design of a calibration apparatus for liquid temperature...

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Design of a Calibration Apparatus for Liquid Temperature Measurements

MIME Prof Narayanan

MIME Prof Narayanan

Temperature measurements using fluorescent dyes in a liquid is the topic of this project. Several dyes exist that fluorescewhen excited by laser source at a particular wavelength. The fluoresced light is captured by a camera or by multiple cameras.The captured light intensity is proportional to temperature, among other variables.The senior project team will be responsible for the design, fabrication and test validation of an apparatus that will be used tocalibrate fluorescence intensity as a function of temperature. The apparatus is to consist of a test cell that contains a liquid(water). Dyes of varied concentrations are to be added to the liquid in the test cell and the fluorescence signal of the dye captured with variations in temperature of the liquid. Once such a calibration is performed, the dye can be used to determinelocal variations in temperature of the fluid in heat transfer experiments.

Design Criteria:1. The test cell shall be transparent to visible light.2. The test cell shall be able to withstand the hydrostatic pressure of liquid in the cell.3. The test cell temperature shall be controllable from ambient temperature to 90 degrees C.4. The temperature of the fluid in the test cell shall be uniform to within 1 degree C during calibration.5. The concentration of the dyes shall be known precisely (exact values will be provided later)6. The intensity data from the camera and temperature of the fluid in the cell shall be recorded digitally.7. Calibration curves shall be generated using a program written in Matlab.8. The cost of the test cell shall be kept to under $600. Costs exclude that of the cameras, lasers and computer- all ofwhich will be made available to the design team.

Team Requirements:The team should be highly motivated and be prepared to commit sufficient time towards completion of the project.Students should have successfully completed ME311, ME331 and ME 332 with an average grade of B or better.

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13

Chicken Tractors

OSU Organic Grower’s Club

Prof. Squires

This project deals with creating a Chicken Dragster for the OSU Organic Growers Club. A "chicken Dragster" is nothing morethan a very jazzed-up chicken tractor. Chicken tractors are very popular with small farmers and are essentially mobile chickencoops that are moved daily allowing birds to have access to fresh grass, soil, air, exercise, and bugs while at the same timeproviding benefits to the environment and bringing in income - eating weed seeds, tilling the soil, adding manure, regulatingpopulations of pests, and egg production etc. All of these benefits are captured while maintaining a safe, clean, and secureenvironment with roosting sites and nest boxes.The "Chicken Dragster" concept is taking this idea to a whole higher level. Using available technology as well as some customengineering, we envision a chicken tractor that can be fully automated to be fully solar powered, self moving (daily), with automatic watering and feed dispensing, temperature reporting, as well as webcams inside the structures and next boxes.

If this can be achieved, there may be a very big market for such a design in many agricultural areas - vineyards, orchards, etc.

Preliminary CRs:

Fully-automated chicken tractors (4-bird occupancy) for use at the student farm featuring:Entirely solar powerAutomatic security doorsAutomatic feed and water dispensingWeb Base-station communications linkWeb-cams in nesting boxes ("egg-watcher" feature) - reporting live data/images to websiteWeb-cams inside living areas - reporting live data/images to websiteGPS controlled mobility (chicken tractors are moved daily and automatically with sub-centimeter accuracy) Must have "flame-job" painting scheme and cool wheels (burn-out capability optional)Chicken Dragster Drag-races to occur at Earthday Hoo Haa April 22nd 2012 (or 2013)!

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14

Water Purification Power System

Paul Berg

Prof. Squires

Project Summary:Design a mounting system to attach a small gear motor to a bicycle to power by pedaling

Background:The UN estimates that 1.0-1.2 billion people do not have access to safe drinking water. The looming challenge is providingsafe water in the urban centers of the developing world. The urban population of the least developed countries is projected togrow from 250 million to 900 million over the next 40 years, far surpassing the rural population.The subject project for the OSU MIME Senior Project team is to design a component of a point-of-use water treatment productintended for the urban poor of the developing world. The product uses UV light to disinfect water, is powered by a bicycle, andintended to become a self-supporting, sustainable business. The owner will set up the unit next to a community tap, allowingpeople to purchase safe water at a lower cost than using charcoal to boil their water.Bicycles are commonplace throughout the developing world and provide an affordable, green method for powering simplemechanical devices. In additional to their use for transport, they have been adapted for powering grinders and flour mills,among other uses. In this case, the bicycle will power a gear motor that will be used to produce sufficient power to operategermicidal UV bulbs through a short connecting cord. Chain drives are an efficient means of power transfer and will be used.

Design Challenges:The concept is simple but the design team will need to overcome numerous design obstacles. The reward can be a workingunit at the conclusion of the project. The gear motor mount must achieve the following objectives to be successful:• Universally adaptable, to fit at least 80% of bike frames• Easily attachable and removable• Provide solid but adjustable mounting to provide proper chain tension• Easily fabricated, since it will be produced in the developing world• Inexpensive

Product Information:The product is patented (US 7,754,090, July 13, 2010), hand-crank prototypes have been built, both lab (through the OSUCBEE Department) and field tests have been conducted, and a preliminary business plan has been prepared. An OSU Ph.D. student is currently addressing an aspect of the process design and the OSU Business School may assign the product to anMBA group this fall. MIME Senior Project participants will be asked to sign a non-disclosure agreement and to provide theworking prototype mounts at the project conclusion.

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16

Vineyard Bird Control

Dick and Gretchen Evans

Grimm Brian <[email protected]>

This project consists of designing, building, and testing an autonomous aerial vehicle system for the control of pest birdpopulations in vineyard environments. Pest birds can have a significant impact on the grape yield and vine health, and the lastfew years have seen unusually severe losses due to pest birds. An innovative solution using the technology associated with anautonomous aerial vehicle will be utilized for this project. Seniors will be supplied with a basic airframe and autopilot system,and be responsible for using these resources to meet the project requirements.

-Device consistently and effectively keeps pest birds out of vineyards and minimizes the loss of crop and vine damage causedby pest birds to vineyards-Device traverses a predetermined path above the vineyard-Path may be readily adjusted as required by the operator-Area of coverage can be easily specified -Area of coverage is at least five square acres-Vehicle system can be operated by vineyard staff-Operation is autonomous, including takeoff and landing-Device may be recovered (i.e. landed) in typical vineyard terrain-Minimized continued operation costs-Device is durable and easily maintained-Will not interfere or drive-off naturally occurring predators -Device causes no harm to birds or other wildlife

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19

Automatic Knotter for Christmas Tree Processing

Holiday Tree Farm

TBD

Holiday tree Farm Inc. (HTF) is seeking a new technology to aid in the harvesting of ourChristmas trees. HTF is one of the largest Christmas tree farms in the world headquarteredlocally in Corvallis, OR. The Christmas tree industry as a whole is very labor intensive and as alocally operated company since 1955 we are continually looking at ways to lower overheadwhile increasing productivity. We are known in the industry as pioneers and wish to maintain this claim. The current method ofprocessing trees for shipping is a technology that has been around since 1959 with the Johnsonbaler. Advances in speed have occurred throughout time, but the process is still the same. It isour hope that you and your team of students can help revolutionize our company.HTF seeks the incorporation of an "automatic knotter" into our current fleet of balers. Currentproduction procedure requires a person to manually start the twine, run the tree through the baler,and finish the process with a knot. Due to the fact that our product is shipped, density of thefinal product is crucial.Each tree has its own unique shape. The variation in shape comes with the territory anddiameters vary throughout. Current baling procedure requires the use of seventy pound test polytwine. We feel that the twine is by far the cheapest and most effective product for packaging, yetwe would consider use of another product if product density could be improved.Speed and repeatability ar e crucial to the design requirements. Current manufacturingproduction rates are repeatable to five, 6-7 ft. trees per minute. The method of power that wecurrently use for our balers is hydraulic with a twelve volt charging system. The system needs tobe robust enough to operate in the Oregon outdoors during the months of October through December and be capable of resisting needle debris with occasional mud. Ease of maintenanceis crucial. We require that a seasonal hire "garage mechanic" can fix the device if it fails andthat down time be minimized. A field trip is available to the team that decides to take on the task and see firsthand how currentprocesses are conducted during the fall quarter. Operations will be ongoing seven days a weekduring this time period. All we ask is for the visit to be scheduled with a qualified HTFrepresentative prior to visiting. A large inventory of parts could be available to the team whichmay offset some of the initial development costs. Parts to service the prototype should be readilyavailable from industry with as little custom machining as possible.We would like to see the design team produce a working prototype given a maximum budget of$6,500 for product development and a focus of no more than $5000 for remanufacture of eachadditional unit which would be incorporated into our fleet.

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25

Efficient-V Part 2

Efficient-V Inc.

TBD

Background: Efficient-V is a patent-pending reciprocating piston technology designed to increase the performance andefficiency of engines, compressors, and pumps. One aspect of the design has been studied by a Fortune-500 company usingsophisticated computer modeling techniques, and was projected to increase efficiency by up to 7% through friction reductionalone. We believe that additional increases in efficiency will be revealed with further study and R&D.

Business Goal: Our eventual goal is to complete the R&D and patent process, and license the technology to manufacturers ina broad spectrum of applications – almost anything that uses a piston and a crankshaft is a potential customer for ourtechnology.

