cell, heating system, and components for grips. By incorporating these into a design appropriately sized for the Nikon TE2000E optical microscope, this provides a way to view the matrix remodeling and cell response while closely monitoring tensile loads throughout the process. Once the design is optimized to the point of being ideally operational, this apparatus will be available for many biomedical applications.

The Riveting Helper

Robert Gauthier et al. — Thu, 17 Dec 2009 16:28:40 PST

The project purpose is to design a device that allows one person to rivet large pieces of sheet metal. When riveting, the operator must hold both the riveting gun and the bucking bar at the correct distance from the work piece, with the forces in the axis of the rivet. Two people are needed if the work piece is too large for the operator to hold both the riveting gun and the bucking bar simultaneously. The Riveting Helper device will allow one person to rivet large pieces. This will be accomplished by having the Rivet Helper hold a bucking bar assembly in place while the riveter operates the riveting gun on the other side of the pieces being riveted. This device will be of practical size and accommodate rivet sizes between 1/16 in. and 5/32 in. The device will also notify the operator when to stop riveting based on the diameter of the rivet being used at a specific time. A prototype will be manufactured for a cost no greater than $750 (see Appendix B). The Riveting Helper can be broken down into three major design components, the bucking bar holder, the frame or positioning system, and the base. Current design paths will be discussed, followed by a description of future considerations and experiments, which will lead us toward a design that satisfies the specified criteria.

Thermally Controlled Syringe Pump

Mark Breneman et al. — Thu, 17 Dec 2009 16:28:40 PST

In the biological engineering and medical fields, there are many applications which utilize a syringe pump to dispense a measurable amount of fluid in a controlled manner. Presently, there are a multitude of syringe pumps on the market with functions ranging from variable flow rates, to infusion and withdrawal capabilities, to programmable dispensing plans. One capability not yet applied to syringe pumps is a controllable heating and cooling system. This report presents a proposal to create a working prototype of a syringe pump with a heating and cooling system.

The One-Armed Wine Bottle Opener

Jason Brown et al. — Thu, 17 Dec 2009 16:28:39 PST

The following report outlines the development of a device that will allow one-armed people, both and old, the ability to easily and safely open a bottle of wine.

The Golf Ball Detector

Asli Savran et al. — Thu, 17 Dec 2009 16:28:38 PST

The following document contains the final report for the Golf Ball Detector Senior Capstone Design Project. This Senior Capstone Design Group has proven the concept for a device to consistently locate golf balls. The golf ball detector is portable, easy to use, reliable, applicable in various situation and conditions, affordable to most golfers and safe for its user and the environment. The report discusses relevant background information on golf and golfers and presents the design developed by this Senior Capstone Design Group as a guide toward the solution. Preliminary researches on patent and existing alternatives are presented. Several preliminary design solutions that were eventually rejected are discussed in detail. After rejecting the earlier proposals, the design group decided to pursue the implantation of radio-frequency identification equipment within the ball as a solution. It has been shown that the RFID tag can still receive and transmit signals from inside a golf ball, that a passive RFID tag can survive the impact of a golf club from inside a ball, and that the addition of the tag does not significantly disrupt the physical properties of the golf ball. An RFID kit with suitable range is not currently available to the design group, but future advancements in RFID technology will complete the long range golf ball locator. In addition to locating lost balls in play, this technology can be applied to prevent the theft of golf balls from driving ranges, saving the owners of these establishments thousands of dollars per year.

The Capstone Hybrid Motorcycle

Paul Ciuc et al. — Thu, 17 Dec 2009 16:28:38 PST

The project goal is to create a working prototype of a hybrid motorcycle.

The Adaptive Optics Demonstration Device

Khalfan Belhoul et al. — Thu, 17 Dec 2009 16:28:37 PST

The project is to improve a simple Adaptive Optics demonstration device by developing a more reliable manufacutring process for the distortion of lenses and designing a lens fixture. The final design is easy to set up and operate and costs less than 75 dollars per unit for a production run of 100 to 200 units.

Sterilization Device for Liquid Chromotography Solvents

Nicolas Roulleau et al. — Thu, 17 Dec 2009 16:28:36 PST

Advances in chromatographic systems have led to progressively smaller packing materials in the analytical columns. The decrease in the size of critical components within these columns has increased the risk for premature failure due to clogging by bacteria growing in the aqueous solvents. The development of a device for reduction or elimination of the microorganisms by disinfection, filtration or sterilization of these solutions is desired. Product design requirements were established in conjunction with the sponsor, Waters Corporation. Several design concepts were the result of research into patents and other literature and were analyzed based on design goals and requirements to determine the preferred approach. Further research determined that the best approach for a prototype is a device that combines ultraviolet radiation with filtration. The main components of the prototype will include: a dual-head pump for the purpose of running multiple sterilization lines, an ultraviolet radiation lamp which will mitigate bacterial growth, and a filter with an effective area to remove the dead bacteria and any particulates over the course of one year. Analysis is presented for the design and specification of each of these components. A summary of proof-of-concept test results is given, and recommendations for continuation of development and further testing are discussed.

The Active Bumper Systems

Matt Bonnell — Thu, 17 Dec 2009 16:28:36 PST

This report describes the development of an active front bumper system for small automobiles. This system anticipates a collision and extends a structure from the front of the car, increasing the length over which the collision takes place. The increased length dissipates the energy of the accident over a greater amount of time and reduces the force transferred to the occupants of the vehicle, lowering their risk of severe injuries. The main components of this design are a sensing system and a collabpsible structure that extends from the front of the automobile prior to impact. This project focuses on the design of the collapsible structure. The final design recommendation for the structure is a series of six columns that collapse in much the same way as the font frame of a modern vericle, or crumple zone. Each column has an aluminum foam center surrounded by a thin steel frame. The columns are 12 inces in length with a 3 inch square cross section, and are connected to the front bumper of the automobile.

Solar Powered Water Distillation Device

Stephen Coffrin et al. — Thu, 17 Dec 2009 16:28:35 PST

Solar distillation is an often overlooked method for providing potable water to coastal, poverty stricken nations with abundant amounts of solar energy available. A single asymmetrical, automatic feed solar distiller was designed to take advantage of the solar energy available in these regions, such as Somalia, Africa. During this process, factors that will optimize single day productivity while minimizing costs have been explored. All aspects that will affect clean water output have been analyzed including: effect of surface area on productivity, material selection and analysis, overall thermal efficiency, and the potential effectiveness of an automatic water feed system. Factors that will directly impact overall build cost per unit have also been evaluated, such as material selection, size, and simplicity. The final design adds numerous features to increase the efficiency of a basic asymmetrical solar still.

Small Wind Powered Generator

Brian Klimm et al. — Thu, 17 Dec 2009 16:28:34 PST

Wind powered generators are a growing source of renewable energy that can ease the reliance of consumers on traditional power sources. Power harvested from wind produces no pollutants unlike the greenhouse gas emissions that come from the combustion of fossil fuels. Leading the way are wind farms consisting of a series of large wind turbines that each generate megawatts of power. There is also a significant market for smaller, household-size wind turbines that generate less than 10 KW. Prepackaged small wind powered generators can be installed by consumers to reduce or replace the need for connecting to the electrical power grid. The system being designed will be able to power a small home or cabin that is off the main power grid. The system will be able to support a building which consumes about 10 kWh of electricity per day. The wind powered generator will be able to perform at a low rpm range as well as at high wind speeds. The storage system will store enough power for 3 days without sufficient wind. The design consists of a horizontal-axis configuration which has the main rotor shaft and electrical generator at the top of a tower and is pointed directly into the wind. The direction of the wind generator is controlled by a simple wind vane. A 7 ft diameter rotor comprised of 3 blades will turn a permanent magnet alternator mounted horizontally. This will charge a battery bank which stores at least 500 Amp hours at 48 V. A sine wave inverter with a maximum rating of 3000 W will use this battery bank to provide 110 V Root Mean Square (RMS) to the cabin.

Self-Righting Kayak Design

Paul A. Averrie et al. — Thu, 17 Dec 2009 16:28:34 PST

A need exists for a device that autonomously prevents kayaks from capsizing. Sustaining an upright position, while maintaining its natural handling characteristics, requires an active system which senses the kayak degree-of-heel and produces a righting moment when necessary. Through buoyancy simulation utilizing Solid Works, a full characterization of kayak system stability determines the degrees-of-heel at which corrective moments are applied to the system and the magnitudes of the moments. The active design is composed of three major systems. First, the mechanical system mounts two buoyant features in a way that does not interfere with the kayak trim or movements. The buoyant features alone, without any powered righting mechanism, raise the kayak system to 90 degrees above the capsized position to a point at which the kayaker can breathe. When powered by the CO2 system, the buoyant features actively return the kayak to a full upright position. The critical angles at which the CO2 system extends the buoyant features are sensed via an inclinometer. Optical interrupt sensors, placed around a circular piece of tubing, detect a passing bubble, indicating when the kayak is tilted into the critical degree-of-heel ranges. Eight AA batteries provide needed power for the inclinometer circuit and solenoid valves. 500+ system actuations are possible via a 20 oz compressed CO2 tank. Aside from turning the system on, the kayaker is free from any interaction with the device, unlike all current, kayaker-dependent, devices on the market.

Self Contained Thermally Controlled Beverage Container

Stephen D. Boyle et al. — Thu, 17 Dec 2009 16:28:33 PST

This Capstone Design Project is to develop a Self Contained Thermally Controlled Beverage Container. The product will be a portable cup capable of heating a beverage from an initial temperature to a maximum temperature of 175 degrees Fahrenheit. The project goal is to create a product which will appeal to people who do not have the time or convenience to heat a beverage in a microwave or on a stove. The target cost of the product is $15-20. A butane gas mixture has been identified as our energy source due to its wide availability and low cost. Product creation will involve determining and analyzing the rate of heat transfer from the thermal reservoir to the beverage volume and performing a transient analysis on the beverage volume and exhaust gases. These analyses will aid in designing a burner for the beverage container. Other topics to be considered include optimal container geometry with respect to thermal conductivity, material selection, and burner control. The safety factors related to the product and its contents are of high importance due to the hazards associated with enclosed flammable gasses and are currently being considered by the authorities at Underwriters Laboratories. Conclusions from all research have yielded an intermediate design concept consisting of 20-24 oz fluid container, which can be heated to 175 degrees Fahrenheit using a Nozzle-Mix burner assembly.

Raytheon Motion Simulator

Caleb Estabrooks et al. — Thu, 17 Dec 2009 16:28:32 PST

Raytheon is working on the development of a defense radar system designed to track and acquire incoming enemy targets. This radar, known as JLENS, is mounted to the bottom of an aerostat (blimp) giving it an advantage over current systems by providing a larger field of view. Due to air currents, the aerostat tends to pitch and roll, creating a need for a radar active stabilization system.

