Matching Items (10)
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- All Subjects: 3D Printing
- All Subjects: Automotive
- Creators: Engineering Programs
Description
Many industries require workers in warehouse and stockroom environments to perform frequent lifting tasks. Over time these repeated tasks can lead to excess strain on the worker's body and reduced productivity. This project seeks to develop an exoskeletal wrist fixture to be used in conjunction with a powered exoskeleton arm to aid workers performing box lifting types of tasks. Existing products aimed at improving worker comfort and productivity typically employ either fully powered exoskeleton suits or utilize minimally powered spring arms and/or fixtures. These designs either reduce stress to the user's body through powered arms and grippers operated via handheld controls which have limited functionality, or they use a more minimal setup that reduces some load, but exposes the user's hands and wrists to injury by directing support to the forearm. The design proposed here seeks to strike a balance between size, weight, and power requirements and also proposes a novel wrist exoskeleton design which minimizes stress on the user's wrists by directly interfacing with the object to be picked up. The design of the wrist exoskeleton was approached through initially selecting degrees of freedom and a ROM (range of motion) to accommodate. Feel and functionality were improved through an iterative prototyping process which yielded two primary designs. A novel "clip-in" method was proposed to allow the user to easily attach and detach from the exoskeleton. Designs utilized a contact surface intended to be used with dry fibrillary adhesives to maximize exoskeleton grip. Two final designs, which used two pivots in opposite kinematic order, were constructed and tested to determine the best kinematic layout. The best design had two prototypes created to be worn with passive test arms that attached to the user though a specially designed belt.
ContributorsGreason, Kenneth Berend (Author) / Sugar, Thomas (Thesis director) / Holgate, Matthew (Committee member) / Mechanical and Aerospace Engineering Program (Contributor) / Barrett, The Honors College (Contributor)
Created2016-12
Description
The goal of our research was to develop and validate a method for predicting the mechanical behavior of Additively Manufactured multi-material honeycomb structures. Multiple approaches already exist in the field for modeling the behavior of cellular materials, including the bulk property assumption, homogenization and strut level characterization [1]. With the bulk property approach, the structure is assumed to behave according to what is known about the material in its bulk formulation, without regard to its geometry or scale. With the homogenization technique, the specimen that is being tested is treated as a solid material within the simulation environment even if the physical specimen is not. Then, reduced mechanical properties are assigned to the specimen to account for any voids that exist within the physical specimen. This approach to mechanical behavior prediction in cellular materials is shape dependent. In other words, the same model cannot be used from one specimen to the next if the cell shapes of those lattices differ in any way. When using the strut level characterization approach, a single strut (the connecting member between nodes constituting a cellular material) is isolated and tested. With this approach, there tends to be a significant deviation in the experimental data due to the small size of the isolated struts. Yet it has the advantage of not being shape sensitive, at least in principle. The method that we developed, and chose to test lies within the latter category, and is what we have coined as the Representative Lattice Element (RLE) Method. This method is modeled after the well-established Representative Volume Element (RVE) method [2]. We define the RLE as the smallest unit over which mechanical tests can be conducted that will provide results which are representative of the larger lattice structure. In other words, the theory is that a single member (or beam in this case) of a honeycomb structure can be taken, tests can be conducted on this member to determine the mechanical properties of the representative lattice element and the results will be representative of the mechanical behavior whole structure. To investigate this theory, we designed specimens, conducted various tensile and compression tests, analyzed the recorded data, conducted a micromechanics study, and performed structural simulation work using commercial Finite Element Analysis software.
ContributorsSalti, Ziyad Zuheir (Co-author) / Eppley, Trevor (Co-author) / Bhate, Dhruv (Thesis director) / Song, Kenan (Committee member) / Engineering Programs (Contributor) / Barrett, The Honors College (Contributor)
Created2018-05
Description
For the past two decades, advanced Limb Gait Simulators and Exoskeletons have been developed to improve walking rehabilitation. A Limb Gait Simulator is used to analyze the human step cycle and/or assist a user walking on a treadmill. Most modern limb gait simulators, such as ALEX, have proven themselves effective and reliable through their usage of motors, springs, cables, elastics, pneumatics and reaction loads. These mechanisms apply internal forces and reaction loads to the body. On the other hand, external forces are those caused by an external agent outside the system such as air, water, or magnets. A design for an exoskeleton using external forces has seldom been attempted by researchers. This thesis project focuses on the development of a Limb Gait Simulator based on a Pure External Force and has proven its effectiveness in generating torque on the human leg. The external force is generated through air propulsion using an Electric Ducted Fan (EDF) motor. Such a motor is typically used for remote control airplanes, but their applications can go beyond this. The objective of this research is to generate torque on the human leg through the control of the EDF engines thrust and the opening/closing of the reverse thruster flaps. This device qualifies as "assist as needed"; the user is entirely in control of how much assistance he or she may want. Static thrust values for the EDF engine are recorded using a thrust test stand. The product of the thrust (N) and the distance on the thigh (m) is the resulting torque. With the motor running at maximum RPM, the highest torque value reached was that of 3.93 (Nm). The motor EDF motor is powered by a 6S 5000 mAh LiPo battery. This torque value could be increased with the usage of a second battery connected in series, but this comes at a price. The designed limb gait simulator demonstrates that external forces, such as air, could have potential in the development of future rehabilitation devices.
