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SOUTH DAKOTA SCHOOL OF MINES AND TECHNOLOGY
DEPARTMENT OF MECHANICAL ENGINEERING
SENIOR DESIGN PROJECT PROPOSAL LIST – FALL 2012
New Project
Project # 1 - ASME Human Powered Vehicle 2013 (ME, IENG, MetE)
Project # 2 - Baja SAE 2013 (ME, IENG, MetE)
Project # 3 - Formula SAE 2013 (ME, IENG, EE, MetE)
Project # 4 - SAE Aero Design 2013 (ME, IENG, MetE)
Project # 5 - SAE Zero Emissions Snowmobile 2013 (ME, EE, IENG, MetE)
Project # 6 - UAV 2013 (ME, EE, CENG, CSC, MetE)
Project # 7 - SAE Supermileage 2013 (ME, EE, IENG, MetE)
Project # 8 - Maya Pedal Guatemala (ME, CEE, ENVE, IENG)
Project # 9 - Composite Acoustic Guitar (ME, IENG, MetE)
Project # 10 - ASME SDC – Remote Inspection Device (ME, EE/CENG, CSC)
Project # 11 - Moonrockers: NASA Lunar Regolith Excavator (ME, EE, CENG, CSC)
Project # 12 - Development of Autonomous Submersible to Explore Extreme Environments
(ME, Chem/ChemE, CENG, EE, IENG)
Project # 13 - Actuator Array (ME, CENG, EE)
Project # 14 - Multifunctional Helmet (ME, MetE)
Project # 15 - Upper Extremity Protective Armor for US Ground Troops (ME, MetE, ChemE)
Project # 16 - Electro-Dynamic Mechanisms for Wave Energy Converters and Wave makers
(ME, EE, CENG, CE)
Project # 17 - purePack 3.0 – Portable Water Purification System (ME, EE, MEM, CEE, GeoE)
Project # 18 - Concrete Airplane (ME, EE, CENG, CEE)
Project # 19 - Steady State Combustor and Exhaust System for Biofuel Research Studies (ME)
Project # 20 - Development of a Grasslands Harvesting Machine (ME)
Project # 21 - Chemical Fuel Cell (ChemE, EE, ME)
Project # 22 - The Needle in the Haystack (or Prairie) (ME, EE, CENG)
Project # 23 – Portable Pop Up Silhouettes (ME, IENG, EE)
Project # 24 - Satellite Attitude Dynamics Simulator (ME, CENG, EE)
Project # 25 - Design of Part Fixturing Table and Clamping System for Refill FSSW (ME, MET)
Project # 26 - AMP Foundry Ventilation, Dust, and Sound Control for Cold Spray (ME, CEE,
EE, IENG, MET)
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SOUTH DAKOTA SCHOOL OF MINES AND TECHNOLOGY
SENIOR DESIGN PROJECT PROPOSAL
Project Title: ASME Human Powered Vehicle 2013
Proposed/Advised by: Dr. Matejcik, Dr. Ellingson, Kim Osberg, Dr. Dolan, HPV team
Sponsored by: CAMP, SA, ASME
Project Description (including objectives and requirements):
A vehicle will be designed, built, and tested for the ASME Human Powered Vehicle Competition.
Information can be found at: http://www.asme.org/Events/Contests/
Project Duration: 2 semesters
Technical Areas Encompassed (e.g., machine design, controls):
machine design, manufacturing, materials, composites, ergonomics, aerodynamics
Any other special requirements:
Senior design members are expected to attend the competition.
Number of Students/Disciplines required (e.g., 2 ME, 1 EE, 1 CS):
3 ME, 2IE, and 1 MetE would be desired
2
SOUTH DAKOTA SCHOOL OF MINES AND TECHNOLOGY
SENIOR DESIGN PROJECT PROPOSAL
Project Title: Baja SAE 2013
Proposed/Advised by: Dr. Dolan, Dr. Muci, Kim Osberg, Baja SAE Team
Sponsored by: CAMP, SAE, SA, Vermeer
Project Description:
Baja SAE consists of competitions that simulate real-world engineering design projects and their related
challenges. Engineering students are tasked to design and build an off-road vehicle that will survive the
severe punishment of rough terrain and in the East competition—water.
The object of the competition is to provide SAE student members with a challenging project that
involves the planning and manufacturing tasks found when introducing a new product to the consumer
industrial market. Teams compete against one another to have their design accepted for manufacture by a
fictitious firm. Students must function as a team to not only design, build, test, promote, and race a
vehicle within the limits of the rules, but also to generate financial support for their project and manage
their educational priorities.
All vehicles are powered by a ten-horsepower Intek Model 20 engine donated by Briggs & Stratton
Corporation. For over twenty-five years, the generosity of Briggs & Stratton has enabled SAE to provide
each team with a dependable engine free of charge. Use of the same engine by all the teams creates a
more challenging engineering design test.
Project Duration:
2 semesters
Technical Areas Encompassed (e.g., machine design, controls):
Dynamics, vehicle dynamics, machine and structural design, human factors, manufacturing
Any other special requirements:
The students must be SAE members to attend the competition. All seniors are expected to attend the
competition.
Number of Students/Disciplines required (e.g., 2 ME, 1 EE, 1 CS):
A team consisting of 6 MEs, 2IEs, and 1 Met student would be desired, with an emphasis for one team
member taking ME 428: Finite Element Analysis to focus on frame analysis.
