Gypsum Water Extraction
First Place Senior Design Award
Team Members
Gordon Brinkman, Kyle Tolman, John Matcheck, Emeke Esemonu, and Jacob Hubert, Mechanical
Engineering
Advisor
Paul van Susante, Mechanical Engineering-Engineering Mechanics
Sponsor
Michigan Tech’s MINE Enterprise
Project Overview
Our team will design, build, and test a system to extract water from gypsum, demonstrating
an Earth version as a step toward a Mars version ultimately needed.
Assembly Cell Changeover
Second Place Senior Design Award
Team Members
John Bailey, Gabrielle Fung, Dylan Lauscher, Rachel Palen, and Zachary Schultz, Mechanical
Engineering
Advisor
William Endres, Mechanical Engineering-Engineering Mechanics
Sponsor
MacLean-Fogg Component Solutions
Project Overview
Our project goal is to develop a new part handling system that requires less time
to changeover across six-part numbers while staying in the original machine’s footprint.
The handling system transports nuts and washers from separate vibratory bowls, aligns
them, and brings them to a hydraulic press to be swaged together. The current system’s
track is made of spring steel and swapped for each part configuration; this requires
numerous adjustments resulting in an unnecessary five-hour changeover time. Our solution
employs two conveyors with adjustable guide rails and a gravity slide to transport
these parts. With the new design, the machine’s footprint will stay the same, changeovers
will be easily repeatable, and the changeover time will be drastically reduced.
FCA Advanced Hood Architecture—Structural and Attachment Team
Honorable Mention Senior Design Award
Team Members
Adam Daavettila, Andrew Schunter, Austin Kastel, Max Tervo, Stanley Peterson, and
Steve Ramfjord, Mechanical Engineering
Advisor
Cam Hadden, Mechanical Engineering-Engineering Mechanics
Sponsor
Fiat Chrysler Automobiles
Project Overview
The introduction of the electric vehicle along with the reduced need for the consumer
to access the under hood components themselves has created the opportunity to redesign
how the hood is attached. Our team was tasked with the design problem to create a
fixed hood that would no longer use the hinging and latching mechanism in order to
save weight and manufacturing costs. By fixing the hood to the frame of the vehicle,
it could also be used as a structural member in the event of a frontal collision.
Our team has designed sets of brackets that will use a leaf spring method to apply
a clamping force to hold down the back of the hood while the front will be bolted
through access point in the grille of the vehicle. This new design will be fully removable
to allow access to larger under hood components, while also having access ports to
fill fluids such as oil and windshield washer fluid without the need to remove the
hood. The current scope of the project is focusing on redesigning the attachment points
on the Chrysler Pacifica, but it could be implemented on other vehicles in the future.
Mobile Active Threat Emergency System (MATES)
Team Members
Kevin Edlebeck, Thomas Richards, Olivia Smith and Riley McMichael, Mechanical Engineering
Advisor
Paul van Susante, Mechanical Engineering-Engineering Mechanics
Sponsor
Air Force Research Labs
Project Overview
Our goal is to help first responders better handle active threat situations by researching
and prototyping a solution.
Electrostatic Precipitator Inspection Device
Team Members
Alexander Hubble, Electrical Engineering; Colton Kettelhut, Jeremy Whitman, Landon
Jakubos, and Luke Olari, Mechanical Engineering
Advisor
Paul van Susante, Mechanical Engineering-Engineering Mechanics
Sponsor
DTE Energy
Project Overview
DTE Energy utilizes a series of four Electrostatic Precipitators (ESPs) to remove
ash particulates from flue gasses. Our team is creating a new device and method to
inspect units and identify broken electrodes that can reduce unit efficiency. The
team’s goal was to replace and improve upon the current inspection process requiring
timely setup and large inspection crews. By utilizing a camera equipped crawling robot,
the team has created a functional prototype that can be used to identify broken electrodes.
The created prototype can operate without the need for long setup times and can be
operated with a crew of two people. The team will make further recommendations to
improve the device, allowing for inspection of more ESP area at once.
