Project goal: To design, build and test a multi-frequency antenna mast for large mining trucks. The sponsor needed to update its antenna mast configuration to better interface its large mining trucks with the data and communication arrays used in its international markets. Design requirements stressed safety, dependability and durability. 3-D modeling was used to limit obstruction of the truck operator’s field of view and to verify that the antennas could be lowered to a safe working height. Finite element analysis modeling was performed to ensure that the antenna mast system’s natural frequency would not couple with the truck’s vibration spectrum; if the frequencies were too close,the resulting resonance would destroy the mast system. Finite element analysis was also used to verify that the antenna could withstand forces of 3g. The antenna mast system is reinforced with a steel frame and fitted with a rack and pinion system that uses an electric motor to raise and lower the antenna. The system has an enclosed housing to cover moving parts and prevent damage by flying debris. The sponsor plans to attach up to five antennas to the mast system to improve communications and data accumulation.

Project goal: To design and build a simplified version of the end turn region of an oil-cooled high-power-density aerospace generator and test for the most effective cooling configuration. The test fixture had to be built at full scale, be flexible enough for multiple configurations, and have a way to determine how well it was being cooled. The oil circulation system of the test fixture allows for the manipulation and measurement of the oil pressure, temperature and flow rate. It provides a constant source of oil to the nozzles that apply the cooling oil to the test item. Effective cooling of the end turn region is critical for proper generator performance. Oil pressure, temperature and flow rate were tested, as were nozzle type, configuration and quantity.Cooling effectiveness was determined using an infrared camera mounted within the system. The most effective configuration was determined using a design of experiments model.

Project goal: To develop a prototype mechanism to mechanically connect and disconnect a gas turbine auxiliary power unit from the load compressor on large commercial aircraft. A review of existing mechanisms indicated that some type of clutch system would be required, and trade studies led to the selection of a design based on a synchro-mesh blocker ring. The first generation of the rotating connect/disconnect was developed and tailored to the sponsor’s torque, centrifugal and thermal load requirements and dimensional constraints. The first-generation mechanism was then evaluated under worst-case scenarios using a combination of manual and finite element analysis. Design aspects that did not meet performance requirements were identified then iteratively modified and re-evaluated until all performance requirements were met. Through this process a final generation mechanism was created and a 3-D printed demonstrator unit produced.

Project goal: To optimize a device from a previous design team that reduces air contamination in engine bleed lines and compressed air ducts without significant loss of air velocity or pressure. Turbine engines, used primarily in aircraft, operate in many environments and are expected to perform nominally, but contamination due to harsh environments has always been a problem. The inline swirl particle separator uses swirl vanes and air flowing through compressed air lines to create a helical airflow that exerts centrifugal force on particles and moves them to the outer perimeter of the flow. At this point, a diffuser incorporated into the flow separates cleaner air from particle-laden air, which is ejected from the engine. Filter boxes located at this intersection capture any remaining dust. To optimize this process, the team determined effectiveness and efficiency by using varying pipe lengths,swirl vane rotations, and diffuser gaps.

Project goal: To design, build and test a bearing test machine to determine bearing service life. Journal bearings used in aircraft landing gear absorb radial and axial loads during landing and takeoff. Being non-serviceable and costly to replace, the service life of the bearings must be predictable and adequate for their application. The test machine uses off-the-shelf and fabricated components to move a shaft linearly through a bearing while a radial load of 3,000 pounds is applied. The team used SolidWorks to design the fabricated parts, conducted finite element analysis and motion simulation tests, and followed design for manufacturability practices to produce geometric dimensioning and tolerancing drawings. The linear shaft induces wear of the polytetrafluoroethylene liner, which is measured using a linear variable differential transformer sensor capable of detecting 0.0001 inches of displacement. Signals from the sensors are sent through the data acquisition system and into LabVIEW, which displays and records data. If any information received from the sensors exceeds safety criteria, the machine shuts off and removes load from the test piece. By gathering data on the wear characteristics of bearings smaller than those used in aircraft, it is the sponsor’s goal to create a scalable benchmark that will help establish industry standards regarding bearing service life.