ContributorsToulouse, Tanguy Nathan (Author) / Sugar, Thomas (Thesis director) / Artemiadis, Panagiotis (Committee member) / Mechanical and Aerospace Engineering Program (Contributor) / Barrett, The Honors College (Contributor)
Created2016-12
Description
Mathematical and analytical approach at the floor and diffuser of a Formula 1 vehicle and how they produce downforce. Reaches a conclusion about how engineers and aerodynamicists creates the desired effects underneath the vehicle to produce substantial downforce.
ContributorsMarcantonio, Nicholas Joseph (Author) / Rajadas, John (Thesis director) / Hillery, Scott (Committee member) / College of Integrative Sciences and Arts (Contributor) / Engineering Programs (Contributor, Contributor) / Barrett, The Honors College (Contributor)
Created2021-05
Description
With FDM printing becoming ubiquitous within the commercial and private sectors, there are many who would want to print a part without supports for a variety of reasons. Usually, they want to prints a part with difficult to reach places that would make it impossible to remove any support material without damaging the part. I will be going over options to consider when designing parts to ensure a given model will be able to be printed without support material.
ContributorsYoshitake, Jacob (Author) / Sugar, Thomas (Thesis director) / Redkar, Sangram (Committee member) / Barrett, The Honors College (Contributor) / Engineering Programs (Contributor)
Created2021-12
Description
Mechanical design can be intimidating, especially for someone new to the discipline because of the complexity and the limited number of resources available. The overarching goal of this project is to help mechanically curious individuals by creating an open-source 3D printed clock with detailed information and explanations for how the systems work and are designed. This increase in available knowledge will allow people to educate themselves by following or recreating the design process and, perhaps, inspire others to continue the learning process and study STEM.
ContributorsBrody, Harris (Author) / Davis, Ian (Co-author) / Frank, Daniel (Thesis director) / Pillalamarri, Pavan (Committee member) / Barrett, The Honors College (Contributor) / Engineering Programs (Contributor)
Created2024-05
Description
All around the automotive industry, the chassis dynamometer exists in a variety of configurations but all function to provide one common goal. The underlying goal is to measure a vehicle’s performance by measuring torque output and taking that measurement to calculate horsepower. This data is crucial in situations of testing development vehicles or for tuning heavily modified vehicles. While the current models in the industry serve their purposes for what they were intended to do, in theory, an additional system can be introduced to the dyno to render the system into an electric generator.
The hardware will consist of electric motors functioning as a generator by reversing the rotation of the motor (regenerative braking). Using the dynamometer with the additional motor system paired with a local battery, the entire system can be run off by their tuning service. When considering the Dynojet and Dynapack dynamometer, it was calculated that an estimated return of 81.5% of electricity used can be generated. Different factors such as how frequent the dyno is used and for how long affect the savings. With a generous estimate of 6 hours dyno run time a day for 250 business days and the cost of electricity being 13.19 cents/kwh the Dynapack came out to $326.45 a year and $1424.52 for the Dynojet. With the return of electricity, the amount saved comes out to $266.18 for the Dynapack and $1161.50 for the Dynojet. This will alleviate electrical costs dramatically in the long term allowing for performance shops to invest their saved money into more tools and equipment.
The hardware will consist of electric motors functioning as a generator by reversing the rotation of the motor (regenerative braking). Using the dynamometer with the additional motor system paired with a local battery, the entire system can be run off by their tuning service. When considering the Dynojet and Dynapack dynamometer, it was calculated that an estimated return of 81.5% of electricity used can be generated. Different factors such as how frequent the dyno is used and for how long affect the savings. With a generous estimate of 6 hours dyno run time a day for 250 business days and the cost of electricity being 13.19 cents/kwh the Dynapack came out to $326.45 a year and $1424.52 for the Dynojet. With the return of electricity, the amount saved comes out to $266.18 for the Dynapack and $1161.50 for the Dynojet. This will alleviate electrical costs dramatically in the long term allowing for performance shops to invest their saved money into more tools and equipment.