Sorting of Bar Ends and Slugs from Hot-Formed
Team Members
Noah Dobrzelewski, Dakota Carpenter, Jake Evilsizer, Logan Stetsko, and Logan Brunette,
Mechanical Engineering
Advisor
Paul van Susante, Mechanical Engineering-Engineering Mechanics
Sponsor
MacLean-Fogg Component Solutions
Project Overview
MacLean-Fogg Component Solutions has a hot forging process that creates hot formed
parts and byproducts. This process is supposed to separate and remove byproducts from
parts, but occasionally lets byproducts through, causing damage to machines further
in the process. MacLean-Fogg Component Solutions is looking for a device that separates
byproducts from parts to accommodate for their machine.
Ball Nut and Ball Screw Inspection Data Post-Processing
Team Members
Patrick McFall, Liz Bergh, Josh Kemppainen, Vilnis Stumbris, and Jason Dvorscak, Mechanical
Engineering
Advisor
Steven Ma, Mechanical Engineering-Engineering Mechanics
Sponsor
Nexteer Automotive
Project Overview
Our team created a digital software tool for Nexteer Automotive, which post processes
inspection data of a ball nut and ball screw assembly from an electric power steering
system. The purpose for developing such a tool was that the clearance values of real
assembled parts were unknown, and Nexteer’s engineers were unable to visualize the
interaction of the ball nut and ball screw during use. Nexteer uses a Coordinate Measuring
Machine (CMM), which collects profile data from a real ball nut and ball screw. The
software tool imports the data from these two components, mathematically assembles
them, and allows the end user to analyze the interaction of the ball nut and ball
screw.
Air Cooled Inverter Heatsink
Team Members
Anson Mannes, John Blanchard, Zach Tibbits, Paul Jacks, and Dominic Fusco, Mechanical
Engineering
Advisor
Jeremy Worm, Mechanical Engineering-Engineering Mechanics
Sponsor
US Army TARDEC
Project Overview
Using modern heatsink designs, computational fluid dynamics, and elementary thermodynamic
equations, our team developed a design tool for TARDEC. TARDEC will utilize the design
tool to select a final heatsink configuration for their air cooled inverter. Our team
manufactured and tested a heatsink to validate the data presented on the design tool.
EPS Ball Screw Lash Measurement
Team Members
Blake Tiber, Sarah Jones, Alex Keit, Mike Werthman, and Cole Stout, Mechanical Engineering
Advisors
William Endres and James DeClerck, Mechanical Engineering-Engineering Mechanics
Sponsor
Nexteer
Project Overview
We were tasked with designing and manufacturing a fixture to accurately measure the
lash between the ball screw and ball nut of the steering mechanism in vehicles.
Automatic Case Sealer
Team Members
Christopher Thormodson, Aaron Curtiss, Christian Elsesser, Cal McCarty, Tania Demonte
Gonzalez, and Jacob Wenzlick, Mechanical Engineering
Advisor
Eddy Trinklein, Mechanical Engineering-Engineering Mechanics
Sponsor
Fapco, Inc.
Project Overview
Our team has been engaged to design an automatic case sealer for fully overlapped
(FOL) cartons using water activated tape for Fapco, Inc. Currently, the production
staff uses two different methods to close FOL boxes. The first is a manual machine
to activate and cut custom tape lengths and apply the tape by hand. The second method
for closing the carton includes stapling the carton before a label is applied to the
finished package. The team looks to improve this process by using a conveyor system
in conjunction with a water-activated tape (WAT) mechanism to seal cartons. In addition,
the design will accommodate multiple different carton sizes to increase versatility
of the machine, which in turn will increase production rates.