Rain Gutter Cleaning Device

Todd Skibinski et al. — Thu, 17 Dec 2009 16:28:32 PST

Rain gutters tend to collect many types of debris throughout the seasons and the storms they endure. This debris can cause serious problems if the gutters are not properly cleaned. The plugging of the downspout can cause a build-up of water, debris, and also ice during the winter months. As buildups increase, dangers are presented to the home, surrounding landscape, and individuals below. The objective of this design is to provide the average homeowner with a device that effectively cleans rain gutters thus avoiding resulting problems. The device must clean gutters of a one-story home without the use of a ladder or platform. It must be operable by a single person, light in weight, as well as being low in cost. This report presents our final design proposal that will successfully complete the task at hand, while being safe and efficient for any homeowner.

Radio Telescope Panel Adjuster

Eric Walters et al. — Thu, 17 Dec 2009 16:28:31 PST

A computer controlled thermal expansion device has been designed for precision adjustment of the primary mirror of a sub-millimeter radio telescope in 1-micron increments. Accompanying the thermal expansion device is an existing panel adjuster that uses a differential screw mechanism for precision adjustment within 10-microns. The differential screw acts as a fail-safe mechanism for the thermal expansion device.

Programmable Anti-Siphon Shunt Project

Samuel Akins et al. — Thu, 17 Dec 2009 16:28:31 PST

We designed an improved shunt valve for the treatment of hydrocephalus. With this new valve, the surgeon can independently control the opening pressure of the valve and the siphoning effects. In the chosen ball diaphragm valve design, a spring-loaded ball obstructs the flow until the proximal pressure rises above the pressure setting. Changes in the distal pressure act on a pressure sensitive surface to vary the opening pressure applied to the ball. A control equation mathematically describes the behavior of the valve and relates design parameters to the desired siphon control ratio and the principal pressure setting. The geometry and dimensions of the individual components were determined with the control equation and other mathematical analyses. This analysis demonstrated that our design is feasible and effective. Design and construction of a scaled-up, proof of concept prototype has been completed. Testing has been carried out to demonstrate that our design addresses the problems of adjustable siphon control and programmability in a single valve.

Portable Automobile Battery Charger

Scott Cionek et al. — Thu, 17 Dec 2009 16:28:30 PST

Automobile batteries are weakened by use, time, and cold temperatures. A battery depleted beyond a critical point will fail to provide adequate power to start the engine of a vehicle. Battery packs exist on the market to be used in such emergency situations, however their performance and shelf-life can be improved upon. We developed a device that addresses these issues and provides a more robust and dependable alternative.

Pelvic Rehabilitation Device: Version II

Anthony Tanner et al. — Thu, 17 Dec 2009 16:28:29 PST

This report details the development of a Version II S.A. Trainer. The S.A. Trainer is a rehabilitation device designed in conjunction with the Motion Analysis Lab of the Spaulding Rehabilitation Hospital. The device is designed to help patients with abnormal gait patterns regain natural pelvic obliquity with the use of newly developed corrective system. Force-field correction induces a patient to use their own muscular structure to correct abnormal gait. This will decrease rehabilitation time and improve brain to muscle communication. Patent and literature searches concerning existing rehabilitation devices have shown that no current device utilizes force fields around the pelvis to improve gait patterns. In the S.A. Trainer, lateral corrective forces will be applied to control the obliquity of a patient while allowing free motion for the natural translation and rotations of the pelvis. The envisioned end result is the delivery of a fully-functional prototype designed for human testing with a minimum safety factor of 2.5. The focus of this project will be on the creation of a truly rigid mechanical structure (for purposes of motion analysis) and the implementation of a closed-loop control algorithm. The control system will gather real-time data on a gait of a patient gait, compare it to the gait profile derived from a healthy subject, and facilitate the necessary forces to normalize the two patterns.

Pole Extraction Device

John Burroughs et al. — Thu, 17 Dec 2009 16:28:29 PST

The objective of this Design Term is to design a device to remove wooden and metal fence posts.

Operative TroCam Design

Michael T. Cooke et al. — Thu, 17 Dec 2009 16:28:28 PST

Image Technologies Corporation, an endoscopic imaging design and production firm, identified a need for an endoscope that combines many surgical functions. The proposed endoscope incorporates imaging, lighting, and a tool channel into a single 12.5 mm diameter device. This device will reduce the number of incisions a patient sustains and will minimize recovery time. The scope also interfaces with Image Technologies??? TroView system to provide image capturing and archiving capabilities. The design term received preliminary product specifications and refined in design reviews, culminating in a final design.

Novel Ceramic Oil Filter: Phase III

Jared Ploss et al. — Thu, 17 Dec 2009 16:28:27 PST

The primary goal of this project is to design an oil filter that is consistent with basic spin-on filter technology and can act as a direct replacement for conventional oil filters. It must not require any special tools or additional adapters, in order to mate to the engine block. The design goal of this project is to improve and build upon the results of Phase II of the Ceramic Oil Filter. Phase II brought the ceramic oil filter past the proof of concept phase and added conventional filter features such as the bypass and antidrainback valves. However, the filter was designed for prototyping purposes, with little to no effort paid to manufacturability, which resulted in numerous sealing problems. Phase III must eliminate all sealing problems as they are crucial in keeping clean filtered oil separated from dirty oil. It must be designed for manufacturability and be priced comparably with conventional filters. It is also desired that evolutionary changes be made in the assembly-disassembly of the filter and functionality of the valves.

Nu2SAT Biological Microsatellite

Kathryn Portale et al. — Thu, 17 Dec 2009 16:28:27 PST

Nu2SAT is a microsatellite project developed through Capstone Design Program in association with NASA Ames Research Center (ARC). Microsatellites are small, unmanned spacecraft with the capability of housing payload chambers. These satellites have minimal mass, power, volume, and are fully automated and capable of communicating results to Earth without returning the payloads. The hermetically sealed payloads hold experiments that monitor biological responses in organisms which are directly related to particular human ailments, such as bone density loss or muscle deterioration. The nu2SAT project delivers a prototype of the mechanical design with the ability to provide the appropriate utilities to support biological experiments. Distinguishing features of the design are the modular system, ease of accessibility to payloads and components, and ability to support existing ARC experiments. This microsatellite is designed to meet representative sponsor and launch vehicle requirements, it has a center of mass within plus/minus 0.635 cm of the center and a mass of approximately 16 kg. There are four potential payload configurations that are thermally isolated from each other and the satellite structure. The pressure and vibration requirements were verified through computer-aided analysis, as well as hardware testing. Space has been allotted for interfacing between all components and subsystems and the entire system meets all design parameters.

Non-invasive, Nano-liter Scale Flow Meter

Matthew Egnaczyk et al. — Thu, 17 Dec 2009 16:28:26 PST

Dr. Darryl Bornhop developed the basic detection technique that forms the basis of our design. The papers and patients of Dr. Bornhop showed that using optical lasers to refract light when striking a capillary tube produced fringed patterns. The fringe patterns were proven to move in one axis when the refractive index of the fluid within the capillary changes. A device to create a non-invasive flow meter dependent on temperature change was developed and tested by the group. The temperature change was created using a wire coil heater with approximately 4 amps of current passing through. The coil is wrapped around a 0.25 inch ID glass tube. Two optical lasers placed on either side of the coil heater are used to create fringe patterns that are detected by two photo resistors. The photo resistors detect the asymmetry heating of the fluid in the glass tube. The differences due to the asymmetry will be correlated to the flow rate of the liquid. All hardware is rigid mounted to prevent mechanical noise.

Miniature Counter Device

Abdulaziz Alsumait et al. — Thu, 17 Dec 2009 16:28:25 PST

To function properly, cars need to have their oil changed at regular mileage intervals. Currently, stickers are adhered to the inside of a car windshield with a mileage or date written on them to notify a car owner when the next oil change should be. When the car reaches the specified mileage or date written on the sticker, it is time for the oil to be changed. Because people often fail to check their sticker, the sticker is hard to read, or they simply remove it from the windshield for aesthetic purposes, this system is inefficient. A more practical system is warranted so that people remember to change their oil at the proper time. An improved oil change reminding method will benefit the owner of the vehicle because their engine will perform better and last longer. It will also benefit auto-mechanics as they will experience a regular flow of work in the form of oil changes.

Nanoliter Flow Meter

Nathan Fleming et al. — Thu, 17 Dec 2009 16:28:25 PST

Recent advances in liquid chromatography have created the need for measurement of nano-scale flow in 50-100 micrometers capillary tubes. The developed flow meter takes a time of flight measurement of a heated volume of fluid, known as a termal slug, over a set distance. The passage of this thermal slug is recorded at the beginning and end of that set distance by a shift in a fringe pattern created by a visible laser. The fringe patterns are produced by the difference in the index of refraction of the fluid and the glass capillary, and will change position as the fluid's index of refraction changes with temperature. The speed of the slug is measured as it passes between the two lasers, therefore, the volumetric flow rate can be determined. The fringe pattern shifts are recorded by a bi-cell detector connected to an oscilloscope. This project is a continuation of the 2003 capstone group project.

Microfluidics Sterilization System

Matt Lototski et al. — Thu, 17 Dec 2009 16:28:24 PST

Our solutions to verify the system sterilization temperature field and eliminate seal failure in the Microfluidics M710 Microfluidizer Processor are described in this document. The Microfluidizer is a device that breaks product particles into uniform nanoparticles. The system is modeled using GAMBIT and analyzed using Fluent. This simulation will allow us to predict the pressures and temperatures across the entire system. The temperature and pressure are not able to be measured in many parts of the system because it can not be broken to add thermal couples. A Fluent simulation is one of the only ways to verify temperature in many locations. This data will enable us to alter the inlet temperature to ensure that all parts of the system will reach 121 degrees Celsius as defined by ASME standard BPE-a- 2004 but will not become so hot that the seals in the intensifier pump fail.

Metallographic Specimen Polishing Attachment

J. Scott Conover et al. — Thu, 17 Dec 2009 16:28:24 PST

The manual preparation of metallographic specimens is a process widely used in industry and research to examine the microstructure of metal samples. Unfortunately, this procedure requires skill and practice to produce specimens that clearly display all of the microstructure. This design project developed a device that will remove as much error as possible from the grinding and polishing steps of metaloographic preparation.

