Industry Projects
2007 - 2008Solar Electric Human Powered Vehicle Design The purpose of this project was to design and build a single person vehicle that would run on electricity, with later implementation of solar and human power, while performing the functions of an inner-city commuter car. This vehicle was to be designed to meet a final production sale cost of $6,000. The vehicle would have a range between 40 and 60 miles and be able to operate up to a speed of 35 miles per hour. The end result of the construction phase of this project was a ‘proof of concept' prototype vehicle that stayed within the budget of $5,000 and mostly met the required vehicle size, speed, and ergonomic specifications. |
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Pitch and Yaw Mount for Laser Illuminator This project is to design a rugged interface mount for nLight's COTS Shamrock Illuminator. The basic project requirements are to design the mount with lower cost, weight, and size than known existing commercially available solutions. The final design interfaces between a MIL-STD-1913 small arms weapons rail and nLight's COTS Shamrock Illuminator. The design allows 2.3° (138 MOA) windage adjustment from center and 1.8° (113 MOA) elevation adjustment from center. Final assembled weight is 0.30 pounds which is under the 0.37 maximum weight requirement. 4340 oil quenched and annealed to 1200F is the specified material thus allowing the correct amount of spring resistance to the mount without permanently deforming at full adjustment. |
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OMSI Kinetic Wall Display The goal of the OMSI kinetic wall project was to create an original exhibit for the museum composed of multiple mechanical movements and actions for under $500. The display is designed to maximize the amount of time viewers spend looking at its various moving components, which are all driven from a single AC Motor power source. The project required brainstorming ideas for the contents of the display, creating conceptual designs of the components, detail designs of the components, construction of a prototype, and construction of a final working display. WSUV students were given access to the OMSI Exhibits shop for construction, including use of OMSI'S CNC router, allowing the production of complex and/or repeated components. The final design incorporates a wind tunnel, gear reduction train, electric generator, a mechanical waving arm, a steel ball bearing elevator, and a cut-away 4 cylinder engine model. |
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Volcano Monitoring Spider Redesign The United States Geological Survey (USGS) needed their volcano monitoring system redesigned. The original system was a tripod design that was set in place on the surface of the volcano by helicopter. The problem with this design was that it was prone to tipping over when exposed to large ice loading and winds. In our redesign we increased stability and portability, while decreasing weight and cost, as well as creating a set of manufacturing specifications for construction. The result of the project is a volcano monitoring system that is more effective in the harsh environment they are exposed to. By redesigning this volcano monitoring system, the USGS will be able to more reliably monitor the activity on Mount St Helens . These “Raptors” may also be used to monitor other volcanoes around the world as well as in other various applications. |
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Human Powered Vehicle Competition Human Powered Vehicles are engineered to provide transportation by land, air or water using the muscles of their drivers and/or passengers. Aerodynamic, highly engineered HPVs have exceeded 60 mph. The Human Powered Vehicle Challenge, sponsored by ASME, hopes to find a vehicle that can be used for everyday activities such as going back and forth to work and for trips to the grocery store. |
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Crank-Slide Mechanism for Insertion of Cardboard Dividers The primary objective of this project required the analysis and design of a prototype system to replace an existing cardboard inserter system. The existing system required constant repair and manual adjustment to vary production speeds. A crank-slider system was chosen to replace the existing system. The dynamics of the crank-slider system were analyzed using a torque optimized input to reduce the system's motor size and electrical usage. Modeling and dynamic analysis were used to determine the position, velocity, and acceleration of the system components. Runga-Kutta and COSMOS Motion were used to model the system's motion and help determine the forces and moments acting on the components. Using the results from the analysis, the system was designed and a prototype system was built, which allowed Applied Motion Systems (AMS) to test the motion profile the team developed. AMS is confident that the knowledge gained from this prototype will allow them to create a fully functional system to replace the existing cardboard inserter system. |