Fuel Economy Impact Tool
Team Members
Jess Gering, Matthew Kenney, Eric Kostreva, Lily Kraft, and Michael Ostlund, Mechanical
Engineering
Advisor
Steven Ma, Mechanical Engineering-Engineering Mechanics
Sponsor
MacLean-Fogg Component Solutions
Project Overview
A software tool that will evaluate the fuel economy impact of mass on a vehicle. The
purpose of the fuel economy impact tool is to instantaneously evaluate the impact
of mass of a vehicle on fuel economy and energy usage. While the initial project scope
focuses on the additional mass of lug nuts, the program calculates the effects of
various additional masses, stationary or rotating. Through AmeSim simulations and
SolidWorks models, it was possible to correlate basic relationships between mass and
energy usage of a vehicle over various drive profiles, which serve as the basis for
a graphical user interface within Microsoft Excel. The user is able to select a variety
of parameters, including vehicle and lug nut mass and drive profiles.
Load Sensor and Calibrator for Crane Control
Team Members
Juan A. Espinoza-Birruete, Christian M. Kniat, Peter D. O’Mara, Alex J. Voigt and
Taylor C. Warren, Mechanical Engineering
Advisor
Fei Long, Mechanical Engineering-Engineering Mechanics
Sponsor
Department of Mechanical Engineering-Engineering Mechanics
Project Overview
For our project, we intend to identify an off-the-shelf load sensor for the specified
loading range. Then we will integrate it into the crane tension-compression measurements
and design a calibrator for load-cell calibration.
AFRL—MATES
Team Members
Zachary Kendziorski, Alec Stilwell, and Justin Niemi, Mechanical Engineering
Advisor
Cam Hadden, Mechanical Engineering-Engineering Mechanics
Sponsor
Air Force Research Labs
Project Overview
Our team will design and prototype a personnel location system usable during active
threat situations.
EPS Belt Drive Analytical Method to Predict Thrust Forces
Team Members
YuXin Chen, Wesley Gratz, Clay Nadolsky, and Robbie Tian, Mechanical Engineering;
Max Dalzell, Computer Engineering
Advisor
Aneet Narendranath, Mechanical Engineering-Engineering Mechanics
Sponsor
Nexteer Automotive
Project Overview
Our team will develop an analytical model to predict thrust forces of a belt drive
power steering system.
Advanced Vehicle Hood Architecture and Design
Team Members
Alex Emmes, Michael Ferron, Alyssa Knoester, Mitchell Menard, Jaime Modolo, and Travis
Zuleger, Mechanical Engineering
Advisor
Jeremy Worm, Mechanical Engineering-Engineering Mechanics
Sponsor
Fiat Chrysler Automobiles
Project Overview
Our team will design and prototype a fixed hood for IC engine, PHEV, BEV vehicle architectures.
Our goal is to take advantage of the many potential benefits (i.e., structure, pedestrian
protection, over slam clearance, aerodynamics, styling, cost, etc.) while minimizing
detractors (i.e., maintenance and ease of use).
Automatic Rotary Indexer with Visual Feedback System for Fine Finish Tooling
Team Members
Jacob Bennett, Alex Sutton, Cody Chartier, and Sean McCann, Mechanical Engineering;
Tyler Nelson and Jacob Oquist, Electrical Engineering.
Advisor
Eddy Trinklein, Mechanical Engineering-Engineering Mechanics
Sponsor
Endres Machining Innovations, LLC
Project Overview
In order to reduce downtime and extend tool life, our project is to design and implement
a system that can automatically index our customer’s cutting tool. Using a visual
feedback system, the machine operator can now interface with the device and allow
the system to index it. Once the cycle is complete, the visual feedback will inform
the user and the operator can safely run the machine.
Pneumatic Flow Totalizer
Team Members
Matthew Olson, Jacob Hendrickson, and Bradley Larson, Mechanical Engineering; Samuel
LaMarche and Owen VanTiem, Electrical Engineering
Advisor
Jeremy Worm, Mechanical Engineering-Engineering Mechanics
Sponsor
Donald Engineering
Project Overview
Our team built a pneumatic device that can be plumbed to the inlet of a machine and
determine the total quantity of compressed air that the machine uses during a predetermined
period of time. The goal is to have the end user apply this totalizer and determine
compressed air usage of a system. By quantifying air usage of an apparatus employing
current components and the usage of the same apparatus employing higher quality components,
potential dollar savings can be clearly demonstrated.
