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Buried Asset Inspection
Get PDFThis senior project, sponsored by NAVFAV EXWC (U.S. Navy Facilities Engineering and Expeditionary Warfare Center,) involved developing a method for inspecting pipelines under normal operation. The team developed an additively manufactured ellipsoid shaped device that could move inside pipelines using the flow of water. The device also collects data using pressure and ultrasonic sensors and uses a scissor jack mechanism to stop when needed. The team successfully created a proof-of-concept prototype that demonstrates the objective is feasible with future product development. A successful product would allow aging water infrastructure to be inspected without causing large disruptions to the water supply system and without needing to dig up large areas of pipeline for inspection. The isolated testing the team performed on the stopping mechanism and suspension system were successful, and the device was able to navigate 12-inch turn radius pipe bends. The final prototype was not waterproof through the shell, but the moving parts of the stopping mechanism prevent water intrusion. The team found that the stopping mechanism was able to stop the device when exposed to the expected drag force of 31.2 pounds. The following report goes into detail about the design, verification, and future recommendations
Backflow Preventer Relief Discharge Detector
Get PDFThis project aims to fulfill a critical need in Zurn\u27s backflow prevention products by developing a versatile external sensor assembly. This assembly is specifically designed to integrate smoothly with the relief valve vent port of the Model 975XL3 RP Backflow Preventer, available in 1-inch and 2-inch sizes. Its primary function is to detect water discharge and send an ON/OFF signal, enabling cloud-based monitoring or in-house alarm system notification of valve status. The sensor assembly ensures high reliability and flexibility with air gap installations, requiring little to no monitoring after installation. By utilizing existing mounting holes on the valve, the design employs for quick and easy setup that does not require a trained technician. The electronic components are also straightforward and just consists of wires and a switch. The 3D printed structure attaches to the valve plate using screws and contains a mechanical limit switch that is activated by a high enough water flow. This switch connects to an alarm system suitable for both indoor and outdoor use, with the design differing only in size to accommodate various valve diameters (1- and 2-inch).
Since the Critical Design Review (CDR), several significant changes have been made to enhance functionality and meet engineering specifications. The most notable change is the addition of vertically extruded mounts with counterbores for air gap screws, replacing an unsuccessful funnel design. To address water leakage through the switch lever slot, a sloped roof section and a 3D printed slot blocker were incorporated, significantly reducing water exposure to the electronics. A circular water plate was added to the switch lever to improve sensitivity at low flow rates, and switch mounting holes were adjusted to slots for customizable flow rate triggering and better manufacturing tolerance. This project document covers the design, implementation, verification, and future recommendations. The design section details changes since the CDR and explains the final design decisions. The design verification section confirms that all critical specifications are met and provides justification for these decisions. Future recommendations are included to guide subsequent project iterations.
For mass production, we recommend manufacturing the mount and tube as a single unit using injection-molded plastic. Similarly, the water blocker and plate fin should also be injectionmolded plastic. Future engineers should focus on simplifying the assembly process. While the current assembly is easy enough for non-engineers, the small dimensions of the tube can sometimes make fitting the fin challenging. Constructing a rig or making minor design adjustments could enhance the speed and consistency of the assembly process. The next steps involve refining the design and iterating the current 1- and 2-inch designs to work with all valves in the 975XL3 series. Overall, we are pleased with our final design, which effectively senses water discharge at low flow rates and provides consistent results after extensive testing. The simplicity of assembly and ease of manufacturing are significant achievements. The project required frequent design iterations based on testing outcomes at the Zurn facility, embodying the true nature of iterative design where each failure provided insights for improvement
Powder Removal System for Additive Manufacturing
Get PDFMetal additive manufacturing, utilized by Parker Aerospace’s Exotic Metals Forming Division, enables the fabrication of intricately designed metal parts that pose significant machining challenges. This technology uses metal powder melted by a laser or electron beam to produce parts, but excess powder often becomes trapped within internal passageways due to complex geometries. Traditional methods like compressed air, vacuum processes, and manual banging are inadequate for effective powder removal. Consequently, an innovative solution is necessary. The designed solution utilizes a pneumatic motor to vibrate the printed part to break up or remove excess powder and was tested both quantitatively and qualitatively, proving more effective than current methods and meeting project specifications yet still removing over 98% of the powder. Despite manufacturing and procurement challenges, the project demonstrated a viable powder removal solution for additively manufactured parts at a significantly reduced cost, well under the $5000 target budget. Recommendations for future iterations include tighter tolerances, motorized rotation, safety enhancements, and additional vibratory power, ultimately contributing to the safety and efficiency of additive manufacturing processes in the aerospace industry
The Dildo Question: when sex positivity and patriarchy clash in the classroom
Get PDFThis Critical Commentary describes how sex positivity can be a Trojan Horse for uncritical and toxic behavior in the classroom and suggests a pedagogical approach to help avoid the co-opting of sex positive ideologies for patriarchal power
Autolacing the DML
Get PDFThe design challenge present is the design of a system to efficiently speed up the lacing of the dry mat loop (DML), part of the GAF production line. For this year, the scope of the project focuses on research and creating a proof of concept for the mechanism responsible for moving the mat within the DML. Compiled research focuses on competitor solutions, material properties, and possible mover mechanisms to be integrated into the major design. Competitor solutions provide an idea of raw material manipulation options. Material properties and possible mover mechanisms provide the foundation for ideation and concept prototyping. The primary deliverable for the project is a prototype to demonstrate a successful proof of concept, that the design chosen capably transports the fiberglass mat throughout the DML
Animatronic Lego Girl Scout
Get PDFThis Final Design Review Report provides a comprehensive overview of our Senior Design Project, with a focus on the testing, modifications, and final design of our animatronic robot. The primary objective was to ensure the robot met the sponsor\u27s requirements through rigorous final testing and targeted enhancements. Significant updates include enabling the robot to display the Girl Scout salute, wave, and give a low five. Throughout the design process, critical milestones were achieved, such as the complete assembly of the robot frame and securing it onto the platform, allowing the robot to perform its programmed actions effectively. The implementation of stress and longevity tests was crucial, as it confirmed the robot\u27s durability and reliability, ensuring it was safe and effective in fulfilling all required tasks.
The successful implementation and thorough testing of the robot guarantees that it meets the sponsor\u27s expectations and is ready for presentation at the EXPO. This report not only documents the project\u27s critical milestones and results but also provides detailed, step-by-step instructions for future groups to replicate and build upon our work. By delivering a functional and reliable product, this project demonstrates our team\u27s ability to meet complex design challenges. Furthermore, the comprehensive documentation serves as a valuable reference for subsequent projects, offering insights and guidelines that can streamline future design processes. The project underscores the importance of meticulous planning, rigorous testing, and precise execution in achieving successful outcomes in engineering design