Project goal: To design, build and test a portable base station for receiving, parsing and recording telemetry data. The portable base station enables a pit crew to monitor vehicle conditions live during a race, and design engineers to analyze events leading up to a component failure.The system is housed in a ruggedized case rated for full submersion while closed. A liquid-cooled computer runs custom software that acquires data from multiple sources. A multi-threaded analysis engine analyzes the data for trends and anomalies. The data is displayed on a 23.8 inch LCD screen in a customizable format suitable for technical and nontechnical users. The graphical interface is built on wxWidgets and a custom graphics library. A removable keyboard and track pad, a 900 MHz wireless transmitter, and the core of a carrier-grade gigabit IP-based network complete the system components. The system can record over 1,000 hours of data for later review and is capable of displaying up to four hours of data at a time.

Project goal: To design a navigation system that is not reliant on GPS technology and can be easily attached to the hitch of a vehicle. The success of autonomous vehicles hinges upon accurate GPS signal reception. Loss of signal makes it nearly impossible for autonomous vehicles to navigate their surroundings, which means they do not always function well in parking garages, tunnels and canyons.A GPS-independent navigation system using the Doppler effect was designed. The system is equipped with two radar modules that collect data while the vehicle is in motion, and all hardware is packaged to survive in standard automotive environments. Custom software was developed for the microprocessor that collects the sensor data. A MATLAB algorithm analyzes the data collected and infers vehicle location based on the vehicle’s last known GPS coordinates.

Project goal: To design and build an 8-inch nominal pipe size wafer-type knife gate valve. The design is scalable to sizes in the product range of 2–24 inches. Research of existing valves identified the differences between valve designs. Stress analysis testing verified that the material chosen could withstand design requirements provided by the sponsor. Although a new valve body design was created, the design used the same actuators and hand wheels used by the sponsor in an existing knife gate valve. The valve prototype was built as a two-piece model, but will be cast as a single piece if the sponsor decides to put the valve into production.

Project goal: To design a robot that autonomously navigates Microsoft data centers to collect temperature, humidity and Wi-Fi signal strength telemetry data. The compact autonomous telemetry system uses a purpose-built robot that incorporates various transducer load-outs such as anemometers, humidity sensors, radio-frequency identification scanners, thermal optics, and thermos probes to measure data center parameters. The robot travels without contacting any surfaces or colliding with any obstacles in its path as it navigates using on board optical sensors. The low-cost telemetry system can run independently without posing a threat to humans, other objects or itself, and uses easily sourced parts while being scalable for small-scale production.

Project goal: To design, build and test a handheld wireless device that locates implantable ports. Implantable ports are surgically placed inside the chest and assist in the administration of large volumes of medications, such as chemotherapy agents and contrast materials for medical imaging. The designed implantable port detection device will aid medical personnel in locating the port without relying on the typical palpation method,which requires the practitioner to feel around for the port on the patient’s chest. The device will interface with the port within the patient. The data received from the port will then be translated into physical coordinates, allowing the device to locate the port. Once the port is located, medical personnel can then access the port and administer therapeutic agents.

Project goal: To design a forgotten item detection system for the storage spaces in super first class airplane suites.When passengers forget to remove their belongings from the wide variety of storage compartments in super first class airplane suites, the result is cost and inconvenience for passengers and airline operators alike.The system is designed to detect items in six different compartments using a visible light detection system. Each compartment has LEDs and photo-transistors mounted on line replacement units that are integrated with an Arduino microprocessor and a display to notify when an item is detected. The optical and electrical performance of the components was analyzed to find the ideal number of LEDs and photo-transistors needed to detect an item left in any location, while minimizing the power drawn by the system. In addition, tests and inspections were performed to ensure system stability during in-flight and storage conditions.

Project goal: To develop touch-free access to all storage spaces inside a super first class airline suite.Super first class passenger amenities are a competitive market for modern commercial airlines, and passengers in this class are always looking for newer, more convenient options. This multi-storage compartment system uses a custom-designed latch that meets safety regulations,including double latching and manual override. Latch actuation is performed with an electric relay and a solenoid. The design explores two sensor solutions: an infrared-based gesture sensor and a capacitive sensor. For esthetic reasons, the sensors are concealed behind infrared-permissive acrylic or Ultraleather fabric material already in use by the project sponsor.All of these components are controlled by an Arduino processor that interprets data from the sensors and controls the electric relays that power the individual latches. The operating current is kept under 2 amps and 24 volts AC at all times.

Project goal: To design, build and test an L-band antenna using 3-D printing.As aviation platforms become smaller, more complex and increasingly cost-averse, a market is being created for novel antenna designs that use manufacturing technologies like 3-D printing. The design was created using a high-frequency electromagnetic simulation software tool, and required development of a custom process for copper plating. Design iteration produced a cost-effective process for building directional and omni-directional antennas that operate in the L-band frequency range. After 3-D printing and electroplating, the antennas were lab tested within a range of 1.0–1.2 GHz. The resultant antennas use less expensive materials and significantly decrease the cost of manufacturing. The next phase will involve connecting the antennas to a frequency transceiver and mounting them on an aircraft.

Project goal: To design a resupply system that autonomously identifies, lifts and stores a 300-pound cylindrical tube aboard a ship following underway replenishment.The U.S. Navy’s ability to remain at sea relies on underway replenishment, a method of transferring cargo and supplies from ship (or aircraft) to ship. These supplies are then moved to their storage location. The process is risky and jeopardizes personnel, especially in extreme weather conditions.The designed system replaces human labor and includes an easy-to-use electronic interface. A key component of the design is the end effector, a software-controlled mechanical design that integrates with a robotic arm to locate and move objects to a specified storage area.The end effector has been tested to withstand harsh marine environmental conditions,such as salt-water exposure, extreme temperatures, humidity, rainfall and ice accumulation. Analysis was conducted to ensure the equipment’s reliability and safety.

Project goal: To design and build a testing apparatus that provides a safe environment in which to bring piezoaccelerometers up to 260-600 degrees Celsius while vibrating 100 Hz at ±1.0 g of acceleration. Caterpillar’s quality control procedures include vibration testing on its equipment using piezoaccelerometers, which export test data to a data acquisition system for subsequent analysis by Caterpillar engineers. Piezoaccelerometer manufacturers, however,do not provide testing or calibration data for some of the temperatures at which Caterpillar operates its equipment, which means that the exported test data might be unreliable. The apparatus designed contains the heat around the accelerometer while keeping delicate electronics from overheating. Combined heat transfer and vibrational analyses provided the correct conditions for the inside of the testing apparatus, and heat transfer calculations determined the amount of insulation required to make the outside surface safe to work with.