Meniscus Suturing Machine

Greg Dion et al. — Thu, 17 Dec 2009 16:28:23 PST

The Meniscus Suturing Device is designed to apply quick, strong, reliable suture repair for transplanted or torn menisci. The new suturing device utilizes the chain stitch, a common, single-thread sewing stitch. The device is simple to use, has internal fault protection and safety mechanisms, and comes apart easily. The Meniscus Suturing Device operates on basic pneumatic and mechanical concepts. A pneumatic system powers the needle and grabber system and ties into the existing nitrogen supply already present in operating rooms. Mechanical systems maintain the appropriate tension in the suturing system. Both the receptor arm and needle assembly are disposable. A simple two-button system makes the device easy for any orthopedic surgeon to operate. The major benefits the suturing device provides include a tremendous reduction in operating time and decreased complexity of meniscus repair.

Liquor Dispenser Team

Andy Kakish et al. — Thu, 17 Dec 2009 16:28:22 PST

The purpose of this project is to design a cost effective and efficient method for holding, chilling, and dispensing an assortment of bottled liquor. We also intend to be able to measure and pour one shot without spilling the liquor. We are not redesigning the refrigeration system, but we need to incorporate our design of an evaporator to minimize the amount of time required to cool one shot of liquor. The output temperature of the liquor is dependent on the input temperature and the temperature of the evaporator. A market analysis was conducted in order to investigate the feasibility of our design. The analysis included who we intend the target audience to be, the marketing aspects, which include the product, price, placement, and promotion, and a cost breakdown of the raw materials for the prototype. There are no patents similar to our design of the liquor dispenser, but there are products on the market that relate to the dispensing of liquor. These products will be discussed, and we will explain why our design is a better system. Existing and additional parts needed to complete the design of the liquor dispenser will also be discussed in this document. The components of the design will be explained, along with the functionality of each part that comprises the liquor dispenser.

Material Handling Equipment

Simon Lam et al. — Thu, 17 Dec 2009 16:28:22 PST

Market analysis shows this is an opportune time to improve current methods for material handling. The objective of this design is to build a lightweight, efficient material mover for loads not exceeding 200 lbs, for large companies and rental customers. The text body will present a thorough market analysis and provide our general concept solutions. This also includes a patent search of various products in the market currently. The basic requirements of the design are to attain a vertical reach of 8-12 ft and a horizontal reach of 4-8 ft with a load of 200 lbs. This unit should be operated by only one person. The design of the lifting arm will be based on two degrees of freedom and be able to place objects over obstacles. It will be powered by a hydraulic piston and hydraulic rotary actuator. Casters and rollers attached at the base will provide necessary maneuvering to move the object. The telescopic arm, vertical column, and base chassis will be made of Aluminum to provide a lightweight design. The choice of Aluminum will be justified using equations and finite element analysis. Connections between each section will be listed with suitable parts with the maximum safety factor. Finite Element Analysis will be performed by ANSYS and COSMOSworks to analyze static stress, buckling tests, deformation analysis, and modal analysis for natural frequencies. Tipping analysis regarding center of gravity will also be discussed to ensure the equipment will not tip-over on its maximum and eccentric load. The hydraulic system to power the telescopic arm and lifting mechanism will be discussed and analyzed thoroughly in the report. The concept of wrist joint design and the selection of the hydraulic rotary actuator will also be discussed. The safety regulations presented by Occupational Safety and Health Administration will be listed to show all of the safety regulations that will be met with the material handler. The control units and safety sensors will be implemented to ensure the worst case scenario will not occur. The budget section will include the list of parts that were purchased. Also it will discuss the budget concerns and solutions to minimize the budget without compromising the design and safety.

Liquid Crystal Calibration Systems

Dave Colanto et al. — Thu, 17 Dec 2009 16:28:21 PST

The calibration of thermochromic liquid crystals (TLC) used for measuring surface temperatures is required to develop a correlation between the surface temperature and reflected color. The few commercially available calibration systems tend to be very costly and are usually sold as complete packages containing a computer, camera, and thermocouples. The project objective is to produce an inexpensive and portable calibration system. The following report describes the development of a final design concept for the system, including the previously available information, concept considered, and the final design. The liquid crystal, adhered to a copper plate, is heated using two Kapton heaters that are controlled by Hewlett Packard Virtual Environment (HP VEE). When the TLC reaches specified temperatures, monitored by termocouples using HP VEE, color images of the TLC are recorded using a digital caera connected to the computer. The hue values of the colors are then analyzed using Matlab. From this series of images and the subsequent hue values, a calibration curve of the TLC is constructed.

Kayak Exerciser Machine

Miriam Barsalou et al. — Thu, 17 Dec 2009 16:28:20 PST

Currently available kayak ergometers do not incorporate the complete kayak motion. Research and consumer feedback show these training devices have shortcomings when it comes to balance training, and torso involvement. To address this issue an improved platform was developed for use with the Vermont Waterways Concept II adapter. The platform will include a cockpit, with features similar to those of a real kayak, which will allow the yaw and roll motion one experiences when using a kayak on water. By increasing the involvement of the lower body and incorporating the need for balance into the ergo-meter, the platform will give the user a better workout and training routine. The lower body adapter includes adjustable features such as thigh braces and a braking system to allow the user to vary the level of resistance.

Lateral Osteo-Arthritis Footwear with Energy Reduction

Lucius Acholonu et al. — Thu, 17 Dec 2009 16:28:20 PST

This document reviews the design of an orthopedic shoe for the purpose of reducing ground reaction forces and internal moment of the knee. The design utilizes a dual density mid-sole and lateral flare that under heal strike to mid-stance walking positions generates a lateral wedge of 5 degrees. Studies have concluded that the use of a lateral wedge insert and a flared heel design, individually, have effectively treated varying degrees of OA patients. Designs compared include the Dual-Density mid-sole, a Multidensity mid-sole and a Lateral support plate. Numerical analysis using the Evart Motion Capture system and Biometrics Platform combined with physical testing demonstrated the reduction of ground reaction forces and internal moment. Benefits include halting progression of knee OA with out costly medical treatments and doctor visits. Prototype testing showed a 13.23% decrease in the internal knee moment, along with a 2.67% decrease in the vertical ground reaction force. This design was deemed a successful way to combat knee moments, which are linked to the progression of osteoarthritis.

Investigation of a New Brake Pad Material

John Komaromi et al. — Thu, 17 Dec 2009 16:28:19 PST

Due to the banishment of asbestos usage in industry, research and experiments are being done using other combinations of materials to find a substitute for the asbestos. None of these new materials perform as well as the asbestos. Newly developed Graphite-Aluminum and Graphite-Brass composite plates showed suitable properties for a new break pad materials.

Internal Gearbox for Downhill Mountain Bikes

Joshua Filgate et al. — Thu, 17 Dec 2009 16:28:18 PST

In the realm of competitive downhill mountain biking, there is a need for advancement of the drive train. The conventional sprocket, chain, and derailleur drive train is not well suited for the high speeds, impacts, and harsh environmental conditions inherrant to the sport of downhill racing. The gearbox created in this project replaces conventional drive trains on downhill mountain bikes. The initial design and proof of concept were designed to provide a comparable gear range and capabilities of a conventional drive train, while providing increased protection, strength, durability, and performance. The scope of the project was to provide a working prototype capable of demonstrating the ability of the gearbox to provide the overall system gear ratio range of 2.1-3.3 when interfaced with industry standard components, as well as a detailed design of a complete prototype system.

Insertion of Heart Valves by Catheterization

Aja Atwood et al. — Thu, 17 Dec 2009 16:28:18 PST

This report discusses the design of two devices that replace a diseased heart valve using minimally invasive surgery. First, it defines the design problem and outlines the deign criteria. Secondly, it introduces the heart structure and function. Thirdly, it describes the need for this project. The reader is then introduced to currently available heart valve and stent technology and their design criteria. A discussion of patent searches proving that no current technology meets the design criteria follows. Next, it introduces the final design and outlines the procedure followed to achieve this design. Following this is the material selection process for the design. This report then explains the testing and analysis performed. Finally, it informs the reader of manufacturers contacted for prototyping and further testing required to finish the design.

Infrared Windshield Defroster

Todd Brown et al. — Thu, 17 Dec 2009 16:28:17 PST

The objective of this project is to design and build a device that is able to defrost a car windshield more effectively than current methods while producing a low environmental impact. Current methods, which include removing the ice using plastic scrapers or melting the ice by running a car on idle to heat up the windshield, prove to be ineffective or environmentally damaging. This device must be able to melt up to one sixtenth of ice from a distance of twenty feet, while meeting the environmental design parameters detailed in the report. An infrared heating element will be used with a reflective shield to create a focused beam of energy that will be used to defrost the windshield. A series of heat transfer calculations determined the theoretical energy required to melt a sixty-four foot area of ice to be 76 watts, and the amount of energy actually transferred through the focused beam after losses was determined experimentally. The testing of a scale model, which utilized diffuse visible light, showed there was an intensity gain of 3 percent from 19 foot by adding a reflector. A focusing factor of about 3 percent was found by a comparison of the intensity of the element at close range to the use of a reflector at 19 feet. The results show that about 9 kW would be needed to defrost one sixtenth of ice to meet the design criteria. The heat transfer calculations, which were completed for an initial set of variables, were used as a tool to see how the system reacted in terms of time and power as other variables were changed. A set of heat transfer calculations were done on the proposed prototype model in order to perform material selection, and it was found that 6061-Aluminum would be acceptable. The final construction of the prototype, using a single 540 W heating element, resulted in testing to find how well the design performed. As the scale model indicated, the time would be too great to melt the frost. Future prototypes will use more powerful elements to match the calculations discussed in this report, and melt the designated amount of frost in a reasonable tin frame.

Hydroelectric Power Generator

Anthony Chesna et al. — Thu, 17 Dec 2009 16:28:17 PST

The objective of this Northeastern University Capstone Design project is to design a hydroelectric power generator to charge batteries on small water vessels. This product will replace devices using nonrenewable fossil fuels by utilizing the Gorlov Helical turbine to capture kinetic energy from moving water.

Human Jaw Motion Simulator

Bryan Galer et al. — Thu, 17 Dec 2009 16:28:16 PST

The following report describes the anatomy and biomechanics of the human jaw along with design ideas for the development of a realistic jaw simulator. Creating a physical simulation gives hope that controls can be applied to study the mechanical properties, dynamic loadings, joint thresholds, and joint degeneration. This knowledge could lead to the ability to test and improve current jaw prosthetics or even to the eventual understanding and treatment of the temporomandibular joint (TMJ) disease. The problems that exist in creating a realistic simulator are the unknown order, direction, and magnitude of muscle forces, the functions of the various ligaments, and the complex TMJ. The project has been broken down into four stages, with the goal of this first stage being simulation of jaw closing. In order to accomplish this goal, three muscles were used: the temporal, the masseter, and the lateral pterygoid muscles. This will be accomplished using servo-motors to act as the muscles. The system control is position-based rather than force-based, a decision that was made because the force equations were statically indeterminate. A LabVIEW interface was created to control the position of the jaw and monitor the lengths of each muscle group. The virtual and physical model indicated unrealistic results. Based on our assumptions of perpendicularity, the mandible fell away from the jaw while simulating the closing motion. More analysis needs to be done on jaw movement to continue on with the project in the future.