Current Status: A single-cylinder 50cc demonstration prototype has been completed in our machine shop. It is being machinedfrom aluminum and steel alloys and does not yet incorporate heads, lubrication, or cooling. US patents are pending. There hasbeen some interest from industry, but the technology may require further development and validation before commercializationwill be successful.In the 2010-2011 academic year, OSU senior mechanical engineering students designed a mechanism using Efficient-Vgeometry that retrofits an existing single cylinder production compressor. This design will require some alteration to improveupon it for the 2011-2012 academic year.For more information, please review the 10-minute presentation available at our website because it provides some backgroundon operation. Please visit www.efficient-v.com and clic k on login, enter username: partners. Password: efficiency. Please Note:A non-disclosure agreement and intellectual property assignment agreement will need to be signed by anyone working on thisproject.

Project GoalsWe realize that this is a long undertaking and it may not be possible to complete all of our objectives within one academic year.Our major goal is to refine our demonstration model to a point where it can be studied as a compressor and any performanceincrease or decrease can be measured against a conventional compressor design (physical testing). To do this, severalplanning, engineering, prototype, and testing tasks must be completed. • Project Planning:o Costs – define differences in this design over a conventional model• Engineering & Prototypingo Examine excessive run-out present at inboard drive member. Design new drive members that are rigidly supported bybearing(s) in the housings and provide balance weight to counter reciprocation forces.o Redesign inboard housing to accommodate bearing and receive drive-member properlyo Redesign crankcase to accept cylinder, electric motor, and crankcase mount points accurately.o Internally, crankkcase needs to allow for proper location and retention of EV mechanism in all 3 axes, aligning with axis ofrotation, and cylinder centerline.o Design a simple jig to provide indexing of ring gears during installation. o If needed, design means of precise assembly and alignment of internal reciprocating/rotating components.• Quality Control:o Perform precise “First Article Inspection” of prototype components as produced, and assembly to determine that componentand assembly dimensions are within tolerance insuring that no out-of-location geometry binding or induced friction isintroduced into prototype subject to testing.

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27

Swim Fin Prosthesis

MIME

Prof. Bay

The customer is a 56-year-old male with congenital absence of the rightleg (at the hip), left leg (below the knee), and fingers of the left hand.

He is in moderately good health, but needs exercise to remain fit. Although swimming is an excellent exercise modality, itrequires a left-hand prosthetic to balance the swimming motion. Both air and water swimming return strokes are required, andthe prosthetic must meet other non-swimming requirements.

He is 5'10" tall and weights 173 lbs (with leg prostheses). Complicating factors include surgical repair of the left rotator cuff (allfour tendons and the long bicep tendon), severe arthritis in the right elbow, and degenerative disc disease in the neck (fourbulging discs).

Customer requirements (initial draft):

(1) Comfortable(2) Functional:(a) Must not interfere with ability to use left hand to get out of pool(b) Must balance water moving ability between hands(c) Must maximize Caloric Burn(d) Must minimize stress on Left Rotator Cuff(e) Must be durable(f) Must be easy to apply with one hand(g) Must minimize degradation from commercial pool chemicals(h) Must be easily repairable by user(i) Must be lightweight (not to exceed 8 oz)(3) Aesthetic qualities are unimportant

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29

Liquid Environment Fatigue Testing Chamber

MIME Prof. Kruzic

Prof. Kruzic

A testing apparatus is needed that will interface with the existing universal fatigue testing machines in Prof. Kruzic’s lab that willallow test specimens to be fatigue tested in controlled temperature, flowing, aqueous salt containing environments.

• The chamber should be versatile enough to interface with any of the three universal fatigue testing machines in Prof.Kruzic’s lab.• The chamber shall allow easy draining and exchange of test specimens such that the fluid does not contact andcorrode the universal testing machine.• The chamber shall allow visual monitoring of the specimen during testing.• A pumping system must allow user controlled flow of the fluid.• A control system must allow user controlled constant ( ± 1°C) temperatures ranging from room temperature to 50°C.• All materials that come in contact with the fluid must be corrosion proof against salt containing aqueous solutions.• The fixtures in the chamber should be versatile enough to hold and test a range of test specimen sizes.• The system must be leak proof and have sufficient secondary fluid containment such that the fluid does not contactand corrode the universal testing machine during testing, sample exchange, etc.• The system shall require minimal user monitoring and adjustment to ensure proper function (no more than once perday).

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30

Water Gauge

OSU Prof. John Selker

TBD

We propose a simple, low-cost method for measuring cumulative rainfall and evaporation using the same system. The systemhas no moving parts and uses solid-state micro-electronics. It addresses some of the short-comings of other systems, such aspotentially being unaffected by wind, and may be of particular use in agricultural field-based and ocean-based installations.

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33

A Flapping Wing Design with Elastically-Mounted Tail Flap Actuator

MIME Profs Liburdy & Apte

MIME Profs Liburdy & Apte

This project is to design, build and test an elastically mounted tail flap that is indented to provide better performance of a thin,flat airfoil due to flow-induced passive actuation. Application is Micro Air Vehicles operating at low Reynolds numbers. Theexperimental measurements of lift and drag coefficients will be determined using a time resolved sting balance. Interactions with graduate students in faculty advisors’ groups and researchers at Air Force Research Laboratory may be possible.

1. Should design a torsion spring mounted tail flap for an existing thin, flat MAV airfoil.2. Should be able to quantify motion of the flap due to flow-induced forces3. Should be able to measure overall drag and lift forces and quantify accuracy of measurements4. Budget is on the order of $600 for materials and supplies. Instrumentation is available for all measurements

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36

Concrete-Cutting Chainsaw: Dust Suppression

Blount International, Inc.

Michael Summers <[email protected]>

ICS (subsidiary of Blount Inc.) is a world leader in concrete cutting chain saw systems. They utilize Diamond Chain Technology, which iscomprised of diamond segments laser-welded to a steel chassis to grind through concrete, brick, and stone. Typical applications includecutting small HVAC openings, windows, and doorways in concrete walls. The key advantage of diamond chain technology is the ability tocreate square corners without overcuts in deep concrete.

The current saw design requires a high-flow pressurized water supply (e.g. a garden hose), which travels through internal passages in theguide bar to critical points along the chain-guide bar interface. This water flow cools the bar, lubricates the chain, flushes away concreteslurry, and suppresses concrete dust.

The purpose of this 2011-2012 design project is to design a dust suppression system that meets OSHA regulations and uses a tenth of thewater flow rate supplied to the saw. This suppression system cannot compromise the other performance characteristics of the cuttingsystem.

This project will be supervised by a Graduate Research Assistant, who will create a fast-paced and high-quality learning environment forthe project team. Diligent work and consistent communication are to be expected.

Customer Requirements• Provide dust suppression data for the modified 633GC at: 0.1, 0.2, 0.3, 0.4, 0.5, 0.6, 0.7, 0.8, 0.9, and 1.0gpm for standard cuts• System shall not exceed 75% of the Threshold Limit Values for dust emissions for standard cuts per OSHA 29 CFR 1926.55 App Aat 0.1gpm input• System shall not exceed vibration total value of unmodified 633GC per ISO 5349-1 and -2 at 0.1gpm input• System shall meet noise requirements per EU Machine Directive 2006/42/EC at 0.1gpm input• Any lubricants or additives must be biodegradable• System shall be self contained• System weight increase shall not exceed 13% of unmodified 633GC• System weight distribution shall be within 10% of unmodified 633GC• System run time shall be greater than or equal to unmodified 633GC for both plunge and vertical cuts• Cost of consumables (guide bar, lubricant additive, etc.) shall be no greater than 20% above existing offerings• Total system cost shall be no greater than 15% above current model • New components shall be installable on existing chainsaw using common tools• The system shall operate with the saw in all cutting angles and orientations• The system shall not be obviously fragile• All costs shall remain under project budget

1 "modified" refers to the chain saw modifications of the 2011-2012 teams

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38

Chainsaw Kickback

Blount International

Drew Arnold <[email protected]>

Blount Inc. is one of the leading producers of chainsaw bar and chain. They are currently developing a consumer-level, gas-poweredchainsaw in which they are hoping to incorporate an innovative safety system.Kickback is the most dangerous phenomena associated with chainsaw use. It occurs when the top portion of the tip of the saw makescontact with an object. The saw then walks upward along the object, and accelerates rapidly toward the operator. Safety regulationsrequire all consumer level chainsaws be equipped with a braking system that is actuated mechanically either by the operator's wristhitting the hand-guard, or by the inertial forces on the guard.Blount, Inc. is developing a new system that does not rely on a weighted hand-guard to sense for kickback, and actuate braking. A packageof sensors will be used to actively sense for a dangerous kickback event and an electronic braking system will then be used to brake thechain. A similar project was completed last year (2010-2011) using a battery-powered, electric chainsaw. The difficulty with this projectwill be finding solutions that can run off the small amount of electric power generated by the chainsaw’s gasoline engine, while still beingable to stop the large amounts of kinetic energy present.The senior project team will be responsible for designing an electronically actuated braking system that will rapidly stop the chain uponactuation. The system must respond fast enough that braking will begin before the saw loses contact with the object that caused kickback.For the purposes of this project, the system will not require the implementation of a sensing system, but the braking must be controlledby a 5V DC output signal. The braking system itself will need to be very low power as well, given that the gas engine has very littleelectronic power to provide.Customer Requirements:1. The brake system must not significantly increase the weight of the saw. 2. The brake system must be operable using only the limited electrical power from chainsaw's gas motor.3. The brake system must decouple the kinetic energy of the engine from the drive sprocket before the chain loses contact withthe work-piece.4. The brake system must begin brake actuation before losing contact with the object causing kickback. 5. The total braking time, from actuation until the chain stops, must be faster than current industry standards.6. The brake system must not negatively affect saw performance.7. The brake system must be actuatable by a standard digital output.8. The brake system must be easy to reset.9. The brake system must be quick to reset.10. The brake system must not damage the saw when used.11. The brake must not require continuous electrical power to remain engaged, after the initial brake actuation.