3
SOUTH DAKOTA SCHOOL OF MINES AND TECHNOLOGY
SENIOR DESIGN PROJECT PROPOSAL
Project Title: Formula SAE 2013
Proposed/Advised by: Dr. Dolan, Dr. Ellingson, Dr. Shahbazi, Kim Osberg, Chuck Schilling,
FSAE Team
Sponsored by: CAMP, SA, SAE, Poet
Project Description:
The Formula SAE competition is for SAE student members to conceive, design, fabricate, and compete
with small formula-style racing cars. The restrictions on the car frame and engine are limited so that the
knowledge, creativity, and imagination of the students are challenged. For the purpose of this
competition, the students are to assume that a manufacturing firm has engaged them to produce a
prototype car for evaluation as a production item. The intended sales market is the nonprofessional
weekend autocross racer. Therefore, the car must have very high performance in terms of its
acceleration, braking, and handling qualities. The car must be low in cost, easy to maintain, and reliable.
In addition, the car's marketability is enhanced by other factors such as aesthetics, comfort and use of
common parts.
The cars are judged in a series of static and dynamic events including: technical inspection, cost,
presentation, and engineering design, solo performance trials, and high performance track endurance.
These events are scored to determine how well the car performs. In each event, the manufacturing firm
has specified minimum acceptable performance levels that are reflected in the scoring equations.
Further information can be obtained at: http://students.sae.org/competitions/formulaseries/
Project Duration: 2 semesters
Technical Areas Encompassed (e.g., machine design, controls):
Dynamics, fluids, aerodynamics, machine and structural design, electric circuits, measurements and
instrumentation, human factors, manufacturing, composites, engines
Any other special requirements:
The students must be SAE members to attend the competition. All seniors are expected to attend the
competition.
Number of Students/Disciplines required (e.g., 2 ME, 1 EE, 1 CS):
A team of 6 MEs, 2 IEs, 2 EEs and 2 Met students would be desired.
4
SOUTH DAKOTA SCHOOL OF MINES AND TECHNOLOGY
SENIOR DESIGN PROJECT PROPOSAL
Project Title: SAE Aero Design 2013
Proposed/Advised by: Dr. Dolan, Kim Osberg
Sponsored by: CAMP, SA, SAE, SAE Aero Design Team
Project Description:
The Aero Design® Competition challenges engineering students to conceive, design, fabricate, and test a
radio controlled aircraft that can take off and land while carrying the maximum cargo.
Competition information is posted at: http://students.sae.org/competitions/aerodesign/
Project Duration: 2 semesters
Technical Areas Encompassed (e.g., machine design, controls):
Dynamics, machine and structural design, instrumentation and testing, controls, fluids, aerodynamics,
manufacturing
Any other special requirements:
The students must be SAE members to attend the competition, and seniors are expected to attend.
Number of Students/Disciplines required (e.g., 2 ME, 1 EE, 1 CS):
A team of 4 MEs, 2 IEs and 2 Met students would be desired.
5
SOUTH DAKOTA SCHOOL OF MINES AND TECHNOLOGY
SENIOR DESIGN PROJECT PROPOSAL
Project Title: SAE Zero Emissions Snowmobile 2013
Proposed/Advised by: Dr. Dolan, Kim Osberg, and the AFV Team
Sponsored by: CAMP, SAE
Project Description:
The object of the competition is to provide SAE student members with a challenging project that
involves the planning and manufacturing tasks found when introducing a new product to the consumer
industrial market. Teams compete against one another to have their design accepted for manufacture by a
fictitious firm. Students must function as a team to not only design, build, test, promote, and demonstrate
a zero-emissions snowmobile within the limits of the rules, but also to generate financial support for
their project and manage their educational priorities.
The SDSM&T team will use an electric motor powered by batteries.
Rules are at: http://students.sae.org/competitions/snow/
Project Duration:
2 semesters
Technical Areas Encompassed (e.g., machine design, controls):
Electric power, motors, controls, dynamics, vehicle dynamics, machine and structural design, human
factors, manufacturing
Any other special requirements:
The students must be SAE members to attend the competition. Senior design members are expected to
attend the competition.
Number of Students/Disciplines required (e.g., 2 ME, 1 EE, 1 CS):
A team consisting of 4 MEs, 4EEs, 2IEs, and 1 Met would be desired.
6
SOUTH DAKOTA SCHOOL OF MINES AND TECHNOLOGY
SENIOR DESIGN PROJECT PROPOSAL
Project Title: UAV 2013
Proposed/Advised by: Profs. McGough, Dolan, Batchelder, Weiss, Linde, Hoover, Tolle;
Kim Osberg, and UAV team
External advisors: Jason Howe, Mark Sauder
Sponsored by: CAMP, SA
Project Description (including objectives and requirements):
This senior design team will work with the UAV team to select a competition and prepare a machine for
that competition.
This Senior Design Team will coordinate all efforts with the Chief Engineer and Team Manager of the
UAV Team as well as the team at large. All final design decisions will be the collaborative efforts of the
UAV Team leadership, the UAV Team, and the Senior Design Team members. Additionally, it is
desired that Senior Design Team members become and remain SDSM&T UAV Team members in good
standing.
Project Duration: 1 year
Technical Areas Encompassed (e.g., machine design, controls):
Controls, machine design, composite materials and structures, fluid mechanics, instrumentation and testing,
software engineering, programming
Any other special requirements:
Students would be members of the UAV competition team. Senior design members are expected to attend
the competition.