Highly Controlled Collagen Nanoloom

Mercedes Castromonte et al. — Thu, 17 Dec 2009 16:28:15 PST

Artificial tissue based on collagen is gaining wider use in the medical community for tissue replacement. Current collagen assembly methods only allow for the production of disorganized, weak scaffolds that can only be used in limited applications such as skin grafts. There is a greater need to create highly organized, load-bearing collagen matrices such as ligaments and corneas. It is essential that a Collagen Nanoloom be developed in order to further advance artificial tissue production. The goal of the Collagen Nanoloom device is to replicate the environments of collagen producing cells known as fibroblasts.

Helical Turbine Generator Housing and Seal

Mazlan Dindi et al. — Thu, 17 Dec 2009 16:28:15 PST

The objective of this project is to design an enclosure that will protect and seal a generator from salt water. The generator is driven by a shaft that is rotated by a series of four helical turbines to produce a small amount of electricity (roughly 1hp). The sealed generator housing and the helical turbines will be mounted on a support structure which will be mounted differently to a concrete slab. These components will be submerged in sea water

Gynecological Speculum for Obese Women

Matt Barra et al. — Thu, 17 Dec 2009 16:28:14 PST

Current gynecological specula on the market are not optimal. They do not adequately open the vaginas of obese women and can be uncomfortable for all women. These specula lack lateral support for the vaginal sidewalls, and allow them to collapse inward during examination, obstructing the view of the cervix. Existing specula can pinch, so the practitioner must use it skillfully to prevent patient discomfort. Few specula open incrementally, a feature that facilitates universal use. Additionally, reusable specula are the most common, but they are expensive to buy and to sterilize. The medical market demands an inexpensive, disposable and comfortable speculum that is effective for all women. Existing specula provided the starting point for a new and innovative design. The most common disposable speculum is the Welch-Allyn. It has incremental opening and is operable with one hand, but it does not retain the vaginal sidewalls, making it useless when examining obese women. Non-disposable specula are widespread and are usually made of uncomfortably cold stainless steel. Using information from patients, the project sponsor, pediatric gynecologist Dr. Estheranne Grace, and from preliminary concept drawings from Children's Hospital, the design team came up with two speculum designs. The most important other factor that affected speculum design was material selection. Testing was also performed to learn about speculum operation forces, internal vaginal pressure, and stress concentrations. These two new designs combine the best features in existing specula with new and innovative components, and the better of these two was prototyped. The new speculum is easy to operate, comfortable, and usable on obese women.

GynaCam(TM) Design

Jessica Corriere et al. — Thu, 17 Dec 2009 16:28:13 PST

GynaCam (trademarked) is the housing unit for a digital imaging device that easily attaches to various vaginal speculums used in gynecological examination procedures. The device interfaces with Troview System from ImageTec to provide image capture, render, and archiving capabilities. The GynaCam used in conjunction with the Troview System will be tested for improving the accuracy of early detection of cervical cancer in women. There are two main units in GynaCam design: the Optics Package and the Disposable Mount. The Project Team designed the reusable Optics Package from components including an aluminum camera housing containing a ?? inch lens, charge-coupled device (CCD chip), pre-amp circuit board, and fiber optic bundle. The Disposable Mount attaches the Optics Package to the speculum and provides the examiner with mechanical adjustments used to position the Optics Package for optimal viewing of the patient. The GynaCam supports the weight of the Optics Package and two 150-gram light and optics cables. The Disposable Mount will be available to the customer as a disposable pre-packaged sterile unit. This final design of the product will be manufactured and marketed by ImageTec.

Gravity Gradient Boom Design

Jason Stricker et al. — Thu, 17 Dec 2009 16:28:12 PST

Attitude control systems are a very important aspect in satellite design. The goal is to develop a passive gravity gradient boom design that can be used on the ONYX satellite or be adaptable to other micro satellites. The ONYX, designed by Santa Clara University in collaboration with NASA, is a micro satellite in an Earth reconnaissance and research mission. During its intended 45 day mission, the ONYX will operationally test autonomous computer control techniques while conducting an Earth observing mission, providing educational services as well. Attitude control for an imaging satellite is vital. The objective of the design team is to develop a gravity gradient boom (GGB) for passive attitude control, while following specified design parameters set forth by the ONYX satellite team. The key design features of this system consist of space qualified materials, a tip mass, a single bolt release mechanism, a non motorized mass launch, and a spool of specifically chosen wire.

Fruit Picker 2000

Antonio Hernandez et al. — Thu, 17 Dec 2009 16:28:12 PST

The main goal of the Fruit Picker 2000 Design Team was to develop a fruit picker mechanism that is manually operated by a single user without the user of any electrical operated hardware. Our FP2000 is uniquely designed with an adjustable pole mechanism, making it capable to reach fruits at different heights. The device is also equipped with a chute that catches and decelerates the picked fruit. Each component of FP2000 is designed ergonomically to reduce fatigue, stress, and to require minimal amount of strain. The device is targeted for homeowners. Therefore, the entire assembly is collapsible for easy transport at an affordable cost of $35.99.

fMRI Compatible Mechatronic Ankle Device

Danielle Doane et al. — Thu, 17 Dec 2009 16:28:10 PST

The cutting-edge technique of functional magnetic resonance imaging (fMRI) is an invaluable tool in the fields of research and rehabilitation, used to generate images of the cortical response associated with certain physical actions. While devices have been utilized with great success in many upper extremity studies, there are presently no such devices designed for use with the foot and ankle. To this end, this paper proposes an apparatus consisting of a foot-pedal interface whose rotation is translated linearly via slidercrank mechanism. The design is such that it allows for both isometric and dynamic functionality, and capably measures force output, rotational frequency, and position. Results of finite element analysis (FEA) indicate that the MRI compatible parts and components chosen are capable of withstanding 100 lbs of force, which has been determined to be more than adequate for its intended use. The implementation of a mechanical actuator and a resistance system has been identified as a future improvement that would increase both the overall functionality of the device and the number of potential users.

Force-Senor for Artificial Lobster Leg

Amy Gamache et al. — Thu, 17 Dec 2009 16:28:10 PST

A robotic lobster system is currently undergoing research and development at the Northeastern University Marine Science Center. The system requires the design of a force sensing mechanism for each of its eight legs. This mechanism plays a crucial role in determining the walking phase of the lobster and in alerting the controller to changed phases of walking. The following report highlights the design efforts and plans put forth in the developmental process of the force sensor design. The team researched various force sensing mechanisms currently available. This research inspired many conceptual designs. With the aid of a decision matrix, the design team was able to evaluate the strengths and weaknesses of each concept. This process led to refinement of the most feasible design: membrane switches. The membrane switch design relies on closing a switch within the sensing mechanism through incurred forces applied to the sensor tip. Preliminary testing indicates initial success of the design, however, further testing is required for analysis. Initial costs are anticipated to be approximately 5 dollars per sensor tip for mass production quantities.

Flexible Carbon Nanotube Based Temperature Sensor for Ultra-Small-Site Applications

Brendan Crawford et al. — Thu, 17 Dec 2009 16:28:09 PST

There are many current and future temperature measurement applications that would benefit significantly from a commercially available, low power consuming, ultra-small-scale temperature sensor. The superior material properties of carbon nanotubes (CNTs) have suggested that it is possible to create a device that will meet these requirements and also have better performance when compared to devices currently available in the market However, there are currently no commercially available temperature sensors that make use of the advantages in using CNTs as a small-scale sensing element due to relatively high cost of manufacturing. This report outlines the design, fabrication, and testing of a novel CNT-based Temperature Sensor encapsulated in a thin film of flexible Parylene C. The design employs a single-walled carbon nanotube (SWNT) network between two micro-scale electrodes as the sensing element. The resulting device exploits the extremely small size of SWNTs as well as their superior thermal and electrical properties by deriving the temperature based on a change in electrical resistance that is induced by thermal strain. The sensitivity of the sensor is maximized by making use of an expansion element, with high thermal coefficient of expansion, which is a novel method for regulating strain in the SWNT network, and was a key factor in relating thermal strain to electrical resistance. The sensor requires power in the microwatt rangeÃ?Â?Ã?Â¯Ã?Â?Ã?Â¿Ã?Â?Ã?Â½Ã?Â?Ã?Â¯Ã?Â?Ã?Â¿Ã?Â?Ã?Â½Ã?Â?Ã?Â¯Ã?Â?Ã?Â¿Ã?Â?Ã?Â½orders of magnitude less than that of typical micro-scale sensors. The basic concept prototype sensors being fabricated can be characterized to measure temperature and predictions can be made successfully about the improvement in overall performance of the expanding element concept, when compared against a device with it.

FIRST Robotics Train Drive

Kerry Creeden et al. — Thu, 17 Dec 2009 16:28:08 PST

The objective of this project is to design a dual speed drive train system for a robot that will compete in the FIRST robotics team competition. The success of a competition robot would be improved greatly by the capability to move at high speeds while still being able to deliver high torque. To accomplish this, a dual speed transmission system that will meet these requirements has been developed. Motor selection, gearing, clutch design and wheel selection are all critical elements involved in the success of the drive train. This report summarizes the four major subsystems that are required for the success of this project. The available motors, as supplied by FIRST, have been categorized and classified according to their usability for this project. The gearing of the transmission was analyzed for exact speed and torque requirements as well as for size and weight constraints. A fully functional clutch was designed to allow the controller to alternate between high speed and high torque modes using a linear actuator as the driving mechanism. Finally, extensive research and testing was conducted for wheel selection such that the coefficient of friction was large enough to avoid slippage and meet our torque requirements.

Device to Rehabilitate Pelvic Obliquity in Stroke Patients Using Force Fields

Mark Guidi et al. — Thu, 17 Dec 2009 16:28:07 PST

Victims of cerebral palsy, stroke, multiple sclerosis and Parkinsons disease often experience a loss of strength and balance as a result of their conditions. This report focuses on the efforts of the Motion Analysis Lab at the Spaulding Rehabilitation Hospital to produce a machine that will help patients with mobility impairing conditions regain at least a portion of their lost function, while reducing the number of therapists involved. With the addition of weight support devices, patients can safely regain much of their mobility. Even after regaining mobility, patients may have developed abnormal gait patterns to compensate for muscles and movements affected by their injuries. The focus of this report is to provide a force field to guide a patient back into normal gait patterns. Force fields are currently used for some aspects of rehabilitation in regards to arm and ankle movement. These devices guide the movement of the patient by providing a resistance force to direct proper movement. This report shows the development of five design concepts based upon customer needs. These five designs were narrowed down to one concept through a concept selection process based on feedback from the project sponsor at Spaulding Rehabilitation Hospital. A commercially available unweighing system (Biodex) will be modified to provide a force field to the pelvis, which is considered to be the center of mass for a human. Resistance forces would be applied in some directions, such as to control the obliquity of the patient, but at the same time, the device will allow for free movement in the uncontrolled translations and rotations of the pelvis.