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40

PCC: Caustic Tank Cleaning

PCC Structurals

Josef Hortnagl <[email protected]>

PCC Structural Is a leading manufacture of large and specialty metal castings. They are leaders in investment casting of large titaniumparts for industries such as aerospace, automotive, and power generation. The process of investment casting involves the creation of awax copy of the desired part, encasing it in a reinforced ceramic casting shell, removing the wax and casting the part in metal. The finishedcasting much then have its shell removed to allow for further processing of the part. This process requires the use of knocking, water-jetblasting, and chemically dissolving the casting and any reinforcement material off the part. A problem has arisen with the chemicalremoval of the castings that is the focus of this project. Castings are placed in a hot and highly caustic solution to dissolve away theceramic particles that make up the structure of the casting shell. Unfortunately as these particles settle in the bottom of the tankcontaining the part they form over time what is know as a Geo-polymer. This Geo-polymer creates a concrete like slab that eventuallymust be removed to allow for full emersion of the casting parts. This is a very labor intensive, inefficient, and hazardous process. The goalof this project is to create a scale proof-of-concept device that will remove this casting material and any other items that are collected inthe tank before they can settle into Geo-polymer. A 3/8th scale tank with simulation casting material and solution will be provided as atesting platform. For safety reasons room temperature water will be used for the solution.Customer requirements:• Device shall remove all casting material from the tank including dissolved flour, sand, wire and chunks of shell material.• Device shall be robust enough to survive the manufacturing environment in the cleaning department• Device shall minimize the removal of the caustic cleaning solution (water).• Device shall operate effectively and efficiently.• Device shall not require modification to the existing infrastructure.• Device shall be robust enough to withstand repeated cleaning cycles with minimal maintenance.• Device shall be safe to operate and not pose any danger to operators or infrastructure.• Device shall operate quickly and have minimal impact to through put (up time).• Device should have the intent to withstand hot concentrated caustic solution• Device should not splash the solution.• Device should stay within a budget of $500

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59

Structurally Enhanced Hydrophobic, Porous Membrane

MIME Prof. Pence

MIME Prof. Pence

At present there are two ongoing research projects at Oregon State University involving the in-situ extraction of water vaporfrom two-phase electronics cooling systems, one using microchannels and the other employing a confined impinging jet. Thevapor extraction in these devices takes place through a very thin, porous, hydrophobic (Teflon) membrane supported on oneside with a plate made of porous aluminum.This arrangement is not robust and is also somewhat cumbersome. Furthermore, there is experimental evidence to suggestthat the combined flow resistance of the membrane and backing is a limiting factor to the quantity of vapor that may be extracted.It is hypothesized that a structurally enhanced membrane system (hydrophobic membrane with integral or engineered support)may result in a less cumbersome device with lower flow resistance and, therefore, enhanced vapor extraction. The goal of thisproject is to design and prototype a structurally enhanced membrane system in order to determine its feasibility for use incurrent and future vapor extraction applications.

Design Objective:1) Select an overall composition for the structurally enhanced membrane system. This might include polymer membranes,photo-resist epoxies, machined or etched silicon, thermoplastics, and/or other components.2) Determine a fabrication procedure for the selected structure. 3) Fabricate a sample of the structurally enhanced membrane system.4) Test the sample for adherence to design constraints.

Design Constraints:1) Retain structural integrity to pressures differentials across the membrane of 40 kPa2) Exhibit a breakthrough pressure greater than 40 kPa3) Be capable of withstanding temperatures of up to 100°C

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41

Set-up and Calibration of the Pocobor Compression Mannequin

Adidas

MIME Prof. Bay

Goal:To create a simple accurate device that will aid in the set up and calibration of the Pocobor compression mannequin.

Customer needs:The Pocobor compression mannequin uses small pressurized silicon domes to measure the compression of a garment. Through internal testing it has been found that both the height of the dome and the curvature of the surface effect themeasurement. A device is needed to accurately measure the height the dome extends beyond the surface of the mannequin.This device should also be able to run a simple check to confirm the dome is reading correctly.- Measure the height that the dome protrudes above the surface of the mannequin.- Take into account the curvature of the surface (the 3d CAD will be supplied by adidas).- Confirm that the dome is reading correctly.

Adidas will supply:- Overview of the Pocobor compression mannequin.- 3d CAD of mannequin leg and sensor placement (3d CAD of full mannequin to follow later).- Access to the pressure measurement mannequin leg.

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42

SAM Medical Products project

SAM Medical Products

Thomas Wright<[email protected]>

Since 1985, SAM Medical has been a developer and manufacture of fracture management, airway management and woundcare products that serve the military, EMS and hospital markets. We are the global leader in field splints, predominantly theSAM Splint, a flexible, lightweight splint that can universally immobilize numerous sites of the body. Our products are usedby medics and corpsmen on the battlefield and by paramedics in EMS agencies around the world. We produce close to 1million splints annually. We currently deliver our SAM Splints to the market in 2 manners; flat folded and rolled. We have semi-automatic rollingmachines currently in production. These machines are slow, generate scrap, and don’t have full capability our market nowneeds. We need to be able to insert bandage wrap into core of splint in line. We are looking to design and implementautomated machines for rolling splints to match the TAKT time of other processes in this work cell. As well as being able toadd the functionality of insertion of bandage material into core of splint.We look forward to design help on development of a mechanical rolling machine that will produce rolled splints in less than 4seconds from start of process to end with the capability to add the insertion of our bandage wrap as required by customerorder.

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43

Wine Barrel Stacking

Cardwell Hill Cellars

Prof. Squires

Cardwell Hill Cellars is in need of an improved method for moving wine barrels. In their barrelhouse, barrels are stacked, ontheir sides, two rows high. Placing the empty barrels onto the upper row currently requires manual lifting. A mechanical deviceto lift the barrels is needed. The device must lift a barrel weighing approximately 100-lbs from the floor to the second row ofbarrels (a vertical distance of several feet). The device must be small enough to be maneuvered among the rows of barrelsand must be able to function at the row-end or row-side. The device must be safe and easy to use. Budget is flexible, basedon what is justified, but is expected to be under $1,000.

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49

High Performance Aerodynamic Body Design

OSU Solar Car Team

Liburdy

Design and test a new body for a 3-wheeled highway-capable solar powered car for the 2014 North American Solar Challengeand design, test and build a new wheel fairing for the 2012 OSU solar car! The body team will work in collaboration withmechanical teams working on the solar car and must pass the safety requirements of the NASC. The team will need to designa body to house 6 square meters of solar cells as well as provide an opening for the windshield. Designs will be tested usingcomputational fluid dynamics software and verified with a 3D printed model in a wind tunnel. The body must have minimal drag(under 1.2 kW of drag at 50 mph) and safely enclose the driver, chassis and drive systems. Design must also accommodate the varying wheel geometry when vehicle is in motion and steering. The team must also design, test and build a new wheelfairing for the 2012 OSU solar car, the Phoenix. The wheel fairing must be symmetrical, stationary and must not increase thedrag of the vehicle by more than 10% from previous design.

Your project will feature:

1. Wheel fairing design, testing and fabricationa. Wheel fairings must be symmetricalb. Fairings must not increase vehicle drag by more than 10%c. Fairings must be made out of pre-preg carbon fiber provided by the teamd. Fairings must feature access hatch for wheel changing.e. Access hatch must be securely fastened such that it can withstand vibrational forces the vehicle experiences on thehighway.f. Fairings must have at between 4” to 6” of road clearance when suspension is at ride height2. New body design and testinga. Solar arrayi. Must provide at least 6 square meters of “good” (low curvature) space for solar cellsb. Cockpit windowi. Must provide space for driver windshield c. Wheel spatsi. Must provide space for two front wheels and one rear wheeld. Turn indicatorsi. Must provide space for two front and two rear turn indicatorse. Drag requirementsi. Must have under 1.2kW of drag at 50 mphii. Optimally, under 1kW of drag at 50 mph

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39

Test apparatus for cutting experiments


Andrew Phan <[email protected]>

This project entails the creation of a device that is able to carry out various cutting operations. The overall goal of the projectis to create a Finite Element Analysis model of the cutting process. This model will not be restricted to just analyzing cuttingusing knife edges but all forms of cutting including machining processes. A senior project team is needed to create a device that can perform various cutting operations and measure desire outputs. This project will allow us to gain insight into cuttingoperations and how to shape future cutting tools to guarantee a smooth cut while minimizing residual stresses. A general listof requirements for the device is as follows:• The device should be able to function the same as if you were to cut a steak, i.e., with a downward motion and ahorizontal motion.• Each motion should be independent of one another and move with a smooth velocity. • Various dynamic parameters must be measured during the use of the device such as force vectors, displacementvectors, and velocity vectors.• Each parameter measured must be in a feedback loop so that they can be measured and controlled at the same time.• The device must be able to change the angle of cut independent of the motion and during a cutting test.• The device must be able to accommodate any kind of blade geometry from knife edges, scissor edges, box knifeedges, and even machining edges.• It must be semi-autonomous in that the device will perform cutting operations after user input through some sort ofuser interface.• The users must be able to stop the device at any given point in time.• The final product is a fully working cutting device capable of performing cutting operations on various materials.