Number of Students/Disciplines required (e.g., 2 ME, 1 EE, 1 CS):
2 ME, 1 EE, 2 CompE, 3 CSc, 1 MET would be desired
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SOUTH DAKOTA SCHOOL OF MINES AND TECHNOLOGY
SENIOR DESIGN PROJECT PROPOSAL
Project Title: SAE Supermileage 2013
Proposed/Advised by: Dr. Ellingson, Dr. Abata, Dr. Dolan, CAMP
Sponsored by: Nucor Steel and CAMP
Project Description: The Supermileage® competition provides engineering and technology students
with a challenging design project that involves the development and construction of a single-person,
fuel-efficient vehicle. Vehicles are powered by a small four-cycle engine. The vehicles will run a
specified course with the vehicle obtaining the highest combined kilometers per liter (miles per gallon)
rating plus design segment points winning the event. Students have the opportunity to set a world
fuel economy record and increase public awareness of fuel economy. Engines are donated by Briggs
& Stratton.
Further information can be obtained at: http://students.sae.org/competitions/supermileage/
Project Duration: 2 semesters
Technical Areas Encompassed (e.g., machine design, controls):
Optimization, Dynamics, fluids, aerodynamics, machine and structural design, measurements and
instrumentation, engines, human factors, manufacturing, composites.
Any other special requirements:
The students must be SAE members to attend the competition. All seniors on the project would be
expected to attend the competition.
Number of Students/Disciplines required (e.g., 2 ME, 1 EE, 1 CS):
A team of 4 MEs, 2 EEs, 1 IE, and 1 Met student would be desired.
8
SOUTH DAKOTA SCHOOL OF MINES AND TECHNOLOGY
SENIOR DESIGN PROJECT PROPOSAL
Project Title: Maya Pedal Guatemala
Proposed/Advised by: Dr. Dolan, Kimberly Osberg - CAMP
Sponsored by: CAMP
Project Description (including objectives and requirements):
Bicycle Technology - Maya Pedal is a Guatemalan NGO (non government organization) based in San Andrés
Itzapa. We accept bikes donated from the USA and Canada which we either recondition to sell, or we use the
components to build a range of "Bicimaquinas", (pedal powered machines). Bicimáquinas are pedal-powered
machines that assist with a variety of jobs in the home, on the farm, on the road and in small businesses. Each
bicimáquina is handmade using a combination of old bikes, concrete, wood, and metal.
Pedal power can be harnessed for countless applications which would otherwise require electricity (which may
not be available) or hand power (which is far more effort). Bicimaquinas are easy and enjoyable to use. They can
be built using locally available materials and can be easily adapted to suit the needs of local people. They free the
user from rising energy costs, can be used anywhere, are easy to maintain, produce no pollution and provide
healthy exercise.
Students have the opportunity to design, build and donate bicimáquinas. This senior design project should
increase pedal power research and development and an information resource for NGO’s promoting
appropriate technology and small scale, sustainable agriculture. For more information visit
http://mayapedal.org.
Requirement: All major materials must be previously used.
Project Duration: 2 semesters
Technical Areas Encompassed (e.g., machine design, controls):
Manufacturing and machine design, previous knowledge of bicycles is encouraged.
Any other special requirements:
Number of Students/Disciplines required (e.g., 2 ME, 1 EE, 1 CS):
To build this bike I think we would need 4 students, preferable an Industrial Engineer and an
Environmental or Civil Engineer with a Mechanical Engineer.
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SOUTH DAKOTA SCHOOL OF MINES AND TECHNOLOGY
SENIOR DESIGN PROJECT PROPOSAL
Project Title: Composite Acoustic Guitar
Proposed/Advised by: Dr. Dolan, Dave Lang, Gary Santa
Sponsored by: CAMP, Gary Santa, Dr. Dolan
Project Description (including objectives and requirements):
A composite (carbon fiber) acoustic 6-string guitar will be designed, built, and tested. It is desired to focus
on the manufacturing technology while assuring a professional sounding guitar. The guitar should have
roughly the shape, size, and sound of a dreadnought guitar.
Project Duration: 2 semesters
Technical Areas Encompassed (e.g., machine design, controls):
machine design, structures, manufacturing, materials, composites, ergonomics, acoustics, vibrations, music
Any other special requirements:
It would be helpful if at least one of the team members were a guitar player.
Number of Students/Disciplines required (e.g., 2 ME, 1 EE, 1 CS):
3 ME, 1 IENG, and 1 MetE would be desired
10
SOUTH DAKOTA SCHOOL OF MINES AND TECHNOLOGY
SENIOR DESIGN PROJECT PROPOSAL Project Title: ASME STUDENT DESIGN CONTEST – Remote Inspection Device
Proposed/Advised by: Mr. Jason Ash + others
Sponsored by: A $500 budget is available from the ASME student chapter with the possibility of an
additional $500 depending on project needs/resources. Travel and hotel expenses will be covered by your ASME
student section.
Project Description:
After the tragedy at the Fukushima nuclear facility following the March 2011 Tohoku earthquake and
tsunami, the nuclear industry has issued a Request for Proposal (RFP) to design and build a small,
remotely-controlled inspection vehicle. The purpose of the vehicle is to determine the level of radioactivity
at specified locations and inspect for damage. This vehicle will protect the human operator from absorbing
a high dose of radioactive contamination. There is information that could be gained by the inspection
vehicle that could inform the plant operators so that they may avert an accident or begin repairs The
ASME student design contest is a scaled down version of this RFP that does not have to contend with a
radioactive environment. The task for the team is to design a remotely-controlled, proof-of-concept vehicle
for inspection purposes. The vehicle must be able to negotiate around obstacles, both in getting to the
inspection points and in bringing the sensor back to the designated return area. The vehicle must then
return to its starting location, ready for another run as described:
http://www.asme.org/events/competitions/student-design-competition
Project Duration: 2 semesters
Technical Areas Encompassed (e.g., machine design, controls):
Machine design, mechatronics, controls, and programming
Any other special requirements:
ASME membership required for 2012-2013 at the $25 student rate.