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RF Module Fixture System Design The goal of this project is to design and build a prototype for a robust, reusable fixture system to hold different sizes of radio frequency modules securely during testing without damage with scalable space for interface electronics and forced-air cooling. The final design incorporates two sections – a “Front Porch” area for the actual module testing area, a rear “Cargo Area” to house all the required electronics components and a Face Plate which provides connections between the areas. Each module type will have a unique adapter plate with a functional prototype built for an LO1 module, pictured above. The modules mount onto four posts, two of which are eccentrically connected to rotary solenoids which, at the flip of a switch, rotate out to hold the module in slight tension. |
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Porosity Fatigue Testing Upon receiving a shipment of forged aluminum Outboard Support Fittings for the Main Landing Gear Beam, Boeing technicians found micro-porosity defects within the forgings. This raised the question as to whether or not the parts could be used in production. It was decided to issue this task of determining the usability of the parts to the Washington State University Vancouver Mechanical Engineering students for use as a senior project. In order to accomplish this project, parts with and without porosity were given to the university students. These parts were then used to make fatigue test samples in which a comparison could be made between the porosity parts and non-porosity parts. After conducting testing a statistical analysis was produced. |
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2006 - 2007Low Power Icing Resistant Enclosure System The goal was to design a low power camera enclosure for the cameras that are placed on Mount St. Helens. The cameras are placed on the mountain to observe the creation of the new dome within the crater of the mountain. Since the cameras are placed in a remote location, where the weather is extreme at times (during the winter months), USGS needed an enclosure that will keep the cameras safe and then allow them to take pictures when the weather gets nice. The structure consisted of a housing made from aluminum that was coated with a product called Wearlon, which is specifically designed to reduce ice build up for many applications. |
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Automated Swage Tool This project entails the design of an automatic band saw swage machine that will be manufactured for under $6,000, to fill the gap identified in currently offered saw swage equipment. A mid-range priced automatic swage will allow more of their customers to enjoy the benefits of automatic saw reconditioning. The design team designed a mechanical linkage arm that connects an existing Armstrong Manufacturing product, an Air Back Feed [ABF], to their manual saw swage. |
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Opto-Mechanical Package Development The focus of the Metolius project was to design and develop a laser diode opto-mechanical package for nLight Photonics Company. This design process involved examining the existing models of the package design and assessing the manufacturing process. Analysis of the package was performed to ensure heat was dissipated properly from the diode, and that the diode could operate within the specified temperature range. The thermal analysis was performed using various methods, including a simple spreadsheet analysis and specialized software. |
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Wave Energy This system, if found to be feasible, would be installed on a buoy to be anchored off the Oregon coast. The first step in this phase of the project was to find a suitable refrigerant. After extensive searching and comparison of different refrigerants the best candidate was determined to be R134a. The wave energy buoy developed is a very practical system. It has the potential to generate large amounts of power by setting up buoy farms off the coast. The project team showed that a solar thermodynamic cycle was not practical since the sun cannot provide the energy required. |
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Acoustic Tracking System The MPS is a part of the ATS issued to the design team at Washington State University Vancouver from SAIC Maritime Technologies. This system will be used to measure the acoustic signature of sub-surface vessels. The MPS will be assembled and deployed off of a ship or a boat and will be deployed to a depth of sixteen-hundred feet in ocean waters. The MPS system contains four sub-assemblies: the Instrument Pressure Housing Assembly, Cable Termination Assembly, Sensor Packaging Assembly, and the Anchoring and Attitude Assembly. The requirements for all assemblies are to endure a seawater environment for a lifetime of 15-20 years. Each sub-assembly shares the same core requirements, all differ in other design aspects. |
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Stresswave Six Sigma Project The goal of this design project was to create an entirely new tool for StressWave Inc. that would lead to better repeatability and reproducibility of its fatigue enhancement process. The purpose of the tool, known as a pressure foot, is to pre-load an annular zone around an area that will be StressWave cold worked. The StressWave cold working process creates a zone of residual stresses concentric to a hole that is machined into the material at a later processing stage. The beneficial residual stresses improve fatigue life of the hole or other discontinuity that is treated by the process. The increased life of the hole lead to better structural integrity and improved safety. |