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37

Concrete-Cutting Chainsaw: Wear Reduction


Michael Summers <[email protected]>

ICS (subsidiary of Blount Inc.) is a world leader in concrete cutting chain saw systems. They utilize Diamond Chain Technology, which iscomprised of diamond segments laser-welded to a steel chassis to grind through concrete, brick, and stone. Typical applications includecutting small HVAC openings, windows, and doorways in concrete walls. The key advantage of diamond chain technology is the ability tocreate square corners without overcuts in deep concrete.

The current saw design requires a high-flow pressurized water supply (e.g. a garden hose), which travels through internal passages in theguide bar to critical points along the chain-guide bar interface. This water flow cools the bar, lubricates the chain, flushes away concreteslurry, and suppresses concrete dust.

The purpose of this 2011-2012 design project will be to design a system that allows the saw to operate at a tenth of the water flow rate supply while preventing any increase in wear on key components. This new system cannot compromise the other performancecharacteristics of the cutting system.

This project will be supervised by a Graduate Research Assistant, who will create a fast-paced and high-quality learning environment for the project team. Diligent work and consistent communication are to be expected.

Customer Requirements• Provide wear data for chain stretch and bar chain interface of the modified model 633GC chainsaw at 0.1gpm and 0.5gpm forstandard cuts• The characteristic wear in terms of chain stretch and chain guide bar interface at 0.1gpm input must not exceed that of theunmodified model 633GC chainsaw with 1.0gpm input for standard cuts• System shall not exceed vibration total value of unmodified model 633GC chainsaw per ISO 5349-1 and -2 at 0.1gpm input • System shall meet noise requirements per EU Machine Directive 2006/42/EC at 0.1gpm input• Any lubricants or additives must be biodegradable• System shall be self contained• System weight increase shall not exceed 13% of unmodified model 633GC chainsaw• System weight distribution shall be within 10% of unmodified model 633GC chainsaw• System run time shall be greater than or equal to unmodified model 633GC chainsaw for both plunge and vertical cuts• Cost of consumables (guide bar, lubricant additive, etc.) shall be no greater than 20% above existing offerings• Total system cost shall be no greater than 15% above current model• New components shall be installable on existing chainsaw using common tools• The system shall operate with the saw in all cutting angles and orientations• The system shall not be obviously fragile• All costs shall remain under project budget

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55

Test Rig for Fiberglass Leaf Springs

MIME Prof. Hurst

Prof. Hurst

The Dynamic Robotics Laboratory is building walking and running robotsthat use fiberglass springs to store energy in each stride, much liketendons in animals. We need to know a precise spring function and spring rate for these fiberglass springs; they are not linear, so theequation F=kx does not apply. We seek a team of mechanical engineersto design and build a test rig that will flex these plate springs by ameasurable amount, and measure the force being applied at eachposition. Students in the DRL can handle the electronics and the sensors; but we need help from a senior design project to design andbuild the mechanism, which must be rigid and allow repeatablepositioning when flexing some rather stiff springs.

See our web site for some information about our robots:http://mime.oregonstate.edu/research/drl/See the Gordon Composites web site for information about theirmaterials: http://www.gordoncomposites.com/

The budget for this project is based on the reasonable personprinciple; try to keep costs down, but if you can justify the cost,we'll buy it. We can spend as much as $10,000 on this device ifnecessary, but I believe it can be done for less than $1,000,including sensors.

List of requirements for the device:- Handle a plate spring that varies in width from 1-4 inches,thickness from 0-0.5 inches, and length from 0-20 inches- Apply forces up to 500 pounds to the end of the spring- Strain the spring up to 2%, which may be a 40 degree deflection forthin plates- Work with DRL students to incorporate appropriate position and force sensors- Be a reasonable size, so the device may be stored away in a cabinetwith minimal disassembly- Document it well so we will be able to use it several years down theroad, after we have forgotten how it works

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56

Mars Rover: Chassis

OSU Mars Rover Team

Prof. Hurst

The OSU Mars Rover Team is a student organization with the intent to build a prototype rover with the purpose of competing inthe Mars Society sponsored University Rover Challenge (URC) hosted by the Mars Society. The rover submitted for thecompetition is to be designed and built by the students, and as such the OSU Mars Rover Team chooses to design and buildthe rover's chassis completely from scratch.

The URC requires a rover with a certain minimum of functionality while limiting the cost and weight. The chassis of therover therefor must be structurally strong enough to withstand the rigors of the competition, have the capacity to carry thefunctionality required of the rover, and be designed for minimum weight, and cost. The chassis is the backbone of the rover,housing the functional elements of the rover in a robust but lightweight structure.

The budget for the Rover Chassis is estimated for now at approximately $2000.

** The 2012 rules have not yet been posted by the Mars society and as such are subject to change from those used in 2011. The customer requirements here are based on the 2011 rules. Historically, the rules have only undergone minor changes fromyear to year.

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57

Mars Rover: Arm

OSU Mars Rover Team

Prof. Hurst

The rover arm is central to the functionality of the rover for the URC tasks as outlined by the competition rules**. The arm willbe a design requiring the cooperation of multiple electrical and mechanical design elements to accomplish tasks designated bythe URC rules. The arm will be used to complete sample return, control panel, and cargo delivery tasks, if such tasks arerequired by the competition rules. The arm will need a minimum level of strength to accomplish possible lifting tasks, be flexibleand accurate enough to manipulate switches, buttons, and power plugs, and be sufficiently lightweight for the overall limitedweight of the rover. The arm must be able to be wirelessly controlled by a human being.

The Rover Arm budget is currently estimated for now to be approximately $5000.

** The 2012 rules have not yet been posted by the Mars society and as such are subject to change from those used in 2011. The customer requirements here are based on the 2011 rules. Historically, the rules have only undergone minor changes fromyear to year.

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62

A Microscale System for Fluid Delivery to an Environmental Sensor

Dahl Natural

Prof. Squires

Dahl Natural LLC is a woman-owned biotech company established in 2007 by Anne Schwartz a biochemist and formermanager of public health programs. The company has a strong management team and includes experienced professionalscovering areas of expertise in business management, marketing, engineering, physics, chemistry, molecular biology andstatistics. Dahl Natural specializes in sensing equipment for detection of biological and environmental contaminants. DAHLNATURAL’s flag ship product under development is the ECM 301 a sampling, signal transport and remote-controlled systemfor routine real-time monitoring and measurement of contaminants.

Currently Dahl Natural has demonstrated feasibility in providing real-time automated measurement of pesticides in unfiltered river water with a dynamic range of 10 ppt to 10 ppm. Dahl Natural is finishing it’s phase 1 grant with NSF to measure heavymetals including mercury to low ppt. The strength of Dahl Naturals platform is that it is: capable of measuring a broad range ofcontaminants, real-time, cost effective, low power, uses nano -textured sensor arrays to quickly identify multiple targets, is verysensitive, reliable and specific.

Opportunity: Design of an effective miro-fluidic fluid delivery system to automatedly pump a sample (at this time from a testcontainer) to the sensing site and then to evacuate the sample, rinse and pump in a new sample. A manafold design isneeded to enclose the sensing array. Special materials are required to prevent adhesion of pesticides or metals to themanifold. Specification needed for the project will be discussed when you meet with the senior interdiciplinary design team.Long term we are looking for a mechanical engineering employee. Through other projects graduate tuition could be payed forif you are choosen and interested in a graduate degree. Direct employment is also an option but an interest in higher educationis prefered.

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101

Utilizing AIDC Technologies For Tracking Plants at Three Oregon Nurseries

OSU Agricultural & Resource Economics Dept.

Porter

Background

In 2007 Oregon’s ornamental nursery industry was the #1 crop grown in the state with over $1 billion in return to growers.Since the collapse of the economy in September 2007, nursery crop returns have fallen to almost $600 million. At a recentindustry meeting, when asked what research would benefit the industry the most, a large portion of the audience statedtracking inventories of their product as it moves through their production system to the retailer is a priority.

Customer Statement of Need

The aim of this project is to evaluate possible solutions to inventory management in ornamental nurseries. Students will workin a larger team with undergraduates from the AREC Department as they conduct a cost-benefit analysis based on yourrecommendation of technologies and processes to nursery owners. An industry presentation and report will be held to informgrowers of findings from the project. Students will participate in multiple field trips to participating nurseries to complete courseobjectives.

Preliminary Customer Requirements

1. In this initial project at the starter nursery, the Automatic Identification and Data Collection (AIDC) system must be ableto track individual nursery stock once it arrives at the packaging shed from the field through storage to the shipping dock.2. As shipments arrive from the starter nursery to the pot-in-pot and container nursery, the AIDC system must be able to track plants from the truck to the field, as they move to the potting shed to be repotted, redistributed and spaced in the fieldseveral times over multiple years, later loaded on trucks, and accounted for at the point of sale (most likely at the retail level).3. The system must be able to differentiate at least 10 different tree species by TBD different sizes and grades, track andreport plant materials from “mother” plants for royalty payments, and provide information to the customer that purchases eachplant.4. The system must be robust to endure impacts from moving and loading, resist high temperatures, water resistant,possibly record temperature (high, low, average), and other production information and be affordable for a nursery thatproduces 12 million plants each year.