Competition Prizes:
Number of Students/Disciplines required
Up to 4 ME/EE/CENG/CSC students (Team cannot exceed 4 students): The ideal team would be 1 of each
discipline or 2 ME, 1 EE or CENG, and 1 CSC.
11
SOUTH DAKOTA SCHOOL OF MINES AND TECHNOLOGY
SENIOR DESIGN PROJECT PROPOSAL Project Title: NASA Lunabotics: Lunar Regolith Excavator
Proposed/Advised by: Mr. Jason Ash and Dr.’s Michael Batchelder, Jeff McGough, and Charles Tolle+
Sponsored by: A proposal for $5000 in funding from NASA will be sent once open for submission.
Additional fundraising is likely required.
Project Description:
The Lunabotics Mining Competition is a university-level competition designed to engage and retain students in
science, technology, engineering and mathematics (STEM). NASA will directly benefit from the competition by
encouraging the development of innovative lunar excavation concepts from universities which may result in clever
ideas and solutions which could be applied to an actual lunar excavation device or payload. The challenge is for
students to design and build a remote controlled or autonomous excavator, called a lunabot, that can collect and
deposit a minimum of 10 kilograms of lunar simulant within 15 minutes. The complexities of the challenge include
the abrasive characteristics of the lunar simulant, the weight and size limitations of the lunabot, and the ability to
control the lunabot from a remote control center. This will be the 4th year of the competition with a major goal of
implementing autonomy this year. Complete details of the competition are provided at the following location:
http://www.nasa.gov/lunabotics
Project Duration: 2 semesters
Technical Areas Encompassed (e.g., machine design, controls):
Machine design, mechatronics, controls, vision systems, and programming
Any other special requirements:
K-12 Outreach required as part of this project.
Competition will be at Kennedy Space Center from May 20-24, 2013.
Competition Prizes:
$5000 for the overall competition Joe Kosmo team award winner and $3000, $2000, and $1000 for 1st, 2
nd,
and 3rd
place along with VIP Kennedy Space Center launch tickets for all of these.
Number of Students/Disciplines required
5-8 ME/EE/CENG/CSC/MINE students (Ideal team would be 2 ME, 2 EE/CENG, 2 CSC, and 2 MinE)
12
SOUTH DAKOTA SCHOOL OF MINES AND TECHNOLOGY
SENIOR DESIGN PROJECT PROPOSAL
Project Title: Development of Autonomous Submersible to Explore Extreme Environments
Proposed/Advised by: Drs. Tolle, McGough, Matejcik, and Mr. Ash
Sponsored by: South Dakota Space Grant NASA ($8k is in place to support implementation)
Project Description (including objectives and requirements):
The AUV (Autonomous Underwater Vehicle) team is looking for senior design students from a variety of
disciplines. The team is tasked with the design and development of a submersible capable of autonomously
navigating in confined spaces at pressures of up to 1500 psi for three hours and then returning to its departure point.
This vehicle is intended for use in the Sanford Lab (aka what is to be DUSEL some day) but is being designed for a
variety of applications including open water exploration with Yellowstone lake, deep ocean exploration, and
possible missions to Europa (http://en.wikipedia.org/wiki/Europa_(moon)). This will be the 3rd
year for the team.
In pervious years the team has created and fabricated two frame designs, two different thruster systems, a
transmit/receiver sonar sounder, battery module controller and a designed for the power distribution system. There
are numerous additional needs yet to be accomplished before basic navigation and operation can begin, some
additional projects are listed below:
• A buoyancy system needs to be developed
• A supervisory power system needs to be designed and implemented – utilizing the existing battery module
controller subsystem
• A battery module enclosure subsystem needs to be designed and implemented
• A force transducer feedback system for thruster control must be designed and manufactured
• Low level thruster control systems must be developed and implemented
• An attitude control system must be developed and implemented
• Sensory systems must be developed and implemented, i.e. the sonar sounder needs to complete testing and
integrated to form a full sonar sub-system, a new UV/IR/visual camera system needs to be designed
• A high pressure water and gas sampling system needs to be designed and implemented
• A transportation and deployment system must be designed and manufactured
• Mission planning, guidance, and navigation algorithms must be designed and put in place
• A GUI interface systems for planning system missions needs to be developed
*Note, not all items listed above needed to be solved during this year’s efforts – the actual
team will focus on items that lien towards their knowledge, interest and talents.
Project Duration: 2 semesters
Technical Areas Encompassed (e.g., machine design, controls):
machine design, mechatronics, electronics, and controls
Number of Students/Disciplines required:
This year 1-2 CENG, 1-2 Chem/ChemE, 4-6 EE, 2 IENG, and 4-6 ME are desired – all are welcome.
For more information stop by our lab in EP-335 and contact Dr. Charles Tolle, e-mail: charles.tolle@sdsmt.edu or
jason.ash@sdsmt.edu
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SOUTH DAKOTA SCHOOL OF MINES AND TECHNOLOGY
SENIOR DESIGN PROJECT PROPOSAL
Project Title: Actuator Array
Proposed/Advised by: M. Bedillion, R. Hoover
Sponsored by: ME Department
Project Description (including objectives and requirements):
An actuator array consists of a planar array of two-degree of freedom actuators that cooperatively
translate and orient objects (e.g., packages) for efficient handling. Each cell of the array consists of an
actuator that approximates a vector force, a microcontroller that communicates with neighboring cells
and controls the actuator, and sensors that detect the presence of an object above the cell. The array uses
a combination of distributed and centralized control, with low level servo commands needed for
cooperation passed from cell to cell, and high level commands broadcast over a centralized
communication network.