ELM : ESPA Launch Load Module

Ben Kneppers et al. — Thu, 17 Dec 2009 16:28:07 PST

A lack of in-flight data for the Evolved Expendable Launch Vehicle Secondary Payload Adapter has prevented engineers from efficiently producing more inexpensive satellites and adapters. Designing and Evolved Expendable Launch Vehicle (EELV) Secondary Payload Adapter (ESPA) Launch Load Module (ELM) capable of recording in-flight accelerations, temperatures, strain, and sound pressure will provide industry with actual conditions to design for. The weight of the ELM is minimized while maintaining a stiffness above 500 Hz, as to not adversely effect the other aspects of the mission. Shaker table testing will be done to verify this requirement. It attaches to one adapter port and extends inward. The design is a 13.5 inch diameter shell constructed of 6061 aluminum, which can house necessary measurement devices. All data will be recorded and stored onboard, then transmitted back to ground receiving stations after all satellites have been jettisoned. Santa Clara University has provided the necessary data acquisition system and electronic components.

Development of a New Arm For the Foster-Miller TALON Robot

Jon T. Hastie et al. — Thu, 17 Dec 2009 16:28:06 PST

Explosive Ordnance Disposal (EOD) robots save the lives of soldiers and civilians every day. The TALON robot by Foster-Miller is the choice of many military EOD teams and civilian bomb squads. The TALON robot manipulator arm is extremely capable, but does have its limitations. The addition of a shoulder rotational degree of freedom while maintaining the ruggedness, ease of maintenance, and mounting points to the platform would greatly improve the ability of the soldier to disable explosives. This paper examines similar EOD robot arms, especially the closest competitor TALON, the Packbot EOD. It also discusses alternative power transmission methods as well as novel manipulator designs. Our design leaves two motors in the base of the robot and transmits power to the shoulder pitch and shoulder rotation using a setup similar to a differential. The elbow motor will be mounted above this and transmit power within the upper arm. The paper also discusses challenges that occurred during the design process and a detailed analysis of all major components within the arm. Solid modeling of the arm, an in depth discussion of how the arm works, and the prototype build process are also included in the report. The arm was ultimately assembled at Northeastern University. The design was integrated with the TALON platform and was tested for dexterity. The test demonstrated the successful rotation and pitch of the new shoulder joint as well as the new elbow drive.

Development of an Automotive Oil Filter

Christopher S. George et al. — Thu, 17 Dec 2009 16:28:05 PST

The purpose of this report is to describe in detail the design of an environmentally friendly oil filter that is highly efficient and cost effective. It also defines what an environmentally friendly oil filter is, why the conventional oil filter is not an environmentally friendly oil filter. The problem statement put before our design team is clearly defined within the report as well as the individual parts of the problem statement. Our design team has chosen to use the principle of centrifugal force in our oil filter design. As an alternative we will also pursue the use of a ceramic monolith as our filtering medium. The report will discuss in detail the mathematical limitations and principles of centrifugal forces. Existing oil filters are bad for the environment and there are several reasons why. This report is intended to be an in-depth look at why the present day oil filters are bad for the environment and what the factors make up the design of a new and efficient environmentally friendly oil filter.

Development and Testing of a Facility to Coat Biomedical Devices with Polymeric Membranes

Philip Cormier et al. — Thu, 17 Dec 2009 16:28:05 PST

The following is the second quarter, mid-quarter report for the Polymer Membrane Senior Capstone Design Project. The problem addressed by the Senior Capstone Design Group is to develop a facility to coat a stent (an intravascular medical device) with a polymeric membrane. The report discusses the relevant medical history and previous attempts at solving this problem. The report presents the project plan developed by this Senior Capstone Design Group as a guide toward the problem solution. The preliminary testing and research as well as the engineering specifications for the proposed coating facility are presented. More importantly, the design concepts generated and the final design chosen by the design group are described within this report. The methods that will be used to evaluate the design solution are also discussed.

Design of Novel Energy Source for Foster-Miller Robots

Laura Caputo et al. — Thu, 17 Dec 2009 16:28:04 PST

One of the major flaws of the TALON and SWORDS robots is their battery life. Currently TALON and SWORDS robots from Foster-Miller rely on lithium ion and lead acid batteries for power. While these batteries provide sufficient power to the robots, there are unsatisfactorily temperamental and require charge times of up to 8 hours. This project provides a unique opportunity for Foster-Miller to explore alternative power sources. This research paper will discuss the current technologies used by Foster-Miller as well as alternative power sources that could be implemented to improve the run-time and reliability of the current system, and provide proof of concept test results and a complete design of a new power source. The enhancement of these systems will not only improve the performance of the robots, but will ensure the safety and productivity of US soldiers in combat.

Design of Patient-Specific Ankle-Foot Orthotics

Alyssa Q. Caddle et al. — Thu, 17 Dec 2009 16:28:03 PST

Current Rapid Prototyping (RP) technology allows for single step manufacturing of complex mechanisms with embedded parts. The ability to quickly move from concept to workable prototype is essential in a fast-paced field such as medicine. RP technology is being implemented currently in all major fields of medicine: dentistry, surgery, medical modeling, orthopedics and prosthetics. However, there are many new and interesting ways to utilize this impressive technology both within medicine and in industry. Developments in three dimensional scanning have made it possible to get accurate 360-degree models of nearly anything with extreme accuracy. Software capable of converting this data into workable computer aided design (CAD) models is currently being used to manipulate this data and allow for the use of RP very quickly. The non-invasive scanning technique makes this technology ideal for medical applications. Several different concepts were considered, however, the design of a patient specific ankle-foot orthotic (AFO) was chosen. This orthotic device will be used to help stabilize the ankle-foot region in patients with limited mobility, and more specifically drop foot. The purpose of this device is to match or exceed the comfort and effectiveness of a standard orthotic while being matched to the patient's specific needs and anatomy.

Design of the Tundra Tiger Trike

Darweshi Patrick et al. — Thu, 17 Dec 2009 16:28:03 PST

Researchers who are part of the Center for Astrophysical Research for Antarctica (CARA) are located in the extreme frigid environment of the South Pole. These researchers are required to travel telescopes a distance of a couple kilometers from the center of the base. These researchers desire a faster mode of transportation in order to reduce travel time. Seven design concept constraints: safety, durability, mobility, stability, performance, weight, and costs were considered in order to build an optimal vehicle for this harsh region. The Northeastern University Polar Trike design team has developed a recumbent tricycle design prototype, the Tundra Tiger Trike, to address these considerations.

Design of a Tree Pruning Device

Brian Carlin et al. — Thu, 17 Dec 2009 16:28:02 PST

Tree pruning is a necessary task that assists with maintaining healthy, structurally sound, and aesthetically pleasing trees. Farmers and other tree professionals are continuously searching for an efficient solution for their pruning needs while minimizing time spent cutting. To expose branches to light and air or to remove dead or diseased wood are necessary responsibilities of a tree professional, but the problem still remains to find a device that can perform all tasks. Currently, manual pruners, although cost effective, are difficult to maneuver and are less efficient than electric trimmers. Saw blade pruners are most often gas powered, which increases the cost to the user, and their bulkiness can hinder the ability of a user to perform smaller trimming tasks. The necessity of tree pruning, coupled with the inefficiency of existing products, provides the opportunity for a new device to alleviate current pruning issues. In this project a new device is under development that aims to provide a safe and ergonomic design that will allow a user to accomplish the simplest trimming task yet still be able to prune larger branches effectively (up to two inches in diameter). The design has an electrically powered motor for portable use. A Makita Circular skill saw was mounted at the top of the pole to allow quick severing of a limb. Manufactured lightweight telescoping poles provide adjustable lengths reaching a maximum of approximately 15 feet. Points such as materials, finances, and power transfer are all addressed and factored into the final design. The design successfully cut through a 2 inch branch at a height of 15 feet with ease and accuracy.

Design of a Solar Powered Fruit and Vegetable Dryer

Ryan Blair et al. — Thu, 17 Dec 2009 16:28:01 PST

Current market research indicates the need for an economical solution to efficiently dehydrate fruit and vegetables in equatorial climates. This is especially true for the banana industry of Central America. The goal is to design a cost effective solar powered fruit and vegetable dehydrator. The proposed design accommodates five (5) pounds fruit or three (3) pounds of vegetables and can remove seventy-five (75) percent of the water content in less than six (6) hours. This design is portable and robust enough to withstand the outdoor elements of equatorial climates. Using thermodynamic, heat transfer, and mass flow analyses, it has been shown that on an average day in this climate the dehydrator can achieve temperatures upwards of 120 degrees Fahrenheit. The design as tested consists of a clear acrylic dome top, solar powered exhaust fan, mesh drying rack, blackened aluminum base and a series of wire mesh acting as a heat exchanger. The fruit dehydrator has been successfully designed at a mass production cost of $48.12 per unit.

Design of a Pulsating Fluidic Device

Jeff Baldic et al. — Thu, 17 Dec 2009 16:28:00 PST

This design project develops a pulsating fluidic device that has no moving parts.

Design of a Cost-Effective Process to Pulverize Waste Automobile Tires

Carlos Alvarez et al. — Thu, 17 Dec 2009 16:28:00 PST

The goal of this project is to develop a method that pulverizes waste tires into a 300 micron crumb rubber for less than $318 per ton. This crumb rubber can be used as an alternative to pulverized coal for power generation. The final design is a two stage mechanical pulverizing system. A prototype has been completed that creates the required size of crumb rubber and a theoretical industrial process has been developed that meets cost requirements.

Design of a Tree Pruning Device

Garth Baker et al. — Thu, 17 Dec 2009 16:27:59 PST

The initial specifications of this design project were to design a pruning device that could cut through a three inch diameter branch that is twenty five feet above the ground in a reasonable amount of time using a waterjet cutting device. Additional requirements include that the device have a competitive cost, be safe, and easy to use. The team determined that the use of waterject cutting technology was an infeasible design concept to meet these requirements because it would take almost two hours to cut through a three inch branch using a pressure washer capable of 3500psi. A shearing device that would be powered by a hydraulic piston was selected as a better and more feasible alternative design solution. The shearing device designed has hardened steel blades from a Corona clipper product, and utilizes a hydraulic piston attached to a 29 foot telescoping pole, which is mounted to a tripod.