Project goal: To create a modern museum display cabinet that improves the protection and display of valuable items.Museum cabinet technology has remained fairly stagnant since its origin. In addition to protecting valuables from wear, dust and theft, contemporary museum cabinets must also consider factors such as temperature and lighting.The smart cabinet design incorporates wireless communication to control and monitor cabinet parameters. Using an advanced thermal model, a temperature-based thermal control system was designed. High-quality illumination is provided by LEDs with a high color-rendering index. The systems also incorporate a purpose-built power supply and a wireless entry notification system. Using an embedded microcontroller in the cabinet itself, the user is able to wirelessly control protective-action temperature thresholds and individual shelf lighting levels through a graphical user interface. This graphical user interface also displays entry notifications to the user when a cabinet door is opened.

Project goal: To design, test and build an automated system to record fuel consumption at the sponsor’s Tucson Proving Ground, where equipment testing uses thousands of gallons of diesel per week. The system replaces the current manual method of data collection with a mobile application that uses a tablet to collect and store fueling data, which is then sent to a sponsor server. A fabricated bracket allows the Windows tablet to be transported safely during data acquisition, after which reports are merged and produced automatically, and checked for quality using a custom application developed using Python and Visual Basic for Applications. The script then produces a final report that goes to billing and a report that identifies quality issues.

Project goal: To develop a methane pyrolysis reactor to increase oxygen recovery aboard the International Space Station.On the International Space Station,carbon dioxide and hydrogen are run through a Sabatier reactor that produces methane and water. An electrolysis reactor splits the water into oxygen and hydrogen, and the methane is vented overboard. The reactor will close the resource loop in the air revitalization systems and reduce the need for hydrogen resupply.The methane pyrolysis reactor designed for this project uses waste methane from the current system to increase percentage oxygen recovery. The reactor takes in methane gas and heats it by induction to over 1,000 degrees Celsius while using a vacuum pump to keep the pressure below 300 torr. This combination of high heat and low pressure facilitates pyrolysis, which splits methane molecules into their constituent atoms, carbon and hydrogen. The carbon adheres to a porous substrate designed by the sponsor, and the hydrogen continues through the oxygen recovery system, starting the cycle over again.

Project goal: To design a dust filtration system that stops particles entering turbine cooling passages, preventing the plugging that leads to hot corrosion of turbine components.The sponsor’s auxiliary power units, or APUs, experience severe dust ingestion in areas such as Middle East. These units operate on the ground and fine particles from dust and sand storms enter through the engine inlet and obstruct the cooling system within the gas turbine. The components most affected are the first-stage nozzle vane cooling passages and the turbine rotor cooling circuit. The designed system is designed to increase APU life expectancy while decreasing premature failure in the field. It incorporates two filters, cyclonic and barrier, which work together to trap the incoming dust particles. Trade-offs in weight, size, reliability, cost and performance were performed to determine an optimal configuration. The final design of the filtration system was analyzed and tested to capture data for the sponsor, and the system was designed as a line replaceable unit to allow easy access for simple maintenance.

Project goal: To identify, prototype and test a filtration system that can reduce dust intake by filtering out large particulates. The sponsor is developing air bearing technology for 131-9 auxiliary power units, or APUs, used in narrow-body commercial airliners, which use pressurized air generated by the APU to operate. In areas such as the Middle East and American Southwest, dust particulates from the environment can enter the air bearing housing and cause premature wear to the air foil. After conducting trade studies, the team selected a lightweight reverse-pitot tube design, which uses inertial separation to isolate clean air from dust without any moving parts. The filtered air is drawn through a tube by a pressure differential, so no additional transport systems are necessary. The design is virtually maintenance-free and can operate for the life of the APU. Testing of various pitot tube prototypes involved a design of experiments and construction of an airtight fabricated flow chamber that could simulate key APU conditions (Mach 0.1 velocity) and accommodate different pitot tube geometries. A measurable amount of dust was passed through the flow chamber, and filters were fitted to catch dust entering a simulated bearing housing and dust continuing through the main flow. Filter efficiency and particulate size could be verified by this method, and the prototype design that met or exceeded all requirements was deemed to have met the project goal.