Actuator array manipulation has several benefits over traditional manipulation schemes that make it well
suited for parcel handling applications. Planar manipulation is typically achieved either through a
conveyor system with gates for orientation or a robotic manipulator. Conveyor belts can transport many
objects simultaneously and perform simple sorting tasks with gates, but they have limited orientation
capability and cannot reorder objects. Robotic manipulators offer precise manipulation of objects at the
expense of high power consumption and an inability to manipulate multiple objects simultaneously. The
actuator array concept combines the benefits of conveyor belts and traditional manipulators by allowing
the precise, low-power manipulation of multiple objects simultaneously with three degrees-of-freedom.
The goal of this senior design project is to design an actuator array and construct a small number of
functional cells (≥4). Using an existing prototype array as a starting point, the design team will choose
and implement a computer vision system to detect object position and orientation on the array, design
electronics at each cell, including a microcontroller, motor drivers, encoder counters, communication
interface, etc., and develop new actuator mechanisms to generate planar forces.
Project Duration: 2 semesters
Technical Areas Encompassed (e.g., machine design, controls):
Dynamics, controls, circuits, mechatronics, computer vision, etc.
Any other special requirements: None.
Number of Students/Disciplines required (e.g., 2 ME, 1 EE, 1 CS):
2-3 CENGs; 1-2 EEs; 2-3 MEs.
14
SOUTH DAKOTA SCHOOL OF MINES AND TECHNOLOGY
SENIOR DESIGN PROJECT PROPOSAL
Project Title:
Multifunctional Helmet
Proposed/Advised by:
Dr. Karim Muci and Mr. Brandon Hinz
Sponsored by:
This senior design project will be part of a research project sponsored by the US ARMY Research
Laboratory (ARL) that involves a close collaboration between the SDSM&T Experimental and
Computational Mechanics Laboratory (ECML) and the SDSM&T Composites and Polymer Engineering
(CAPE) Laboratory.
Project Description (including objectives and requirements):
The purpose of this project is to develop a multifunctional helmet for first responders that has a reasonable
cost and can provide adequate protection to the head in a wide variety of scenarios. The following example
illustrates the need for such a helmet. Currently Search and Rescue (SAR) teams across the nation
commonly use different helmets for the different services that they provide like vertical rescue, swiftwater
rescue, vehicle extrication, and building shoring among others. Besides the inherent costs and logistic
problems of having to deal with several different helmets, few if any of them are designed with
multifunctional capability for situations encountered beyond the mission profile.
Arrangements will be made so that the members of the senior design team have the opportunity to interact
with first responders in the Pennington County area to determine the needs that they have for the product
under consideration.
Project Duration: September 2012 – May 2013
Technical Areas Encompassed:
Product development, manufacturing, solid mechanics, fluid mechanics, and dynamics. The work will
include performing computer simulations, manufacturing of prototypes, and experimental testing.
Any other special requirements:
US Citizenship is required to participate in this project.
Number of Students/Disciplines required:
2–3 Mechanical Engineering students.
Optional: 1 Metallurgical Engineering student.
15
SOUTH DAKOTA SCHOOL OF MINES AND TECHNOLOGY
SENIOR DESIGN PROJECT PROPOSAL
Project Title:
Upper Extremity Protective Armor for US Ground Troops
Proposed/Advised by:
Dr. Karim Muci and Mr. Brandon Hinz
Sponsored by:
This senior design project will be part of a research project sponsored by the US ARMY Research
Laboratory (ARL).
Project Description (including objectives and requirements):
The body armor currently used by US ground forces has resulted in a reduced number of casualties in the
battlefield due to improved protection of the head and chest. Unfortunately, a Soldier is commonly faced
with treats that can produce severe damage to the extremities and result in their amputation. The goal of
this project is to work on the design of an effective extremity armor that uses existing technologies and has
a reasonable cost. Prototypes of the selected product concept will be manufactured and tested.
Due to the confidentiality requirements associated with this project, very few details can be provided here.
However, interested students can contact Dr. Muci (office CM-171) who can provide more information.
Work related to this research project started in the fall of 2006. A comprehensive list of customer needs is
available as well as an extensive literature search. A small ballistics lab for testing product concepts is
available on campus and basic prototypes of possible concepts have been built and tested with very
promising results. Two high speed monochrome Photron SA1.1 cameras and a color Photron SA4 camera
are often used during ballistic impact testing.
Project Duration: September 2012 – May 2013
Technical Areas Encompassed:
Product development, manufacturing, solid mechanics, fluid mechanics, and dynamics. Extensive
experimental testing will be done. Also, some of the work may require performing computer simulations.
Any other special requirements:
US Citizenship is required to participate in this project.
Number of Students/Disciplines required:
2–3 highly motivated Mechanical Engineering students.
Optional: 1 highly motivated Metallurgical Engineering and/or Chemical Engineering student.
16
SOUTH DAKOTA SCHOOL OF MINES AND TECHNOLOGY
SENIOR DESIGN PROJECT PROPOSAL
Project Title: Electro-dynamic mechanisms for wave energy converters and wave makers
Proposed/Advised by: U.A. Korde, M.A. Langerman, C.F. Schilling
Sponsored by: ME Department
Project Description (including objectives and requirements):
Water waves concentrate the sun’s energy by two orders of magnitude, can travel long distances and last
a long time. Waves have been seen as a source of ‘clean’ energy for many decades in the worlds of
commercial and academic research and development. Energy conversion from waves usually requires
some form of dynamic mechanical interaction with the waves. This is often achieved by means of a
floating or submerged body oscillating in response to the waves and driving a linear or rotary electric or
hydraulic generator via a suitable power transfer mechanism.