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Human-Powered Vehicle Competition The American Society of Mechanical Engineers (ASME) hosts the West Coast Challenge, an annual design competition for collegiate level students in engineering. The objective is to exhibit engineering and manufacturing skills designing, building, and racing a human-powered vehicle (HPV). The design, speed and ingenuity of each team's vehicle are reviewed by an ASME panel of judges. A winner is awarded for the combination of best design and highest performance. The ASME HPV West Coast Challenge consists of three classes for 2007, which are speed, utility, and multi-rider classes. WSU Vancouver HPV chose to enter the speed event this year. This required preparation for both a sprint and endurance race for both male and female riders, in addition to a design report and presentation. |
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2005 - 2006Human-Powered Vehicle Competition The American Society of Mechanical Engineers (ASME) hosts an annual human-powered vehicle competition each year. Students design and manufacture unique vehicles that they can propel themselves. The competition is judged on vehicle design and on speed through a sprint and 60-km endurance relay course. Students travel to the event site from around the United States to compete against top engineering schools. The vehicles might be two, three, or four-wheeled, but are generally very low and very fast. At WSU Vancouver, this event is in conjunction with the senior student engineering project. |
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Utility Trailer Design |
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| Electrical Conductivity, Rockwell Hardness, and Tensile Strength Correlation for Aluminum Alloys Sponsor: Boeing, Portland, OR The objective of the project was to determine the existence of a correlation between tensile strength, Rockwell hardness, and electrical conductivity for selected aluminum alloys. Students produced 50 test specimens per each alloy, conducted statistical analysis of the production methods, and tested samples of Rockwell hardness, electrical conductivity, and ultimate tensile strength. Collected data was used to estimate 95% confidence intervals of the material properties for each alloy, determine any correlations between the material properties, and construct the contour maps. |
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Improving Material Flow of A Molded Gear Cell The MICROPUMP team was tasked with creating a process map of the molded gear cell in order to get a visual representation of machine and operator cycle times within the cell. The team then used this process map to analyze the area and provide recommendations to MICROPUMP that would improve these cycle times. Some of these suggestions included standardization of work, moving the mold configuration station, replacing inefficient heaters, and some small part reconfigurations like installing quick release plugs. Current state process maps and possible future state process maps were composed using actual and simulated cycle time improvements. One example, analysis of molds and simulated heating, showed MICROPUMP how they could save up to 47% on heating times. |
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Air Duct to Test Air to Liquid Micro-Channel Heat Exchangers The purpose of the air duct is to test air liquid micro-channel heat exchangers. This testing apparatus will allow students to develop a better understanding of how heat exchangers work and allow students to test air liquid heat exchangers of their own design. |
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Static Rack Analysis The objective of this project was to analyze four concrete curing racks under normal static loading. Our team started the analysis using concepts developed in both machine design and strength of material courses. The hand calculations were then complimented by the use of finite element analysis and solid model computer software. We extended the investigation to cover the affects of corrosion. This affect was modeled by reducing the cross-sectional areas of the model's weld elements and then the total structure elements. We concluded from both our hand calculations and our finite element analysis results that the rack systems are safe under normal static loading with minimal corrosion. |
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Redesign of Automated Semi-Rigid Coaxial Cable Bender The design team was responsible for working with industry engineers to develop an improved automated process to bend semi-rigid coaxial cables. The cable assemblies are used as electrical interconnects for a variety of industrial applications. The existing bending machine could not meet manufacturing standards. The team redesigned key components of the existing bending machine, allowing for enhanced accuracy and flexibility. |