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102

Design of a New OSU Moving Service

OSU Business Services Property Operations

TBD

Background

OSU Business Services provides essential support to the Oregon State University campus community by offering a variety ofservices, including mailing, freight, risk management, procurement, contracting, and property management. BusinessServices' Property Operations is responsible for surplus property and recycling. Lately, partly because of their personnel andfleet of trucks, Property Operations has been called upon to move OSU offices, including furniture and equipment, from onecampus location to another.Presently this unofficial moving service is ad hoc and there are no formal policies or procedures. But, properly developed, itoffers an opportunity to fill a campus-wide need to move offices more quickly and more cost effectively than could beaccomplished with outside moving companies.


To realize the potential of this service, Business Services' Property Operations needs a Moving Service Plan to formallydocument processes, policies, and procedures required to implement an effective and efficient moving service.


1. The Moving Service Plan shall document all considerations and tasks required to move a *representative* OSU office.2. The Plan shall include lists of equipment, materials, and supplies necessary and desirable to perform moves, and shallprovide cost estimates for those items.3. The Plan shall describe the processes and provide written procedures necessary to develop *accurate* cost estimatesfor a moving job.4. The Plan shall describe processes and provide written instructions required to plan the move, including a movetimeline.5. The Plan shall describe processes and provide written instructions required to perform the move.6. The Plan shall include cost comparisons with commercial moving companies for several *representative* moving jobs.7. The Plan should provide recommendations for offices being moved to help them prepare for their move.

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103

MU Building Services New Shop Design

OSU MU Building Services

TBD

Background

OSU's Memorial Union Building Services is responsible for maintenance of the Memorial Union as well as seven other campusbuildings and five OSU food services. A room in the basement of the MU called “The Shop” is used for storage of a largecollection of building repair tools and supplies (saws, hammers, light bulbs, window hardware, etc.). The Shop also hasseveral versatile workstations including a workbench, tools, and equipment for repairing smaller building components, such asfurniture, lighting fixtures, and other items that cannot or are inconvenient to be repaired in place.The layout and organization of The Shop has evolved into a reasonably effective configuration, thanks in large part to a 2010Capstone project, but it is anticipated that by 2014 the Shop will be relocating to another part of the MU. Schematic design haslocated the future home of the Shop in the basement of the East Wing, currently housing the Bookstore, in 1200 square feet ofequivalent space.


We need to design our new Shop space to a schematic design level of detail.


1. The Shop shall include space for all current work processes.2. The Shop shall include adequate ventilation for all current work processes except painting.3. Shop work processes shall be laid out to be effective, efficient, and safe.4. RWS processes shall be documented.5. Written work procedures should be provided for each RWS process.6. The layout of the RWS storage area shall be compatible with re-engineered RWS processes.7. All RWS processes and procedures shall comply with safe workshop practices.8. RWS processes shall be compatible with the new work order software.

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105

ReStore Transition Plan

Habitat for Humanity ReStore

TBD

Background

Habitat for Humanity is a worldwide volunteer organization that works with low-income families to build affordable housing forthem. To directly support and also to fund its operations, the Benton Habitat for Humanity operates the ReStore in Corvallis, areduce – reuse – recycle retail store that accepts donations of used and new building and construction materials, uses them inits building projects, and also offers them for sale to the general public. Income from these sales support the broader work ofHabitat.The ReStore is outgrowing its current facility on NW 9th, and a move is being planned to a larger site. Its intake, inventory,sales, and business processes and equipment must be transferred to the new facility. Not all of its stock can be sold prior tothe move, so remaining inventory must be transferred as well. Moreover, ReStore's current building will be demolished after themove, so any reusable building material must be recovered from it and moved to the new site's inventory. An additionalchallenge is that any disruption of ReStore's operations for more than one week could seriously impact future business.


The ReStore needs a Transition Plan to smoothly transfer its current operations, equipment, and inventory to the new facilitywithout disrupting ongoing operations for more than one week. The Transition Plan must be well-thought out and clearly documented, with specific instructions, so that volunteers and employees with minimal experience in such activities canexecute it correctly, efficiently, and safely.


1. The Transition Plan shall identify and document all tasks that must be completed in the transition process.2. The Plan shall include criteria, process descriptions, and written instructions for categorizing and sorting existinginventory for transfer to the new facility, recycling, or disposal.3. The Plan shall include criteria, process descriptions, and written instructions for identifying furniture, equipment, andother items currently in use in the ReStore for transfer to the new facility, recycling, or disposal.4. The Plan shall include criteria, process descriptions, and written instructions for identifying materials and fixtures in thethe current ReStore building for transfer to the new facility, recycling, or disposal.5. The Plan shall include criteria, process descriptions, and written instructions for identifying furniture, equipment,records and other items used in the ReStore's business operations for transfer to the new facility.6. The Plan shall include details and written instructions for the move itself. 7. The Plan shall include a list of equipment and materials needed to complete the move.8. The Plan shall provide for completion of the transition by a date *TBD*.9. The Plan shall include a detailed timeline for the transition, documenting when each task must be completed.10. The Plan shall be such that the ReStore's business operations are not interrupted by more than one week.11. The Plan shall be feasible for completion by the available workforce of ReStore volunteers and employees.12. The Plan should include guidelines for safe manual material handling.13. The Plan should be designed so that it can be readily adapted for use by other ReStores.

Special Note: This project must be closely coordinated with the ReStore New Facility Design project.

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106

ReStore New Facility Design

Habitat for Humanity ReStore

TBD

Background

Habitat for Humanity is a worldwide volunteer organization that works with low-income families to build affordable housing forthem. To directly support and also to fund its operations, the Benton Habitat for Humanity operates the ReStore in Corvallis, areduce – reuse – recycle retail store that accepts donations of used and new building and construction materials, uses them inits building projects, and also offers them for sale to the general public. Income from these sales support the broader work ofHabitat. The ReStore is outgrowing its current facility on NW 9th St., and a move is being planned to a larger site.


The ReStore needs a design for the new facility that includes spaces and processes to support all of its current operations,including intake, inventory, sales, recycling, and business processes, with enough flexibility to accommodate anticipated futureone. The design must be compatible with the buildings and grounds at the new site and capable of handling projected volumes.


1. The ReStore New Facility Design shall document current spaces and processes as a baseline.2. The Design shall include space and process specifications for intake, inventory, sales, recycling, disposal, businessprocesses, and *other operations*.3. The Design shall be compatible with and appropriate to the structures and grounds at the new facility.4. The Design shall provide *detailed* process descriptions of new facility operations.5. Spaces and processes shall be designed to *optimize* space, time, and resources at the new facility.6. The Design's spaces and processes shall be capable of handling *projected* volumes.

Special Note

This project must be closely coordinated with the ReStore Transition Plan project.

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107

PTD Stabilization System

US Army

Nix / Funk

Precision Targeting Devices (PTDs) are electro-optical devices soldiers use to locate and identify targets and to determine their precisecoordinates so that those coordinates may be communicated to air and artillery and other units for delivery of ordnance against enemytargets. A PTD ranges in size from a large pair of binoculars upwards, weighing as much as eight pounds. Its subsystems include an opticaltelescope, digital magnetic compass, and laser rangefinder, and may include infrared optics, GPS unit, and a datalink interface. A Soldieruses the PTD to locate a target, identify it, and determine its coordinates. From its own GPS-determined coordinates and orientation, and theazimuth, elevation, and range to the target, the PTD determines the target's coordinates, which may be communicated either by datalink orvoice radio.But the ability to deliver these coordinates with adequate precision depends upon the physical stability of the PTD when used. Any movementimparted by the Soldier or the environment that causes the PTD to deviate even a few milliradians when target azimuth, elevation, and rangeare captured will result in targeting error. This error is, of course, compounded as target range increases. In particular, an aiming error of wellunder a milliradian can cause the laser rangefinder beam to miss the target, and instead range on targets in the foreground or backgroundthat may be hundreds of meters or more from the intended target. While hand-held PTD precision is satisfactory for many situations, thereare others where greater stability is required.Most PTD systems come with a tripod, but current tripods are unsatisfactory. Some are little more than adapted commercial camera tripods,better suited for table-top use than use in the field. Others, though more substantial, are too heavy to carry into combat or are designed suchthat small (e.g., 5th percentile, height) or large (e.g., 95th percentile, height) soldiers find them difficult to use in postures dictated by thecombat situation. Moreover, current tripods are difficult to set up and may not work on steep slopes, atop ledges, or on other restrictedspaces. While the manufacturers of PTDs have delivered “game-changing” devices in the PTDs themselves, seemingly little thought hasbeen given to systems to stabilize the PTDs in use, which is absolutely critical for their effectiveness.


The Army needs better means to stabilize PTDs for precision targeting, that is, a PTD Stabilization System (PSS). The PSS need not be atripod and need not be a single device, but may be a suite of two or more devices (e.g., tripod, bipod, monopod, body mount, etc.), of varyingsize and capability, from which the Soldier can choose prior to deployment. The equipment that soldiers “need” to carry already exceeds theamount they can physically carry, and many trade-offs must be made to optimize what they actually carry. Thus weight and size are anoverarching factor in whether a PSS can actually be carried on a mission.

Preliminary Customer Requirements (partial list)

The following Customer Requirements are preliminary and do not cover the entire scope of need, but they provide a starting point for thedesign team. In these requirements, a term enclosed in asterisks (*term*) is unverifiable and must be replaced, in the final EngineeringRequirements, with an appropriate quantity (in appropriate units), or other objectively verifiable condition or characteristic.