Design of a Tension Control System

Dan Jordan et al. — Thu, 17 Dec 2009 16:27:58 PST

Professor Joseph Blucher has developed a composite wire fabrication process at Northeastern University Egan Research Facility. The process involves drawing 10 to 20 tows, each consisting of 400 to 2000 fine ceramic fibers, from a feed reel through a high pressure aluminum infiltration chamber, and onto a take up reel. For optimum results, uniform tension in all of the tows is necessary. The goal of our project is to design a closed loop tension control system to maintain uniform tension in the tows.

Design of a Nail Removal Device

Bryan Caron et al. — Thu, 17 Dec 2009 16:27:57 PST

The process of repeatedly removing double headed nails from temporary wooden structures is very strenuous on the body. Sometimes this process causes a condition that is known in the construction industry as hammer elbow. Currently the only refined method of removing nails is using a common hammer. The objective of our project is to design a power assisted device that removes double headed nails while minimizing the impact on the user. This report presents a final design, along with its analysis, that solves the defined problem.

Design of a Self-Righting Kayak

Giulio Segurini et al. — Thu, 17 Dec 2009 16:27:57 PST

A device that self rights a kayak was developed and tested. This device consists of a buoyancy chamber that is mounted on the kayak surface, creating a shield like shape behind the sitting kayaker. This device increases the critical tip over angle, therefore, creating a more stable position. Once a kayak tips over, the device generates additional righting moment to assist the self righting process. The device is constructed of Styrofoam in a reinforced shell. The device is mountable on a variety of sea kayak designs, shapes, and materials using Velcro. The Velcro is attached to the kayak and the device using adhesives. The device is given a colorful appearance using colorful water based spray paint. The device is designed for easy manufacturing, as well as low production cost. It will be able to compete with other kayak safety features in the market.

Design of a Setup for Discharge Coefficient Measurement

Tareq Al-Qarawi et al. — Thu, 17 Dec 2009 16:27:56 PST

This paper presents the design of a system to measure discharge coefficients through complex geometry and conical orifices. Gas dynamic theory as it relates to this project is discussed. Orifice mass flow rate calculations and main flow channel mass flow rate characteristics are presented. Seventeen design concepts are illustrated and discussed. Design concepts are rated based upon weighted criteria. The concepts that best suit the design concepts are rated based upon weighted criteria. The concepts that best suit the design criteria are reevaluated. The best attributes of each concept are then combined to form the final design. The complete description of the final design as well as photographs of the assembled system is presented along with the assembly procedures. A stress analysis is performed to ensure the safety of the design. A testing procedure and laboratory data log sheet is presented. A complete list of metal costs and CAD sketches are included.

Design of a Cost-Effective Process to Pulverize Waste Automobile Tires

Adam Belmont et al. — Thu, 17 Dec 2009 16:27:55 PST

This paper is a report on the progress of our hypothetical engineering consultant company, the Alternative Energy Group, in its design of an economical process to produce tire derived fuel(TDF). Our client has commissioned our team to design a process that produces 100mm TDF powder at a price that is cost competitive with coal. His goal is to blend it with pulverized coal and burn it in existing pulverized fuel boilers. We have evaluated various methods for pulverizing tires A brief description of these methods is included in this paper. After assessing each of the methods, we have decided on a three stage process. The first is a primary cut stage, that will be performed by water jets, this stage will remove the bead wire and then divide the tire into 8-15 segments to one inch chips. Product from the first stage is fed into a series of shredders that reduce the tire segments to one inch chips The final stage will cryogenically pulverize the tire chips to the desired particle size using a hammermill. An initial economic analysis, included herein, proves the potential for this process to produce low-cost TDF. Finally, the report describes future plans for optimization of this design.

Design of a Setup to Study the Discharge Coefficient for Airflow Through a Rotating Hole

Creed Cotard et al. — Thu, 17 Dec 2009 16:27:54 PST

This report presents the methods and steps taken to design and build an experimental setup that can be used to study the effects of rotation on the discharge coefficient of an orifice. The goal of this project is to develop an experimental apparatus that allows fix tile calculation of the discharge coefficient for airflow through a rotating orifice. Fundamental equations of fluid mechanics or compressible flow were employed to analyze the airflow in the orifice. Nondimensional parameters were then determined to examine the effects that various geometrical physical parameters have on the discharge coefficient. The design of the test setup was broken down into four major subsystems. The four major subsystems are: the plenums, the disk, the sealing mechanism, and the power transmission system. Conceptual designs were developed for each of the subsystem and the final design was developed using the most acceptable conceptual designs of the subsystems. Also this project discusses theoretical developments, safety concerns, testing procedures, and instrumentation. Since the seal has not been received to date, testing of the apparatus has not been performed.

Design of a One-Handed Tying Tool

F. Haq et al. — Thu, 17 Dec 2009 16:27:54 PST

A garden tool is developed to enable the tying of a vine plant to a wooden stake using only one hand to operate the tool. The tool is a hand-held device containing several mechanisms that work together to produce a knotted loop of string around the plant and the stake. These mechanisms include a circular needle that forms the loop of string and a pair of rotating jaws that manipulate the two ends of the looped string to form a knot. The user holds and operates the tool by repeatedly squeezing a trigger. Internal gearing transforms the linear reciprocation of the trigger to unidirectional rotary motion of the needle and the jaws. The gear system also times the motion of components, so that the needle forms a loop of string then stops while the jaws rotate to make the knot.

Design of a Laser Welding Environment Enclosure

Christian Carven et al. — Thu, 17 Dec 2009 16:27:53 PST

Nitinol Medical Technologies (NMT) uses laser welding to fabricate medical devices. These medical devices are made out of a nickel-titanium alloy called nitinol. Laser welding of nitinol should take place in an environment containing little or no oxygen. Trace amounts of oxygen present during welding combine with the molten metal, creating undesireable oxides. NMT is not satisfied with their existing method of isolating the weld zone from oxygen. The current method utilizes a plastic bag to contain the noble shield gas, which wastes a great deal of inert gas and is difficult to manage. The configuration of NMTs welding system makes any improvement to this method a challenging engineering problem. The design team developed specifications and metrics from the requirements of the customer. Five conceptual designs were created and evaluated using a design matrix. This report summarizes the design process in finding a better oxygen evacuation system.

Design of a Lab Setup for the Measurement of an Air Motor Efficiency

Ahmad Al-Duwaisan et al. — Thu, 17 Dec 2009 16:27:52 PST

The subject of this report is the design of a laboratory setup to effectively measure the efficiency of an air motor. This laboratory design is going to be used in the undergraduate thermodynamics course, as an experiment to evaluate the performance of the air motor. Therefore, after the design is completed, a laboratory manual with clear instructions to operate the experiment will be completed.

Design of an Industrial Clamp

Atul Patel et al. — Thu, 17 Dec 2009 16:27:51 PST

The magnetic chukc is a unique device to be used in a machine shop setting to clamp or hold firmly an irregular, fragile part for machining. This is accomplished by embedding the part in a ferrous media, then hardening the media via electromagnetism. This unique device has three major components: a workpiece container, electromagnetic coils and a yoke. When energized, the coils induce a magnetic flux through the entire device, cause the ferrous medium to harden and secure the part firmly in place. Experimental models based on theory were built and tested to determine the interrelationships among design variables. Once these relationships were established, the three key parameters were then adjusted such that the device provided maximum clamping force. Consequently, prototype testing showed that this device meets all of the design requirements set forth for this project, however, future refinement is necessary to ensure outstanding, practical performance.

Design and Construction of a Safer Bungee Cord

Mark Krzystek et al. — Thu, 17 Dec 2009 16:27:50 PST

This report documents the research, requirements, specifications, conceptual designs, prototypes, and engineering analysis for the design of a safer bungee cord.

Design of a Hedge Trimming Mechanism

John S. Murray et al. — Thu, 17 Dec 2009 16:27:50 PST

The objective of this design project is to develop a product that can trim vegetation up to the fifteen feet from a balcony or porch. The design problem is to develop a device that can attach to a handrail, extend up to fifteen feet, and attach to a conventional electrical hedge-trimming tool. The design specifications included the device be able to firmly attach to common railings, use universal hedge trimming attachments, require minimum maintenance, and have a maximum weight of 75 pounds.

Design and Construction of a Collapsible Bicycle

Michael Gorhan et al. — Thu, 17 Dec 2009 16:27:49 PST

This report discusses the final conceptual design, engineering analysis and construction of a collapsible bicycle. The bicycle is designed such that it will easily achieve 8MPH over normal city streets while carrying a rider of 250 pounds. The collapsed size of the bicycle needs to be 6x16x20 inches, which is roughly the size of a small suitcase. Urban commuters will be targeted as the users of this bicycle. We have achieved a final conceptual design which meets these guidelines and constructed a fully functional model of the bicycle. The working model proves that our design functions properly and satisfies the given constraints, it also shows where improvements to the design would be necessary for a marketable product.

Design and Construction of a Collapsible Bicycle: Phase II

Ying Chan et al. — Thu, 17 Dec 2009 16:27:49 PST

The objective of the collapsible bicycle design team is to design and construct a collapsible bicycle. This collapsible bike must fit into a volume of 6x 16 x 18 (the size of a large brief case). This bicycle must also support a load of 250 pounds, have few to no loose parts, ride like a normal bike, and have a functioning braking system. Using AutoGad, a 3-D model was constructed allowing the team to visualize the ultimate goal and areas for improvement. A flat plate style frame, made of three eighth of an inch thick aluminum, has been chosen along with a belt drive system. Calculations have been performed to ensure stability and support during normal operation. The gear ratio for this bike is 4: 1 and the mass of the frame is approximately 8.6 lbs. Construction of our design is currently underway.

Design and Construction of a Helical Turbin Support Structure

Terrence Barnes et al. — Thu, 17 Dec 2009 16:27:48 PST

During tests at the Cape Cod Canal, the structure that housed a single helical turbine was found to be inefficient. This paper discusses problems encountered during previous tests, conceptual designs to eliminate these problems, and an analysis of a design for a final prototype structure. This paper further discusses the manufacturing of a prototype support structure. This paper concludes with a detailed description and manufacturing process of the prototype which will be tested by June 1997.

Cryogenic Optical Microscope

Mohammad Ali et al. — Thu, 17 Dec 2009 16:27:47 PST

The transmission electron microscope (TEM) is extensively used in medical research because of its high magnification and resolution capabilities. One drawback of the TEM is that as the magnification increases, its field of view decreases, and more time is required to identify points of interest on a biological sample. This longer exposure can degrade the sample integrity. A solution is to first map the sample with fluorescent nanoparticles, flash freeze it in vitreous ice at cryogenic temperatures, then study the sample under the optical microscope (OM). The OM provides a much larger field of view, allowing the identification of the key points of interest, before transferring it to the TEM. The described solution is comprised of a custom optical microscope with a built-in cooling system that is compatible with current TEM equipment.