Sand Point Tower and Boardwalk
Team Members
Ryan Baumann, Kaleb Glowacki, Erik Lemmen, Jared Meyer, and Alex Stine, Mechanical
Engineering
Advisor
Steven Ma, Mechanical Engineering-Engineering Mechanics
Sponsor
Keweenaw Bay Indian Community
Project Overview
Our team is designing and prototyping a mechanical elevator to be installed in a bird
watching tower for the Keweenaw Bay Indian Community.
John Deere Gator XUV835 Exhaust Redesign
Team Members
Tyler Wells, Trevor Marvin, Thomas O’Hotzke, Austin Bittner, Daniel Ellsworth, and
Josh Loiselle, Mechanical Engineering
Advisor
James DeClerck, Mechanical Engineering-Engineering Mechanics
Sponsor
John Deere
Project Overview
Our team will redesign the current exhaust system on the John Deere Gator XUV835.
The current system on the John Deere Gator XUV835 was designed for a previous Gator
model in 2010; since this design, customer expectations and needs have changed. The
new design improves on overall weight of the system, complexity, exhaust noise level,
sound quality, and maintain or improve upon the rear hitch accessibility.
Red Laser Inspection Device Improvement
Team Members
Alex Lautenbach, Brody Berry, Brian Messman, Joe Jarvi, John Medley, and Becca Ratkowski,
Mechanical Engineering
Advisor
Eddy Trinklein, Mechanical Engineering-Engineering Mechanics
Sponsor
MacLean-Fogg Component Solutions
Project Overview
Our team will design and prototype a red laser inspection device and accompanying
process for the quality of wheel nut internal threads for MacLean-Fogg Component Solutions—Royal
Oak. The problem is that current automated inspection processes lack the capability
to locate and sort out several common defects seen due to machining. MacLean-Fogg
would like to end third-party defect hand sorting and integrate automated laser inspection
onto their line(s).
Mobile Active Threat Emergency System
Team Members
Aaron Eskola, Electrical Engineering; Jordan Kieltyka, Computer Engineering; Quinn
Kaspriak, Ryan Washington, and Rebecca Spencer, Mechanical Engineering
Advisor
William Endres, Mechanical Engineering-Engineering Mechanics
Sponsor
Air Force Research Labs
Project Overview
Tasked with designing and prototyping a personnel location system usable during active
threat situations, our team created a remotely operated device that would analyze
the environment around it and relay it to the operator. Combustible gas, carbon monoxide,
oxygen, smoke, and temperature sensors are assembled on the device along with a cell
phone, which is used to give the user “eyes” from the camera when driving the device.
Eddy Current Inspection In-line Integration
Team Members
Kathryn Keen, Sean Lusk, Wiley Thomas, Ryan Quigg, Christopher Thompson, and Ethan
Prehoda, Mechanical Engineering
Advisor
William Endres, Mechanical Engineering Engineering Mechanics
Sponsor
MacLean-Fogg Component Solutions—Metform
Project Overview
MacLean-Fogg Component Solutions is a leading manufacturer of fastener components,
engineered components, engineered plastics, and linkage and suspension components
for automotive, heavy truck, and other diverse industries. The MacLean-Fogg-Metform
facility focuses on horizontal hot forging, machining, and light assembly of components
primarily for transportation industries; one of which is the wheel nut. These assemblies
are comprised of a washer and a nut, which are staked together in an assembly cell.
Currently, the washers are taken to an offline Eddy Current Tester (ECT) before staking,
which inspects the parts for cracking that may lead to failure. Washers flow into
an indexing table, are rotated and tested by the ECT, and based on the result, are
passed or failed. The purpose of this project was to eliminate handling between inspection
and assembly by integrating inspection into the assembly process. A smaller version
of the existing indexing table was designed, so that it can fit in-line with the assembly
cell, along with the ECT.