1. The PSS, when stowed, shall be *small enough* and *light enough* for a Soldier to carry, hands-free, so as to be *easilyaccessible* yet *unobtrusive*.2. The PSS shall be capable of supporting and pointing a mounted PTD so as to allow unrestricted azimuth movement of the PTD ineither direction and *sufficient* vertical angle movement of the PTD above and below the horizontal.3. The PSS shall permit *smooth* and *rapid* pointing of the mounted PTD. 4. In particular it shall permit *fine* adjustment of pointingto insure the laser beam impinges on the target and does not under- or over-spill onto other objects.4. The PSS shall be non-magnetic. 5. The color of finishes on all external surfaces of the PSS shall be olive drab or tan to the maximum extent possible.6. The PSS shall have no *sharp* edges.

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108

Document Storage Lifecycle System

Samaritan Health Services

TBD

Background

Record retention and management is a major component of Samaritan Health Services business operations. The life cycle ofrecords spans from creation, distribution and use, storage and maintenance, archiving, and destruction. Business needs andlegal requirements mandate that records be retained, but it is not advisable to keep them forever.


Samaritan Health Services needs a record management system for its business records. The scope of this project willconcentrate on the retention disposition and destruction stages.


1. The archiving stage/processes shall be integrated into current business processes with the use of the retentionschedule.2. The archiving stage/processes shall address all types of record sources (e.g. paper, electronic, mobile storage, etc.).3. The archiving stage/processes shall allow for easy retrieval of records.4. The archiving stage/processes shall notify authorized parties for record destruction.5. The destruction stage/processes shall maintain a Certificate of Records Destruction Form effectively.6. The destruction stage/processes shall ensure documents on Legal Hold will be preserved during the legal holdtimeframe and not be destroyed.7. The archiving and destruction stage/processes shall be cost effective.

Team member requirements:

To work in the hospital environment the entire team must receive training on HIPAA (patient privacy protection law), infectioncontrol, and harassment. Additionally, arrangements must be made for all team members to be current on certainimmunizations, complete a drug screening, and authorize a background check. Skip Panter ([email protected] or at 768-6452) will assist the team with these arrangements. These requirements will be taken care of at GSRMC once team membersare selected.These requirements must be completed within 3 weeks of project selection.Additional general requirements of the SHS project include: 1. Participate, communicate, and interact as part of a team with GSRMC employees2. Attend all relevant SHS project related meetings.3. Clearly and concisely document the team’s work.4. Abide by all SHS policies and procedures.

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109

MU Electrical Distribution Identification System

OSU MU Building Services

TBD

Background

OSU's Memorial Union Building Services is responsible for maintenance of the Memorial Union as well as seven other campusbuildings and five OSU food services. A room in the basement of the MU called “The Electrical Switchgear Room” is adjacentto the electrical power transformers that supply the building with 4700 amps of electrical current, and contains the 1960-eraWestinghouse switchgear that distributes that current to over 61 electrical distribution panels throughout the Memorial Union.Current inadequate labeling of distribution system components makes it difficult and time consuming to accurately identifythem. This can in turn lead to delays and errors in repairs.The MU is staffed by a team of maintenance technicians, to include an Electrical Supervisor. This person is involved inbringing ArcFlash training and compliance to the Memorial Union.


MU Building Services needs a system to name and clearly label elements of the electrical distribution system to facilitate theirrapid and accurate identification by the Electrical Supervisor and maintenance technicians. This system must take into accounta number of identifying features about the building and about the electrical load and its path of distribution.


The electrical distribution system naming system shall1. be consistent throughout the electrical system.2. be usable by the Maintenance Connection CMMS software system.3. be easily understood by Student Building Managers, Student Event Services Staff, the Shop staff and others who haveoccasion to access this information.4. meet the requirements of ArcFlash and the approval of the MU electrical Supervisor.

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110

Swing Grinder Operator Interface

PCC Structurals

Williamson / Funk

Background

PCC Structurals uses the investment casting process to make nickel superalloy parts for aerospace, industrial, medical, andother applications. After the parts are cast, gating (solidified metal left where flow channels penetrated the mold) is removed bytorches, then belt grinders are used to remove the remaining gating “stubs”. Operators change the abrasive belts at their own discretion, when they think they are worn (about every 8 – 10 minutes), but there are no objective criteria to determine when belts should be changed, and it is likely that they are changed too frequently. Moreover, there are no standards for operatingthe grinders so as to both optimize metal removal and maximize belt life. Belts and grinding time are expensive and PCCwishes to reduce the cost of both.Preliminary findings from an OSU grinder belt life project, underway since 2009, suggest that metal removal and belt life can beoptimized with reference to the grinding force applied to the part, temperature, and elapsed grinding time. Data collection and analysis currently underway is expected to determine the relationship between these parameters and metal removal and beltlife.


PCC needs its grinders instrumented to collect force and time data and an operator interface to display information to operatorsto help them optimize metal removal and belt life. The purpose of this project is to develop a prototype grinder operatorinterface to do this.


1. The Grinder Operator Interface shall display information to the operator to facilitate high rates of metal removal.2. The Interface shall display information to the operator to facilitate maximization of belt life.3. The information displayed by the Interface shall be based on grinding force, grinding time, and other parametersdetermined by the OSU grinder belt life project.4. The Interface shall not obstruct the operator's view of the primary grinding task.5. The Interface shall not distract the operator or interfere with the grinding task.6. Sensors mounted on the grinder to support data collection and Interface shall not interfere with grinder operation.

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Project 111

Sponsor: Layton Manufacturing

“... our proposal would be for your students to automate the process of taking a Solidworks assembly and inputting the information directly into the ERP system we are developing.

In addition to that, the project would include developing an "on the floor" shop information system that would allow our employees access to the documentation they need to process our standard products.”

200

Design of the OSU Baja SAE vechicle

Oregon State Baja Team

Prof. Paasch

Baja SAE (Society of Automotive Engineering) is an international design competition in which students build an off-roadracecar. A new vehicle must be created each year and comply with the current set of rules which are designed to keep thecompetitions safe, fare and challenging. Oregon State has been competing in Baja SAE competitions since 1978. OSU Bajahas a rich history of success with placing in the top 5 every year for the last 10 years and holding five 1st place trophies in thelast seven years.

In general, SAE offers a very hands on and unique experience at OSU. Students will be working with a large collaborative teamto design a complex, integrated system. Designs will then be used and tested on an actual performing vehicle. Then yourknowledge and skill learned throughout the year will be tested at a highly competitive competition with students from all overthe world. SAE speaks volumes on a resume and employers look very favorably on individuals that have been involved withSAE for their “real world” experience.

For the 2011-12 year the OSU Baja team will continue to develop its already highly successful design with incremental improvements to reduces weight, reduce cost, ease manufacturability and to maintain/improve system reliability. Projects willinclude; Suspension design, Powertrain design and Chassis design.

The suspension team will design, manufacture and test a suspension system which allows the vehicle to negotiate roughterrain and jumps in a stable manner. Kinematics of the suspension and steering systems will need to be analyzed to provideappropriate movement and handling characteristics of the vehicle. Shocks will need to be tuned to give the vehicle theacceptable ride/pitch/roll response. Components will need to be designed to be lightweight and yet reliable.

The OSU Baja transaxle as proven in the last several years to be one of the most sophisticated drivetrain systems on an SAEBaja car at competition. This system will continue to be developed with an emphasis on ease of manufacturability whilemaintaining/improving reliability. The Continuously Variable Transmission (CVT) will need to be tuned for the new vehicle inorder to reduce drivetrain losses and increase acceleration and drive response.

The chassis team will be responsible for designing, building and testing the chassis. A vehicle chassis provides three mainfunctions; it integrates all components together, it acts as a compliant member to transmit roll moments between the fourwheels, and it provides a safe and hopefully semi-comfortable envelope for the driver. This team will design the tooling andfixtures to manufacture the chassis within a relatively high level of accuracy and they will perform physical tests on thecompliance of the chassis to determine torsional and bending stiffness of the chassis as well as validate the chassis FEAmodel.

General Requirements of an SAE Project:1. Participate, communicate, and interact as part of a team with fellow team members to meet project requirements anddeadlines.2. Attend all relevant SAE meetings unless prior arrangements are made with a team leader (senior project, generalteam, and sub-team meetings).3. Clearly and concisely document relevant information on your work so others in the future may easily follow your work.4. Continue to support SAE in your area of expertise to the best of your ability during spring term.5. Expand experience and knowledge in racecar design and engineering.

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OSU MIME Senior ProjectProject Submission Form

Project Name: Powertrain for a Baja SAE VehicleSponsor: Oregon State Baja SAE TeamFaculty Advisor: Bob PaaschOwner of IP: Oregon State Baja SAE Team

Baja SAE Project Description

Baja SAE (Society of Automotive Engineers) is an international design competition in which students build an off-road racecar. Competing in Baja SAE since 1978, the Oregon State Baja SAE team has a rich history of success with placing in the top 5 every year for the last nine years and holding five 1st place trophies in the last six years.

SAE offers a very hands on and unique experience at for students at Oregon State. Students will be collaborating within a large team to design a complex, integrated system. Designs will then be implemented and tested on an actual performing vehicle. The year culminates in the the vehichle and team going to competition where they go against other students and schools from around the world. SAE speaks volumes on a resume and employers look very favorably on individuals that have been involved with SAE for their “real world” experience.