Design and Construction of a Gear Exhibit

Karl Axelson et al. — Thu, 17 Dec 2009 16:27:47 PST

The idea behind the plan of our team of constructing a gear exhibit is to demonstrate to the viewer how the design of gears has evolved over the years and the way new applications have affected different aspects of gears used today. We intended on displaying a three part exhibit. The first part will be an apparatus using wooden gears fashioned after those that would have been used in 2600 BC. The second portion of the exhibit will be a setup of two different diameter gears used to measure dynamic effects on metal helical gears. The third portion is a photoelastic assembly for the demonstration of stresses that develop on a system of two spur gears.

Corner Adapting Motorcycle Headlight

Anthony Fry et al. — Thu, 17 Dec 2009 16:27:46 PST

The purpose of this project is to improve motorcycle lighting in corners. Given that motorcycles need to lean or bank to turn, the headlight aim becomes obscured and inadequate around curves. This lighting phenomenon can present a safety hazard to riders at night. Although this problem has been present since headlights were first put on motorcycles, it is now prudent to accept the challenge of correcting this problem thanks to the recent advances in sensor and microprocessor design. The solution was to design a headlight control system that sensed the dynamic behavior of the motorcycle, predicted the current situation on a roadway, and manipulated the aim of the headlight to best illuminate the roadway. The system senses the bank angle and speed of a motorcycle, and then uses that data to manipulate a small projector beam headlight. The result of the project is a light that reacts to the banking of a motorcycle and corrects the beam aim quickly and accurately along two axes. In this project a working prototype was constructed. This prototype will be used to demonstrate and prove the concept with the intention of marketing the technology to motorcycle manufacturers.

Continuation of the development of a laboratory for the internal combustion engine course

Shawn Brickner et al. — Thu, 17 Dec 2009 16:27:44 PST

The development of a laboratory for the Internal Combustion Engine (ICE) course institutes the design of experiments which examine various engine-related controls by integrating mechanical and electronic components for experimental applications. The following report details the progress in developing a laboratory that will accompany the internal combustion engine offered to mechanical engineering students at Northeastern University.

Construction of a Laboratory Facility to Demonstrate Engine Control Management

Hanafi Younes et al. — Thu, 17 Dec 2009 16:27:43 PST

The objective of our Design Project is to design and construct a laboratory arrangement, for the Internal Combustion Engine course offered at Northeastern University, to illustrate engine control management. The target of this laboratory is to construct both experiments and displays various engine related control systems, from the purely mechanical to the most novel electro-mechanical devices. The laboratory will enhance the experimental facilities of the Mechanical Engineering Department by relating students theoretical classwork with hands-on exercises. At present time, such a laboratolry does not exist. Our repod exadnes the multiple facets of engine ignitions ystems, engine sensors, fuel pumps, and fuel injection systems. Each category of systems was researched individually by its numerous designs, with each design serving a different application in the automotive industry. The different components of each sub-system within the internal combustible engine will be on display for use in experiments and as visual aids in the laboratory. Experience gained in this laboratory facility will benefit mechanical engineering students at Northeastern University.

Construction of a Laboratory Setup to Study Gas Flow Concepts

Bassam Abraham et al. — Thu, 17 Dec 2009 16:27:42 PST

The purpose of this project is to create a working laboratory experiment featuring demonstrations on air flow to enhance the educational experience of mechanical engineering students at Northeastern University. Our design team constructed an experiment that is permanently housed in the basement of the Forsyth building. This experiment features demonstrations of converging-diverging nozzles with supersonic and subsonic air flows as well as demonstrations on drag and down-force in a wind-tunnel. Our experiment illustrates the tangible differences between air traveling at supersonic speed through a converging-diverging nozzle and air traveling through the same nozzle at subsonic speed. Our supersonic flow demonstration takes air supplied by an in-house air compressor and passes it through an ejector nozzle, a very small converging-diverging nozzle that accelerates the flow of air to supersonic velocities. Our subsonic flow demonstration takes the same air flow and passes it through the diffuser portion of the supersonic apparatus. The diffuser is essentially another converging-diverging nozzle. The temperature and pressure of both the supersonic and subsonic flows are measured with a series of sensors. Temperature, pressure and velocity profiles for both supersonic and subsonic flows are then generated and used to illustrate their differences. The second part of our experiment shows the aerodynamic effects of drag and down-force. The phenomenon of drag is demonstrated by subjecting two different automobile models to a blower generated air flow in a wind tunnel. The resulting drag exerted on the automobiles is measured by means a load cell. Similarly, the phenomenon of down-force is demonstrated by subjecting two different automobile models, one with a spoiler wing mounted on the trunk and one without, to the same air flow. The resulting down-force is also measured by means of a load cell. Finally, we will interface the experiments with a computer for the instantaneous display of the results in graphic form.

Combined Emergency Power and Refrigeration Source

Christopher Dancewicz et al. — Thu, 17 Dec 2009 16:27:41 PST

A device was designed to provide a refrigeration effect using the waste heat generated from a portable generator. The device is primarily intended for emergency situations, disaster relief, or remote military locations. The waste heat in the exhaust of the generator is used to power an absorption refrigeration cycle which eliminates electrical demand, allows for smaller generators and reduces fuel consumption and emissions. A 8 HP engine/3500 W peak power generator was used for prototyping. Testing performed with the engine-generator and load bank produced critical design parameters of stock muffler backpressure of .09 PSI, and an exhaust temperature range of 500-780C with fuel/air ratios of ~15. Engine-generator efficiency varied from 0-30%. Thermodynamic analysis of these limitations applied to a balanced combustion equation showed that a maximum of 6.5 kW of thermal energy was available in the exhaust stream. A heat exchanger design with an effectiveness of 0.7 yielded a maximum of 4.55 kW of energy for use in the absorption refrigeration cycle. Refrigerator research provided information to use an ammonia/water refrigeration cycle having a COP of 0.55 at an operating temp of 170C. Applying this COP value to the 4.55 kW of energy available to the refrigeration cycle yielded a theoretical available energy of 2.50 kW. Due to time constraints, an optimized refrigeration system was impractical to produce. To prove the concept, a 100 W absorption refrigerator was powered using the waste heat from the exhaust. Further development and optimization of this product would require a custom assembly of a larger ammonia absorption refrigeration system by an ASME certified welder in conjunction with a optimized heat exchanger. A heat exchanger that optimizes the cooling effect was designed and theoretically proven.

Collagen Bioreactor

Ryan Cahill et al. — Thu, 17 Dec 2009 16:27:40 PST

Tissue engineering promises to revolutionize treatment of connective tissue disease and injury. Tissue engineers can generate collagenous matrices but they are typically unable to bear in vivo loads. It has been shown that application of mechanical load to living collagenous matrics results in the improvement of mechanical properties and organization. The tissue is theorized to reorganize under tensile load in order to compensate for the force applied to it. Currently bioreactors capable of applying a mechanical load are being developed for large connective tissue however, nothing is developed for cornea or other small tissue specimens. Small tissue or cornea is highly organized and load bearing however there is no comparable device. The basis of our project is to design a miniature bioreactor capable of applying mechanical loads and resulting in organized cornea development. The cornea will be housed saturated environment while controlling strain and load. The bioreactor must measure the force applied to plus/minus0.01 N and the displacement to 1% of its overall length (0-200 micrometers). Cornea will be used in testing with dimensions of 2-4 mm length, by 8-20 mm length and only 50 microns thick. The specimen must be completely saturated in a sterile, anticorrosive visible environment at body temperature. A requirement was added later in the semester which included a 3 mm distance between specimen and outside environment. The requirement lead to a sliding quartz glass tubing design as seen in Figure 1. The quartz glass slides up to load specimen and is compressed down to seal container maintaining a 3 mm distance and a visible specimen. Copper block were used to heat chamber and pre heat tubing with the entering circulating fluid. Heat transfer analysis confirms the specimen will be heated to 37 degrees Celsius in 80 seconds. A zaber screw actuator was used to apply a force and measure displacement and a submersible load cell was used to measure the amount of force applied. The following summary states the requirements needed, design and components selected, as well as thermal and mechanical analysis completed.

Chemical Heat Pipe Storage Device

Keith Wright et al. — Thu, 17 Dec 2009 16:27:40 PST

A bench top test bed is designed that investigates various, common mixtures for longterm energy storage by stored chemical energy. Low temperature energy captured by heat pipe is converted into chemical energy which is stored by separation of acid and salt solutions by means of evaporation. Mixing of separated elements results in an exothermic reaction there thermal energy may be extracted for use. The system is designed for lithium romide and water and sulfuric acid and water.

Capstone Hybrid Motorcycle : Phase IV

Anthony Clancy et al. — Thu, 17 Dec 2009 16:27:39 PST

The following report discusses the implementation of a hydraulic launch assist system to function as a method of regenerative braking in a hybrid motorcycle. The design will be implemented on a hybrid gasoline-electric motorcycle constructed by past groups during Phases I through III of the Capstone Hybrid Motorcycle Project. Multiple design options were considered including hydraulic and electric systems. The final design consists of a customized hub pump/motor based on a variable axial piston pump, a diaphragm-type accumulator, and a 1.5 gallon reservoir integrated into the existing fuel tank. This system applies torque to the front wheel to assist the motorcycle during acceleration. The system operates at an input RPM ranging from 0-875 and within a temperature range of 32- 120F. The operating efficiency of the system is between 79.2% and can recover 169 kJ of energy along the EPA Urban drive cycle. The overall estimated prototype cost for this system is $4,475.

Biomechanics: Kayak Exercise Machine

Stefan Cautino et al. — Thu, 17 Dec 2009 16:27:38 PST

A kayak exercise machine that accurately reproduces the forces and motions of a real kayak was designed and built. Kayaking is an increasingly popular sport and both enthusiasts and amateurs need a way to train during the off season. There are very few kayak exercise machines that are commercially available and those that exist are oversized, expensive, complicated and do not work all of the correct muscle groups required for kayaking. They are not designed for high volume use, such as in a gym setting, or compact enough for the home environment. The approach for the design was to simulate the basic paddling motion, as well as the motions and forces the kayak encounters from water resistance. Rotation of the torso and water resistance is simulated through the use of a two part frame design, a lower stationary frame and an upper rotating frame. The energy absorption mechanism is from a Concept II (TM) rowing machine and is an accepted form of energy absorption in watercraft exercise machines.