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Linear Motion Speaker Testing Apparatus Dr. Lakatos from the WSUV psychology department needed a fully functional linear motion apparatus for acoustic testing. The objective presented to the team was to design and build a linear motion apparatus which will meet the following design parameters: be capable of moving a new type of back up alarm, have an adjustable travel distance up to 4m, maintain a controlled velocity ranging from .25-1m/s on command, have a positional accuracy of at least 6.35mm, be programmable in the field, cost approximately $3000, and the apparatus must not emit speed dependent noise. The apparatus will be used to move and test a new type of back up alarm which may be used on forklifts or other machinery. Essentially the psychology department needs this device, to determine if the new back up alarm better cues the human ear speed and distance. If people are able to understand the speed and direction of vehicles, by simply hearing a noise, this could dramatically improve safety. By March 2006, the staging platform was successfully designed, assembled and noise problems which arose were creatively solved. The final product exceeded the initial requirements, the final velocity was 2 m/s, the positional accuracy was .001inches, and the product was gladly accepted by the customer. |
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2004-2005 |
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Improving efficiency of the six-step drilling process
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Corebar assembly welding fixture design The objective of this project is to design a universal welding fixture for Columbia Machine. The existing set-up for welding corebar assemblies is time consuming, and requires a lot of manual adjusting. An universal welding fixture will shorten set-up time, and make welding operation more profitable for the company. |
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Wind energy conversion system development The project goal is to develop a wind based energy conversion system that uses wind energy to generate an electrical current from advanced materials . The method of approach can be divided into 1) experimental approach, and 2) analytical approach. The team designs, builds, and operates the testing system in order to investigate a direct relation between output voltage and material oscillation frequency and amplitude. Another challenge facing the team is the development of the math models of the vibration amplitude of the cylindrical rod due to vortex induced vibration. The model, along with the existing math models, will provide the needed values for aspect ratio and diameter. The existing models include critical airflow velocity, system natural frequency, critical ratio, the Strouhal Number, lift force, drag force, and the Reynolds Number. |
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Mounting doors to the cab of the business class truck The project scope consists of hinge-mounting fixture, door-to-cab locating fixtures, and measurement fixtures, methods, and procedures for statistical feedback loop for adjustment of the hinge mounting fixture. |
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| Production-capable measuring system research and development Sponsor: Micropump, Vancouver, WA The scope of this project is to identify and validate a production-capable measuring system using statistical methodology of gage reliability and repeatability. Currently the tolerance of the most problematic gears is +0.0003 inches and – 0.0002 inches, which is being measured with a digital micrometer. Unfortunately, the digital micrometer cannot accurately measure the gear width with acceptable resolution, reliability, and repeatability. |
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2003-2004 |
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Test device design and manufacturing The project was to design and build a device to test printer paper path designs. The test fixture gives HP design engineers the ability to adjust and test the effects of changing different parameters of the paper feed system for the commercial/home printers. |
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Mechanical property evaluations for cold-worked resistance spot welds We developed a new technology to minimize the cost of improving mechanical properties of spot weld structures. The goal of this project was to perform mechanical property experiments on sample pieces of resistance spot welded low carbon steel that have and have not been subjected to an indention process using the Stress-Wave indenter. |
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| Supercharger manifold casting Sponsor: Miller Fuel Injection, Vancouver, WA Presented with the need to produce a part defined as “casting”, we evaluated cost and delivery time of production using sand casting or other means. Completed production of casting pattern and machining fixturing. Part was approx 300mm x 200 mm x 70mm, 1000cc of aluminum or similar material, 2 to 50 part production run. Part was major section of supercharged sandrail intake manifold, interfacing with N/C turned, water jet and milled parts. Planed manpower, cost and schedule needs based on supplied rough task breakdown, revised breakdown as required. Designed, estimated cost and built tooling to enable part production starting with 3D CAD of part, pattern and rough fixture designs. |
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New solder paste selection The student team tested several manufacturers' solder pastes and compared their properties to the paste that the sponsor is currently using. The team checked references of the paste manufacturers to see how their product is performing at other companies. They used references to cut their choices down to two or three manufacturers. The team conducted experiments on paste performance using the DOE technique. They investigated grain structure to determine if the new product is acceptable. |
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