For the 2011-12 year the Oregon State Baja SAE team will continue to develop its already highly successful design with incremental improvements to reduces weight, reduce cost, ease manufacturability and to maintain/improve system reliability.

Baja Powertrain Project Description

The OSU Baja transaxle has proven in the last several years to be one of the most sophisticated and reliable drivetrain systems of any vehicle at the Baja SAE competition series. This system will continue to be developed with an emphasis on ease of manufacturability while maintaining/improving reliability.

This year the transaxle will be a collaborative development with the Tennessee Technical University Baja team. The powertrain will work with members from the TTU team to develop a common transaxle to be used by both teams cars.

The team will work closely with the driver interface team to develop driver controls for the transaxle.

General Requirements of an SAE Project

1. Participate, communicate, and interact as part of a team with fellow team members to meet project requirements and deadlines.

2. Attend all relevant SAE meetings unless prior arrangements are made with a team leader (senior project, general team, and sub-team meetings).

3. Clearly and concisely document relevant information on your work so others in the future may easily follow your work.

4. Continue to support SAE in your area of expertise to the best of your ability during spring term.

5. Expand experience and knowledge in racecar design and engineering.

6. Abide by all SAE rules.

Project Specific Requirements

1. Design a transaxle case with improved manufacturability, and chassis interfaces which will work for both teams.

2. Design transaxle internals (shafts, gears, differential, locker and shifting) to support required load, and provide reliable shifting and differential locking.


Project Name: Chassis for a Baja SAE VehicleSponsor: Oregon State Baja SAE TeamFaculty Advisor: Bob PaaschOwner of IP: Oregon State Baja SAE Team





Chassis Project Description

The chassis team will be responsible for designing, building and testing the chassis. A vehicle chassis provides three main functions; it integrates all components together, it acts as a compliant member to transmit roll moments between the four wheels, and it provides a safe and comfortable envelope for the driver. The team will use FEA to design a chassis that will support the required loads, and provide the required stiffness.This team will design the tooling and fixtures to manufacture the chassis to the required tolerances and twill perform physical tests on the compliance of the chassis to determine torsional and bending stiffness of the chassis as well as validate the chassis FEA model. This team will work closely with all other subteams to design interfaces between the chassis and the rest of the systems on the car.






5. Expand experience and knowledge in racecar design and engineering.6. Abide by all SAE rules.


● Design and analyze the chassis. This includes designing chassis tubing and bracketry, and optimization through FEA to achieve required strength and stiffness with minimum weight.

● Design interfaces between chassis and other vehicle subsystems.● Design and manufacture fixtures for producing chassis to required tolerances.● Manufacture the chassis.● Perform testing on chassis to validate FEA stiffness results.● Ensure chassis compliance with all applicable SAE regulations.


Project Name: Suspension for a Baja SAE VehicleSponsor: Oregon State Baja SAE TeamFaculty Advisor: Bob PaaschOwner of IP: Oregon State Baja SAE Team





Suspension Project Description

The suspension team will design, manufacture and test a suspension system which allows the vehicle to negotiate rough terrain and jumps in a stable manner. Kinematics of the suspension and steering systems will need to be analyzed to provide appropriate movement and handling characteristics of the vehicle. Shocks will need to be tuned to give the vehicle the acceptable ride/pitch/roll response. Components will need to be designed to be lightweight and yet reliable.

This team will work closely with the human interfaces team on integration of the steering and braking systems.








1. Analyze suspension kinematics.2. Design and manufacture A-Arms.3. Use FEA to design uprights to support required loads. Package required components

(hubs, wheels, braking, spindle).4. Design steering system from wheels to steering rack.5. Tune shocks for improved performance.


Project Name: Data Acquisition / CVT Tuning for a Baja SAE VehicleSponsor: Oregon State Baja SAE TeamFaculty Advisor: Bob PaaschOwner of IP: Oregon State Baja SAE Team





Data Acquisition / CVT Tuning Project Description

The Baja Data Acquisition / CVT Tuning team will be responsible for selecting sensors, and setting up the car’s data acquisition system. The team will tune the car’s CVT using collected data. The team will also be responsible for measuring engine output on the engine dynamometer.

This team will work closely with other subteams to integrate sensors into the car. The team will also work with the Formula SAE data aquisition team to setup the MoTeC ACL for use on the Baja car, and coordinate use of the ACL, which will be shared between teams.








1. Select appropriate sensors to collect required data.2. Design and manufacture data acquisition wiring harness.3. Learn how to use MoTeC hardware and software.4. Plan and perform tests to tune the CVT.


Project Name: Driver Interface for a Baja SAE VehicleSponsor: Oregon State Baja SAE TeamFaculty Advisor: Bob PaaschOwner of IP: Oregon State Baja SAE Team





Driver Interface Project Description

The Oregon State Baja driver interface team is responsible for the design & optimization of the Baja SAE cockpit & driver interface components with a focus on driver comfort. The Oregon State Baja car from the previous season has some weaknesses regarding driver ergonomics, comfort, steering wheel, seat belts, brake rotors, as well as the functionality of the shifter and locker control.

The driver interface should be the best combination out of less weight, high rigidity, less costs, good finish, and good comfort for the driver while driving. The driver interface team should work closely together with the suspension subteam, in order to develop a rugged and reliable brake system.








1. Comfortable yet rigid seat & driver’s restraint.2. Steering wheel within easy reach of driver.3. Reliable shifting & locker actuation systems developed in coordination with

Powertrain subteam.4. Pedal assembly optimized around driver comfort & reachability while maximizing

braking performance. (coordination with Formula)5. Turning brake handle.6. All design have to comply with the SAE Rules.

201

Design of the OSU Formula SAE vechicle

Oregon State Formula Team

Prof. Paasch

Formula - Society of Automotive Engineers (FSAE) is one possible senior project that you can choose. We offer a wide varietyof comprehensive, multidisciplinary senior projects for ME, IE, MfgE, and EE's that closely resembles working in a real-worldengineering environment. FSAE is essentially an international collegiate racing series. Every year schools around the worlddesign, build, and race open-wheel cars at a variety of international competitions. Our team, Global Formula Racing, is a oneof a kind, successful, global collaboration between OSU and DHBW-Ravensberg, a university in Germany. If you chooseGlobal Formula Racing you will be getting involved with a program that's an excellent resume booster and has a high hiringrate. SAE alumni employers include companies like A-Dec Inc, Boeing, Hewlett-Packard, Honda, Intel, NASA, Space-X,Tektronix Inc, and many more.

As a future member of Global Formula Racing your project will be on one of several sub-teams; body, combustion powertrain,electric powertrain, or suspension. Body team includes chassis manufacturing and aerodynamics. On this sub-team you willlearn how to lay-up carbon fiber, use computational fluid dynamics (CFD) to simulate airflow over wings, and use finite elementanalysis to analyze vehicle crash structure. Combustion Powertrain (cPowertrain) includes intake and exhaust design, engine tuning, and drivetrain design. Electric Powertrain (ePowertrain) includes battery pack management, charging interface, andelectric motor cooling design. Suspension includes vehicle simulation, brake design, and carbon fiber a-arm and wheelmanufacturing. These are just a sample of the projects available through Global Formula Racing. If you have a particularinterest or skill, we are willing to work with you to plan a project that fits those interests.

To ask any questions or learn more about our program, please contact me at [email protected]. Alsocheck out the team at http://www.facebook.com/TeamGFR or www.global-formula-racing.com.

Project Number:

Sponsor:

MIME Advisor:


Project Name: Suspension for a Formula SAE VehicleSponsor: Oregon State Formula SAE TeamFaculty Advisor: Bob PaaschOwner of IP: Oregon State Formula SAE Team

Formula SAE Project Description

Formula SAE (Society of Automotive Engineers) is an international design competition in which students build a Formula style racecar. Over 450 universities around the world design, fabricate, and test cars for nine international Formula competitions, making it the largest student engineering competition in the world. A new vehicle must be created each year and comply with the current set of rules which are designed to keep the competitions safe, fair and challenging. Oregon State has been competing in FSAE competitions since 1987.

For the 2011-12 year the OSU Formula SAE team will continue an international collaboration with the German university Duale Hochschule Baden-Württemberg Ravensburg (DHBW). The new vehicles will again be collaboratively designed both at OSU and DHBW, then two vehicles will be assembled, one at OSU and one at the DHBW. The two vehicles will have different powertrains: one will comply with Formula SAE rules and the other will comply with Formula Student Electric rules. Effective international communication and project management will be critical to success.

SAE offers a hands on and unique experience at OSU. Students will be working with a large, international team, similar to how global engineering organizations operate today. Successful completion of a Formula SAE project will be recognized with an international design collaboration certificate awarded beyond a normal engineering degree.

Suspension Project Description

The suspension team will design, manufacture and test suspension system components. Of particular interest this year are carbon fiber A-arm development, improved steering system to reduce compliance, adjustable suspension kinematics, improved adjustable brake pedal box, and improved data analysis. Components will need to be designed to be lightweight and yet reliable.


1. Participate, communicate, and interact as part of a team with fellow SAE members both at OSU and the DHBW to meet project requirements and deadlines.

2. Attend all relevant SAE meetings unless prior arrangements are made with a team leader (senior project, general Formula SAE, and sub-team meetings).

3. Clearly and concisely document relevant information on your work so that others in the future may easily follow your work.