Basketball Backboard and Hoop Lighting Apparatus

Anas Bukhash et al. — Thu, 17 Dec 2009 16:27:37 PST

The goal of the Night Hoops lighting project is to allow basketball games to continue after the sun goes down. This project provides a lighting apparatus that can be placed on any existing basketball backboard and hoop. The apparatus adequately illuminates the hoop, backboard and an area of approximately one square meter under the hoop. These critical areas determine a shot of the person while playing basketball. The decision process used by hand to eye coordination to make a shot requires the hoop, backboard and area underneath to be illuminated by the lighting apparatus. The effects of shadows on the hoop and backboard must be considered in the design of the lighting apparatus and therefore eliminated.

Beer Chiller

Keith Boudreau et al. — Thu, 17 Dec 2009 16:27:37 PST

Extensive market research revealed a desire for a device that can chill a six-pack of beer in less than five minutes. Given this market interest, the group has set forth to design and build this device at a market price of potentially twenty dollars. The device will be able to chill an entire six-pack in less than five minutes while the beer is still enclosed in its original containers. This has been accomplished by placing six bottled or canned beverages into the device and manipulating the containers to increase the thermal convection rate between an ice bath and the fluid in the can. The unit will be completely submersible. Extensive analysis, including experimentation and calculation, are discussed in the text. Design for the dynamics of the system and the holding mechanism for the beverages are also addressed in detail. Finally, there is a market analysis proving the significant commercial interest.

Auto-Dispensing Prophy Angle

Ari Katz et al. — Thu, 17 Dec 2009 16:27:36 PST

Current dental cleaning procedures require the use of two separate components: a disposable prophy angle and a container of dentifrice. Dental professionals must manually load the dentifrice into the prophy cup several times throughout the course of the cleaning. This process can be simplified and made more efficient through the use of a prophy angle that automatically dispenses dentifrice while in use. Such a tool would allow dental professionals to clean teeth in one continuous process, saving time and reducing the materials used. It enables easier cleaning in hard to reach areas, and has the potential to reduce packaging materials used and sterilization processes required. The most significant design hurdle has been in characterizing the dentifrice and determining parameters for it to flow. As a two-phase visco-elastic abrasive mixture, dentifrice is more solid than liquid. This limits dispensation mechanisms to augers and requires that the flow path not be constricted in any way. Initially two dispensation designs were investigated: one that dispenses dentifrice at a constant flow rate, and one that has a user-controlled, variable flow rate. After preliminary testing, it was determined that the rotational velocity of the handpiece is too high to be used to dispense dentifrice at a gradual, constant flow, and thus a user controlled design was used. This design was accomplished by using a brake mechanism combined with a spring, acting as an auger, which is contained within a reservoir of dentifrice. The mechanism causes reservoir to rotate relative to the spring, driving the dentifrice out of the reservoir. Throughout this process, the prophy angle can remain in the mouth until the cleaning is complete.

Assisted Bottle Opener

John Collins et al. — Thu, 17 Dec 2009 16:27:35 PST

Today more and more devices are being created to aid those who are handicapped and make their daily routines easier and their lives more independent. The focus of this design involves the opening of a medicine bottle for one-hand use and is targeted primarily to an audience that includes those who are disabled and have only the use of a single functional hand. Design requirements of the device include being easy and safe to use, lightweight and having minimal assembly and maintenance requirements. In addition to opening the bottle cap, the cap must also be able to be put back on. The design must be flexible enough to incorporate different bottle styles, including over the counter as well as prescription applications.

Antarctic Cycle

Walter Coyle et al. — Thu, 17 Dec 2009 16:27:34 PST

This report outlines the development of the Antarctic cycle. The original objective of the project was to finish building and test a 2000 Northeastern University Capstone Design Project, the Tundra Tiger Trike. The Tundra Tiger Trike is a recumbent style tricycle that was designed for travel in Antarctica. In the fall of 2000, we conducted tests on it that simulated the terrain that it would be subjected to in Antarctica. This testing revealed that the initial design of the Tundra Tiger Trike would be unsuccessful. A decision was needed whether to go with a redesign of the Tundra Tiger Trike or go with a completely new design. Since concepts of a redesign could be simulated by quick modifications to the Tundra Tiger Trike, several concepts were quickly tested. The tests proved the existing cycle would not meet the needs of a sponsor. Ineffective steering, poor weight distribution, and extensive frame rework due to failwes pushed the team towards developing a new design. The new design, known as the Hybrid Tricycle, was developed based on the knowledge gained from testing of the Tundra Tiger Trike. The concept is similar to a tricycle, with one front tire and two rear tires. it mates the drive assembly of an all-terrain vehicle to a bike ailowing for greater stability, better weight distribution, and easy operation. By using standard components, we cut costs dramatically while maintaining a wide variety of flexibility and completing the project on time. We believe that this hybrid concept will meet the needs of the Antarctic researchers.

Airplane Storage Rack

Ricardo Cabra et al. — Thu, 17 Dec 2009 16:27:33 PST

Small airplane owners often encounter problems when trying to store their airplanes in a hangar. The hangar space available for storing small airplanes is both limited expensive. The goal of the Airplane Storage Rack Team has been to design a convenient, cost-effective, and safe device that effectively uses the space of a standard hangar to store two airplanes rather than just one. Many design concepts were generated during brainstoming sessions. Through quality function deployment analysis, a single concept was found to be superior. This design consists of a fixed frame, retractable ramp, and a wheeled pallet. The pallet is pulled up the ramp by a cable system. A gear drive system then engages the ramp, and retracts it into the storage position. This report outlines the development of the Airplane

Ambulatory Intravenous Fluid Holder

Anthony Tomasi et al. — Thu, 17 Dec 2009 16:27:33 PST

Hospital patients who require intravenous infusions to aid in their recovery are currently encountering several physical challenges while ambulating using standard IV pole assemblies. There are several devices already designed, which alleviate these difficulties. However, many of these require electronic controls, making them too complex and expensive to be implemented as standard hospital equipment. Other designs do not incorporate existing hospital IV equipment. Due to cost and in-service training, hospitals prefer not to modify their existing IV equipment. Therefore, a need exists for a simple and inexpensive device that allows for safe and comfortable ambulation while making use of existing IV equipment. A design concept has been developed that will address these needs. Testing and analysis have shown that this design will safely and effectively provide ambulatory intravenous infusion.

Air Mass Flow Rate Measurement

Kian C. Lim et al. — Thu, 17 Dec 2009 16:27:32 PST

In the field of engineering studies, experimental lab activities are necessary for engineering students to relate what they have learned in class as ideal situations to the actual application settings and conditions. This project presents a design of an experimental lab setup for undergraduate mechanical engineering students to perform air mass Row rate measurements. The air mass Row rate measmements are to be conducted using various flow rate measurement devices, allowing an accuracy comparison study among the different devices. The experimental lab setup also incorporates a device to measure the discharge coefficient of different disk geometries. Several design concepts were generated throughout detailed analysis of various flow rate measurement devices and data acquisition system, which results in the optimum device configuration setup.

Adhesive Temperature Data-Logger

Chris Hardy et al. — Thu, 17 Dec 2009 16:27:31 PST

This report outlines the development of a flexible temperature data-logger for McClellan Automation by a capstone design team at Northeastern University. The capstone group began with a technology developed by McClellan Automation of Bedford, NH to print thin, flexible circuits. The decision was made to develop a small, flexible, temperature data-logger which can be used to record temperature data of products such as blood, and various other refrigerated products in storage and transport. It has been determined that there is a clear market opportunity for such a device, and that McClellan's technology is suitable for such a product. McClellan Automation has the ability to print flexible polymer circuits on virtually any material, with very little waste or environmental consequences. Initial brainstorming revealed four major market opportunities which were researched by the team. The markets are: human wearable-military, human wearable-medical, sterilization validation, and temperature sensitive package transport. This report discusses these possible market applications through research of current products, patents, and professional literature. Based on the research, the team originally decided to develop a human wearable temperature device, and outlined design criteria and anticipated challenges. The team then conducted a number of surveys with potential customers and found little use for the product as initially described. The team subsequently changed their application focus to the packaging industry, and more specifically the blood packaging industry, where there is both a market niche and a demand for the proposed product. The team continued on to present several concepts for the design of the product. Design concepts were generated from customer needs and specification matrices which were created through interviews of various professionals in the field. The selected concept consists of a single temperature sensor inside housing that protects the circuit from outside elements. The specific components used to construct the device are outlined in detail in this report and include the printed circuit, surface-mount electrical components, polymer encapsulant, and adhesive. The capstone group successfully completed the entire design process including market analysis, concept development, analysis, and testing. The group was successful in completing a fully-functional prototype, which measured and recorded the temperature profile of a bag of blood (simulated with saline). The recommendations for the future improvements of this device are also outlined in this report.

A Wire Insulation Lubrication System For Bulk Wire Manufacture

C. Cockrill et al. — Thu, 17 Dec 2009 16:27:30 PST

This report documents the work of the Northeastern University senior design project, A Wire Insulation System for Bulk Wire Manufacture. This project was sponsored by the General Cable Corporation (GCC), located in Lincoln, RI. GCC manufactures insulated copper wire and multiwire cables. During the single wire manufacturing process, a hopper applies a layer of talc to the insulated wire. This layer prevents the wire from bonding to itself once wound onto a take up reel, and prevents individual wires from bonding in the multi cable. The talc currently causes problems in the plant because it falls off the wire damaging machinery and creating a slipping hazard. The design team set out to replace this process with an alternative that cost effectively prevents the wire from bonding to itself on the take up reel and in the multi wire cable without adversely affecting plan operation.

A Safe and Convenient Needle Disposal Device

Timothy Demers et al. — Thu, 17 Dec 2009 16:27:29 PST

Every day in the United States there are over fifty people who are accidentally stuck by a used needle. It can be estimated that over the next year, one in every six health care professionals will be stuck, and of those, one in every thirty shall contract the HIV virus. Current needle disposal devices have failed to provide the medial world with the safety and reliability that is needed when dealing with hazardous materials. This paper describes a new and safer device for the disposal of needles while adhering to the guidelines set by OSHA that deal with the containment and disposal of expended needles and syringes.

A Demonstration Floating Platform for a Helical Turbine

Suzanne Brunetti et al. — Thu, 17 Dec 2009 16:27:28 PST

As world reserves of fuel dwindle and pollution due to fossil fuel use increases, the importance of non-polluting, renewable energy sources and ways to tap those resources become more important. Professor Gorlov of Northeastern University in the Mechanical Engineering Department developed a helical turbine to take advantage of the tremendous power potential of moving water. To promote widespread acceptance and implementation of this turbine, the turbine must be demonstrated to potential customers.