Successful implementation of any such energy conversion scheme depends on rigorous analysis and
model testing. To that end, a wave tank was constructed last year with the ability to reproduce at model
scale the large variety of wave amplitude and directional spectra encountered in large bodies of water
(such as the Great Lakes or the oceans). The design focus of the senior design team this year will be on
the development and testing of electro-dynamic mechanisms that will be used as power take-off devices
for the model-scale wave energy converters to be tested in the wave tank. Larger scale versions will be
used in reverse to drive a bank of wave makers to be installed in the tank. The mechanisms will be
controlled using digital electronics but muse be capable of handling the right amount of power
depending on the application. Demonstrations and systematic testing of at least 2 mechanisms will take
place in the ME wave tank.
Project Duration: 2 semesters
Technical Areas Encompassed (e.g., machine design, controls): Dynamics, Fluid mechanics, solid
mechanics, vibrations, controls, circuits, mechatronics, machine tool operation, etc.
Any other special requirements: None.
Number of Students/Disciplines required (e.g., 2 ME, 1 EE, 1 CS): 5/6; MEs, EEs, CENGs, CEs all
welcome.
17
SOUTH DAKOTA SCHOOL OF MINES AND TECHNOLOGY
SENIOR DESIGN PROJECT PROPOSAL
Project Title: purePACK 3.0
Proposed/Advised by: Mr. Jason Ash, Mr. Caine Shagla
Project Sponsor: LABSCI, LLC
Project Duration: 2 Semesters (FALL 2012 – SPRING 2013)
Project Description:
For implementation at the orphanage in Chile for purePack 1.0, the system worked and is continuing to
work perfectly. The field evaluation in Africa of purePack 2.0 clearly demonstrated the portability and
function of system for immediate source remediation. This year we will be addressing a more focused
adjustment to the systems sediment reduction. Current sediment removal is accomplished by a mesh pre-
screen followed by a Doulton ceramic cartridge. The system needs to reduce turbidity of any water
source to a level of 1NTU or less. The tasking of this design project will consist of three primary areas of
focus:
1. Conceptual investigations of fluid dynamics as they relate to particle separation and settling
a. Possible inter-particle dynamics and electron chemistry
2. Mechanical investigations of components necessary to enact the findings of part 1.
3. Finally a physical look at production of these components and incorporation into the current flow
line of purePack system.
With that said, the design requirements for this year’s purePack 3.0 project, are represented by the
following:
Applied investigation of particle behavior and sizing manipulation relevant to given constraints.
a. Multi-stage flow line collection
b. Variant methods of collection material
c. Both turbulent and laminar evaluations with target flow being approx. (.5 Gal/Min)
d. Post collection particle dispersion and or discharge
General deliverable will consist of a detailed CAD recommendation for design of useable system with a
physical production of a bench top apparatus. Other optional deliverables can include:
e. Prototype production of CAD
f. Field evaluation in Africa Summer 2013 attached to an ESA effort.
Technical Areas Encompassed (e.g., machine design, controls):
Fluid Mechanics/Hydrology, Materials Science, among others depending on student background
Any other special requirements: It is recommended that students are a part of Engineers and
Scientists Abroad
Number of Students/Disciplines required (e.g., 2 ME, 1 EE, 1 CS):
Open up to 4 students from the following backgrounds: CE, GEOE, ME, MEM, MET. It is preferable to
have no duplicated backgrounds.
18
SOUTH DAKOTA SCHOOL OF MINES AND TECHNOLOGY
SENIOR DESIGN PROJECT PROPOSAL
Project Title: Concrete Airplane
Proposed/Advised by: Dr. M. R. Hansen and Dr. Lidvin Kjerengtroen
Sponsored by: SDSMT Concrete Airplane Club.
Project Description:
The concrete airplane did taxi last year but needs many improvements before it can fly. A new, larger wing needs to
be cast. Servos need to be installed for all control surfaces in addition to the throttle. The entire design and
configuration needs to be studied and improved. Remote control methods need to be practiced.
Project Duration: 2 semesters
Technical Areas Encompassed (e.g., machine design, controls):
Aerodynamics, airplane design and construction, servos, and control systems.
Any other special requirements:
Competition will be at Embry Riddle Aeronautical University, Daytona Beach, during the week of May 6-
10, 2013. Partial funding for travel will be provided by the SDSMT Concrete Airplane Club.
Number of Students/Disciplines required
3-4 ME/EE/CENG/CEE students (Ideal would be 2 ME, EE/CENG, 1 CEE)
19
SOUTH DAKOTA SCHOOL OF MINES AND TECHNOLOGY
SENIOR DESIGN PROJECT PROPOSAL
Project Title: Steady State Combustor and Exhaust System for Biofuel Research Studies
Proposed/Advised by: Dr. D. Abata, Dr. B. Simmons
Sponsored by: Externally Funded
Project Description (including objectives and requirements):
The mechanical engineering department is launching an initiative to study the combustion characteristics of
Biofuels. This work will require the development of a steady state combustor and exhaust system. The
combustor and exhaust system must be designed and components specified. Components of this system
will then be purchased and assembled. The system will be tested with an appropriate biofuel such as a
mixture of bio-oil and cellulose. The system will also involve designing, specifying, constructing, and
installing a fuel injector and delivery of the fuel with an appropriate injector. The injector may be
pneumatic where compressed air will be mixed with the biofuel to aid delivery and combustion of the fuel.
Several other university research laboratories around the country have such systems. The work will involve
initially studying these systems as well.
The system should be able to accommodate a ‘can’ type combustor found in the combustion sections of gas
turbines.