5. Expand experience and knowledge in racecar design and engineering.6. Abide all Formula SAE rules.


1. Design, manufacture, test and develop control arms for the OSU Formula suspension system.

2. Design, manufacture, test and develop an improved steering system.3. Design, manufacture, test and develop an adjustable suspension kinematics system.4. Design, manufacture, test and develop the braking system.5. Develop methods and tutorials for data extraction and analysis.6. All necessary components must be designed to function equally on both the combustion

and electric cars.


Project Name: Combustion Powertrain for a Formula SAE VehicleSponsor: Oregon State Formula SAE TeamFaculty Advisor: Bob PaaschOwner of IP: Oregon State Formula SAE Team





Combustion Powertrain Project Description

The primary engine systems team will be responsible for designing, documenting, manufacturing and testing of an E85 fuel delivery system for the Formula engine, tuning fuel and ignition maps and integration of all electrical components to the car. Engine tuning will have an emphasis on fuel economy and broad “drivable” torque ranges. The team will work closely with the engine simulation and component design teams at the DH. The team will bear ultimate responsibility for the design of the fuel delivery system, as well as engine building, tuning, and testing. The project will be highly hands on with testing being a primary focus. The goal of the team will be ensuring reliability and drivability of the engine in all conditions with secondary focus on fuel economy and performance. Strong familiarization with engine systems and MoTeC ECU Manager will need to be learned immediately during the first term in order to successful on this team.








1. Design, manufacture, test, and develop an E85 fuel delivery system for the OSU Formula engine.

2. Develop, implement, and test a high compression piston for the OSU Honda engines3. Tune and ensure reliable starting and running of the engine under all conditions.4. Develop tuned engine maps specific to each event to maximize points gained at

competition.5. Manufacture engine ancillaries such as the cooling system, intake system, and exhaust

system.6. Maintain and keep in good condition all OSU Honda engines, engine parts and testing

equipment. Engine room must be kept clean at all times.7. Collect, analyze, and utilize data in Motec system to further improve engine system.


Project Name: Composite Manufacturing and Testing for a Formula SAE Vehicle.Sponsor: Oregon State Formula SAE TeamFaculty Advisor: Bob PaaschOwner of IP: Oregon State Formula SAE Team





Composites Manufacturing and Testing Project Description

The Composites Manufacturing and Testing team will be responsible for designing, documenting, testing and manufacturing composite components for the car including the wings, undertray, sidepods, and impact attenuator. The team will perform testing on composite parts and materials in order to determine material properties, validate FEA results, and for compliance with the Formula SAE rules. The team is required to communicate and work regularly with all other teams as this team will provide central integration for all other sub-systems on the car. Strong familiarization with composite manufacturing techniques will need to be learned early in the design phase in order to properly design parts and tooling.








1. Manufacture and test samples to determine composite material properties.2. Manufacture and test samples required by the Formula SAE rules, and produce required

documentation of these tests.3. Test torsional rigidity of the completed chassis in conjunction with suspension stiffness

testing to validate FEA results.4. Develop structure, manufacturing methods and mounting of aerodynamic elements

(wings, undertray and sidepods), working with the Aerodynamics team designing the shape of these components.

5. Design and test a composite Impact Attenuator (nose cone), and produce documentation to show compliance with Formula SAE crash safety regulations.

6. Assist with any additional composite and chassis manufacturing.7. All necessary components must be designed to function equally on both the combustion

and electric cars.8. Maintain and keep in good condition all OSU composite materials, tools and equipment.

The composites lab must be kept clean at all times.


Project Name: Aerodynamic Development for a Formula SAE Vehicle.Sponsor: Oregon State Formula SAE TeamFaculty Advisor: Bob PaaschOwner of IP: Oregon State Formula SAE Team





Aerodynamic Development Project Description

The Aerodynamic Development team will be responsible for researching, simulating, designing, documenting, manufacturing and testing an undertray, wings, sidepod and cooling for the Formula SAE car. The team will work closely with the Composites team designing the structure and mounting of the aerodynamic elements, and the DHBW side of the CFD team.

Formula SAE is unique in that active control of aerodynamic devices while racing is permitted. The team will be responsible for development of active aerodynamic elements, and will work closely with the Vehicle Dynamics team to define activation requirements.








1. Design aerodynamic element shapes that meet the customer requirements of the Formula SAE team and SAE rules.

2. Develop CFD models for simulation of aerodynamic performance.3. Test and document the performance of the elements on the 2011 and 2012 FormulaS

AE cars.4. Develop active aerodynamic elements.5. All necessary components must be designed to function equally on both the combustion

and electric cars.


Project Name: Drivetrain for a Formula SAE VehicleSponsor: Oregon State Formula SAE TeamFaculty Advisor: Bob PaaschOwner of IP: Oregon State Formula SAE Team





Drivetrain Project Description

The focus of the drivetrain team will be to adapt the Drexler Formula SAE differential to the GFR12 car. A detailed comparison differential options should be compiled to help justify the Drexler as the compromise in our needs. This project will involve mechanical design and manufacturing of all interfaces between the differential and the chassis, chain sprocket interface to the engine, and design of mechanical interface between the differential and the driveshafts. The project will also involve differential testing to show effectiveness of the limited slip system. Strong familiarization with limited slip differential system will need to be learned quickly so that comprehensive manufacturing and testing plans can be made.








1. Design, manufacture, test, and develop mechanical interfaces between Drexler differential and the chassis, drive chain, and drive shafts

2. Use FEA analysis to improve mounting stiffness (known issue from ‘10-’11)3. Test effectiveness of Drexler limited slip and tune to reduce lap times4. Collect, analyse, and utilize data using on car Motec system for use in tuning drivetrain

system


Project Name: Chassis Interfaces and Manufacturing for a Formula SAE VehicleSponsor: Oregon State Formula SAE TeamFaculty Advisor: Bob PaaschOwner of IP: Oregon State Formula SAE Team





Chassis Interfaces and Manufacturing Project Description

The Chassis Interfaces and Manufacturing team will be responsible researching, designing, documenting, testing, and creating a composite manufacturing process for the Formula SAE chassis, and the interfaces and mounting methods between the chassis and all other components of the car. The chassis manufacturing team will work closely with other team members both designing the monocoque chassis itself, and components that interface with the chassis. The team will be responsible for developing and testing the lay up process, creating necessary mold tooling, and producing two chassis. The team is required to communicate and work regularly with all other teams as this team will provide central integration for all other sub-systems on the car. Strong familiarization with composite manufacturing techniques will need to be learned early in the design phase in order to properly design parts and tooling.








1. Develop and document a composite manufacturing process that meets the customer requirements of the FSAE team and FSAE rules.

2. Design and create additional mold tooling and improve existing molding for manufacturing two monocoques to desired tolerances and quality standards.

3. Manufacture two monocoque FSAE chassis.4. Work with other teams to design all necessary interfaces to the chassis and packaging

of components.5. Develop manufacturing methods for all interfaces to the monocoque.6. Use parametric CAD modeling techniques based off of provided geometric points to

allow for modification of the geometric points with minimal impact on parts.7. All necessary components must be designed to function equally on both the combustion

and electric cars.8. Maintain and keep in good condition all OSU composite materials, tools and equipment.

The composites lab must be kept clean at all times.


Project Name: Supply Chain Management for a Formula SAE VehicleSponsor: Oregon State Formula SAE TeamFaculty Advisor: Bob PaaschOwner of IP: Oregon State Formula SAE Team





Supply Chain Management Project Description

The operational supply chain management needs to have an overview of all components and assembly units; this includes manufacturing and purchasing parts. In cooperation with the Technical Directors, a time schedule with deadlines and milestones has to be prepared, controlled, updated and communicated regularly with the team. In cooperation with the designers, possible vendors and manufacturers have to be identified in order to allocate those resources to all manufacturing parts. The part tracking and detection of critical parts is essential to recognize and solve any problems in the supply chain. Special focus has to be put on the shipments between both universities. This involves dealing with time, cost, customs regulations, and the shipping company.

The supply chain management system team will be responsible for analyzing, designing, documenting and implementing a database system, which includes certain information like internal and external contact persons, previous part manufacturing or sponsoring, and manufacturing capabilities from all vendors, manufacturers, and sponsors. The database will be used by multiple subteams like accounting, marketing, and supply chain. Furthermore, the supply chain management system team needs to maintain and improve the existing GFR enterprise resource planning system, which includes a part evaluation system, a purchase request system, and an accounting tool.

In order to understand the current supply chain process and supplier issues, the team will manage the scheduling, ordering, and purchasing of off-the-shelf raw materials, finished parts, donated parts and custom parts.These resource allocation is very dependent on the organization of the whole team, therefore this team must become very familiar with the ongoing status of parts on the car, where they are to be manufactured/acquired and distributed.








1. Allocating manufacturing resources and organizing part manufacturing and shipments between both universities.

2. Prepare, control, update and communicate a time schedule with deadlines and milestones regularly with the team.

3. Design and implement of a database system for organizing vendor, manufacturer, and sponsor information.

4. Existing platforms used by the team (Catia V5, Google Docs, {Catia V6 a proposed system for the future}) should be leveraged in the design.

5. Good documentation to support the use of the database after the completion of the project

6. Supply Chain team will work closely with the Supply Chain team at DHBW, and with the design and manufacturing teams at both schools.

7. Attend management meetings, vehicle work sessions, drive days, etc.

design of a calibration apparatus for liquid temperature...

Documents