Project Duration: 2 semesters
Technical Areas Encompassed (e.g., machine design, controls):
machine design, manufacturing, materials, pneumatics, composites
Any other special requirements:
Senior design members are expected to study existing systems, design, specify, purchase, construct the
system, and demonstrate its operation. A user’s manual should also be prepared.
Number of Students/Disciplines required (e.g., 2 ME, 1 EE, 1 CS):
2-3 ME students
20
SOUTH DAKOTA SCHOOL OF MINES AND TECHNOLOGY
SENIOR DESIGN PROJECT PROPOSAL
Project Title: Development of a Grasslands Harvesting Machine
Proposed/Advised by: Dr. D. Abata
Sponsored by: NSF Center for BioEnergy Research and Development
Project Description (including objectives and requirements):
Ethanol based fuel produced from grasslands is a rapidly developing area. This grassland growth is a
hardy stalk-like agricultural product much like poplar, sugar cane, willow or bamboo. There are other
uses as well such as basketry and fence making. A company in Denmark wishes to develop a harvester,
to be carried on an agricultural tractor and powered by the mechanical PTO and hydraulic power output
from the tractor. The idea is to develop a relatively simple harvester from components available on the
market. It should be possible to operate the harvester with one person.
This agricultural growth is planted in rows with a distance of 80 cm (~30 inch) between the rows. The
growth is harvested in full lengths when it is 3 years old. The dimensions of the growth varies from
about 7 meters (~25 ft) high with a diameter at the base (root end) of 5-6 cm (2 inches) down to a height
of 2 meters (~7 ft) with a diameter of 1.5 cm (3/4 inch).
This work will involve collaboration with a design team in Copenhagen under the European Project
Semester (EPS) Program. The Copenhagen team will be given the same (or very similar) assignment.
The academic calendars between SDSMT and Copenhagen are different so the work will probably not be
done together but there will be interaction between teams with teleconferences and videoconferences
(Skype, etc).
The initial step of the project will be to study existing harvesting machines. Then the design of the
harvester will be developed. Detail and assembly drawings with SolidWorks will be necessary. Finally,
there is some possibility of constructing a portion of the harvester such as a frame prototype, cutters or
material handler devices.
A machinist with experience in developing specialist agricultural equipment and the owner of the Danish
company will be available as consultants for the practical part of the project.
Project Duration: 2 semesters
Technical Areas Encompassed (e.g., machine design, controls):
machine design, manufacturing, materials, hydraulics, composites, ergonomics
Any other special requirements:
Number of Students/Disciplines required (e.g., 2 ME, 1 EE, 1 CS):
3-4 ME students
21
SOUTH DAKOTA SCHOOL OF MINES AND TECHNOLOGY
SENIOR DESIGN PROJECT PROPOSAL
Project Title: Chemical Fuel Cell
Proposed/Advised by: Ralph Grahek
Sponsored by: Alevtina Smirnova, PhD
Project Background:
Chemical based fuel cells are coming into use and getting usable energy out of them is essential. Dr.
Smirnova would like to demonstrate her fuel cell design with a practical application.
Project Description:
MEs to work with Dr. Smirnova on optimal design of catalyst interface plate. EEs to work on getting
usable DC output for demonstration of fuel cell capability. The goal is to use the power output of the fuel
cell to operate a system (motor, microcontroller, etc.).
Task 1: Single polymer electrolyte fuel cells (PEMFCs) manufacturing and testing in O2/Air-H2 gases at
various flow rates and temperatures with expected power density of 0.8W/cm2 at 30oC for the active area
of 6.25 cm2.
Task 2: Design and manufacturing of a PEMFC stack.
Task 3: System design and implementation.
Project Duration: 2 semesters (Fall 2012 – Spring 2013)
Technical Areas Encompassed (e.g., machine design, controls):
EE: DC to DC power conversion, fan/motor operation, microcontrollers, and sensing (electrical circuit
design)
ME: Metal design and fabrication needed to get fuel cell operational.
ChemE: Manufacture membrane electrode assemblies (MEAs) using screen printer/decal approach.
Any other special requirements:
Working with microcontrollers, motors, electrical circuits, and fabricating metal are a plus.
Number of Students/Disciplines required (e.g., 1-2 EE/CENG/ChemE):
1-2 EE
1-2 ME
1-2 ChemE
22
SOUTH DAKOTA SCHOOL OF MINES AND TECHNOLOGY
SENIOR DESIGN PROJECT PROPOSAL
Project Title: The Needle in the Haystack (or Prairie)
Proposed/Advised by: Sherry Farwell, Dr. Dolan, and John Nelson
Sponsored by: Sherry Farwell
Project Description (including objectives and requirements):
Former Dean of Graduate Education at SDSM&T, Sherry Farwell, has an interest in mapping routes used
by settlers for western expansion. This involves finding metallic artifacts hidden beneath the pathways that
have been long since been obscured over the past two centuries. John Nelson has been using three metal
detecting systems that are dragged behind an ATV. All three systems are independent and have their own
speaker output. Listening to three speakers simultaneously is tedious although has proven effective in
finding very small artifacts at speeds around 5 mph. The goal of this project is to design and develop one
larger metal detecting system or other scenario that would eliminate the need to listen to three speakers
simultaneously. Increasing the speed and size will help reduce the time required to search the prairie. The
ability to distinguish metal type and discriminate certain materials would also be beneficial.
Project Duration: 2 semesters
Technical Areas Encompassed (e.g., machine design, controls):
Machine design, electrical design, coil design,
Any other special requirements:
Number of Students/Disciplines required (e.g., 2 ME, 1 EE, 1 CS):
2 ME, 2 EE, 1 CENG
23
SOUTH DAKOTA SCHOOL OF MINES AND TECHNOLOGY
SENIOR DESIGN PROJECT PROPOSAL
Project Title: PORTABLE POP UP SILHOUETTES
Proposed/Advised by: Tim Johnson, Todd Curtis, Eric East
Sponsored by: Zone Four Engineering, LLC
Project Description (including objectives and requirements):
There are a variety of silhouettes for target shooting on the market today. Most targets drop and have to be
manually set up to shoot them again, meaning you have to stop shooting, clear the area, and go down range
to reset your target. With a portable pop up silhouette the shooter would be able to set the target down
range and remotely reset the target without having to go back down range. This not only improves safety
but also increase the number of rounds that can be shot in a day. There are other systems like this on the
market but they are either very expensive or offered only to military and law enforcement. The design of
the entire system is needed to produce a prototype to test and move into production. The main objectives
of this project are detailed below:
• Design a mechanism to raise a steel plate to a vertical position and allow the steel plate to fall
back after being hit.
• Design a remote system so that the target can be raised quickly by either the shooter or another
person.
• Make the system battery powered.
• Optimize the life of the battery.
• Make the system as light weight and portable as possible.
• Develop a scale-up and commercial production plan.
Student project team members with do a market analysis to identify current products available and design a
unique system that meets the requirements listed as a prototype that can be tested and further developed for
production. The team will need to develop a cost analysis and determine a feasible selling cost for the
system. The system prototype will use animal silhouettes as targets.
Project Duration: 2 semesters
Technical Areas Encompassed (e.g., machine design, controls):
machine design, manufacturing, materials, ergonomics, commercialization, controls
Number of Students/Disciplines required (e.g., 2 ME, 1 EE, 1 CS):
2 ME, 2IE, and 2 EE would be desired
24
SOUTH DAKOTA SCHOOL OF MINES AND TECHNOLOGY
SENIOR DESIGN PROJECT PROPOSAL
Project Title: Satellite Attitude Dynamics Simulator
Proposed/Advised by: Drs. Tolle, Bedillion + others potentially
Sponsored by: South Dakota NASA Space Grant / AUV Team
($5K is in place to support implementation)
Project Description (including objectives and requirements):
This project is an offshoot of the South Dakota NASA Space Grant AUV team. If we are to travel to
Europa (http://en.wikipedia.org/wiki/Europa_(moon)) our submersible spacecraft rover will need a
communication link back to earth. This project is to design and build a small satellite simulator so that
future students can work on satellite controllers, star pointing algorithms, communication links, etc.
Several such simulators can be seen in Agrawal and Rasmussen paper entitled: “Air Bearing Based
Satellite Attitude Dynamics Simulator for Control Software Research and Development” available at
http://faculty.nps.edu/agrawal/docs/spie-agrawal-rasmussen.pdf. The main goal in this year’s effort is to
fabricate an air bearing, design a mounting table (similar to a tooling table), design a thruster system and
implement low level thruster electronics.
Project Duration: 2 semesters
Technical Areas Encompassed (e.g., machine design, controls):
machine design, mechatronics, and controls
Number of Students/Disciplines required:
This year 2 ME, 1 CENG, 1 EE are desired, additional students are welcome.
For more information Contact Dr. Charles Tolle, e-mail: charles.tolle@sdsmt.edu or visit our lab in EP-
335.
25
SOUTH DAKOTA SCHOOL OF MINES AND TECHNOLOGY
SENIOR DESIGN PROJECT PROPOSAL
Project Title: Design of Part Fixturing Table and Clamping System for Refill
Friction Stir Spot Welding
Proposed/Advised by: Dr. Widener, Dr. Jasthi, and Todd Curtis
Sponsored by: AMP
Project Description:
The object of the project would be to design 2-ft. extension tables for each side of the Riftec Refill
Friction Stir Spot Welder for the AMP center, and a clamping system for both large parts and test
coupons.
Project Duration:
2 semesters
Technical Areas Encompassed (e.g., machine design, controls):
Refill Friction Stir Spot Welding, machine and structural design, manufacturing
Any other special requirements:
At least 1 student who is currently a researcher from AMP is preferred to help coordinate and lead the
project.
Number of Students/Disciplines required (e.g., 2 ME, 1 EE, 1 CS):
A team consisting of 3 MEs, and 1 Met would be desired.
26
SOUTH DAKOTA SCHOOL OF MINES AND TECHNOLOGY
SENIOR DESIGN PROJECT PROPOSAL
Project Title: AMP Foundry Ventilation, Dust, and Sound Control for Cold Spray
Proposed/Advised by: Dr. Widener, Owen Britton (AMP-GRA), Adam Well (AMP-GRA)
Sponsored by: AMP
Project Description:
The object of the project would be to design a ventilation and dust control system for the maintaining air
quality and additionally sound damping for cold spray systems in the AMP Foundry building. Currently,
the existing air ventilation system is being used, which was not designed for mitigating risks in a cold
spray environment. A thorough study of the environment, available options, and some detailed design
options for enhancing the safety, air quality, and sound pollution from the system is greatly needed.
Project Duration:
2 semesters
Technical Areas Encompassed (e.g., machine design, controls):
Electric power, motors, controls, human factors, sound damping, air ventilation, handling & filtration,
dust collection, environmental disposal, structural design, air quality (O2 content, volatile gas detection,
etc.).
Any other special requirements:
N/A
Number of Students/Disciplines required (e.g., 2 ME, 1 EE, 1 CS):
A team consisting of 1 ME, 1CE, 1 EE, 1 IE, and 1 Met would be desired.
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