ContributorsCrisostomo, Ryan-Xavier Eddie (Author) / Contes, James (Thesis director) / Wishart, Jeffrey (Committee member) / Engineering Programs (Contributor) / Barrett, The Honors College (Contributor)
Created2020-05
Description
Sport Utility Vehicles have grown to be one of the most popular vehicle choices in the automotive industry. This thesis explores the history of SUVs with their roots starting in the 1930s up until 2020 in order to understand the essence of what an SUV is. The definition applied to the SUV for this thesis is as follows: a vehicle that is larger and more capable than the average sedan by offering more interior space, cargo area, and possibly off-road capability. This definition must be sufficiently broad to encompass the diverse market that manufactures are calling SUVs. Then the trends of what current (2020) SUVs are experiencing are analyzed from three major aspects: sociology, economics, and technology. Sociology focuses on the roles an SUV fulfills and the type of people who own SUVs. The economics section reviews the profitability of SUVs and their dependence on a nation’s economic strength. Technology pertains to the trends in safety features and other advances such as autonomous or electric vehicles. From these current and past trends, predictions could be made on future SUVs. In regards to sociology, trends indicate that SUVs will be more comfortable as newly entering luxury brands will be able to innovate aspects of comfort. In addition, SUVs will offer more performance models so manufacturers can reach a wider variety of demographics. Economic trends revealed that SUVs are at risk of losing popularity as the economy enters a hard time due to the COVID-19 pandemic. Technological trends revealed that hybrids and electric vehicles will now move into the SUV market starting with the more compact sizes to help improve manufacturer’s fleet fuel efficiency.
ContributorsMarske, Trevor Holmes (Author) / Henderson, Mark (Thesis director) / Contes, James (Committee member) / Engineering Programs (Contributor) / Barrett, The Honors College (Contributor)
Created2020-05
Description
Multi-material manufacturing combines multiple fabrication processes to produce individual parts that can be made up of several different materials. These processes can include both additive and subtractive manufacturing methods as well as embedding other components during manufacturing. This yields opportunities for creating single parts that can take the place of an assembly of parts produced using conventional techniques. Some example applications of multi-material manufacturing include parts that are produced using one process then machined to tolerance using another, parts with integrated flexible joints, or parts that contain discrete embedded components such as reinforcing materials or electronics.
Multi-material manufacturing has applications in robotics because, with it, mechanisms can be built into a design without adding additional moving parts. This allows for robot designs that are both robust and low cost, making it a particularly attractive method for education or research. 3D printing is of particular interest in this area because it is low cost, readily available, and capable of easily producing complicated part geometries. Some machines are also capable of depositing multiple materials during a single process. However, up to this point, planning the steps to create a part using multi-material manufacturing has been done manually, requiring specialized knowledge of the tools used. The difficulty of this planning procedure can prevent many students and researchers from using multi-material manufacturing.
This project studied methods of automating the planning of multi-material manufacturing processes through the development of a computational framework for processing 3D models and automatically generating viable manufacturing sequences. This framework includes solid operations and algorithms which assist the designer in computing manufacturing steps for multi-material models. This research is informing the development of a software planning tool which will simplify the planning needed by multi-material fabrication, making it more accessible for use in education or research.
In our paper, Voxel-Based Cad Framework for Planning Functionally Graded and Multi-Step Rapid Fabrication Processes, we present a new framework for representing and computing functionally-graded materials for use in rapid prototyping applications. We introduce the material description itself, low-level operations which can be used to combine one or more geometries together, and algorithms which assist the designer in computing manufacturing-compatible sequences. We then apply these techniques to several example scenarios. First, we demonstrate the use of a Gaussian blur to add graded material transitions to a model which can then be produced using a multi-material 3D printing process. Our second example highlights our solution to the problem of inserting a discrete, off-the-shelf part into a 3D printed model during the printing sequence. Finally, we implement this second example and manufacture two example components.
Multi-material manufacturing has applications in robotics because, with it, mechanisms can be built into a design without adding additional moving parts. This allows for robot designs that are both robust and low cost, making it a particularly attractive method for education or research. 3D printing is of particular interest in this area because it is low cost, readily available, and capable of easily producing complicated part geometries. Some machines are also capable of depositing multiple materials during a single process. However, up to this point, planning the steps to create a part using multi-material manufacturing has been done manually, requiring specialized knowledge of the tools used. The difficulty of this planning procedure can prevent many students and researchers from using multi-material manufacturing.
This project studied methods of automating the planning of multi-material manufacturing processes through the development of a computational framework for processing 3D models and automatically generating viable manufacturing sequences. This framework includes solid operations and algorithms which assist the designer in computing manufacturing steps for multi-material models. This research is informing the development of a software planning tool which will simplify the planning needed by multi-material fabrication, making it more accessible for use in education or research.
In our paper, Voxel-Based Cad Framework for Planning Functionally Graded and Multi-Step Rapid Fabrication Processes, we present a new framework for representing and computing functionally-graded materials for use in rapid prototyping applications. We introduce the material description itself, low-level operations which can be used to combine one or more geometries together, and algorithms which assist the designer in computing manufacturing-compatible sequences. We then apply these techniques to several example scenarios. First, we demonstrate the use of a Gaussian blur to add graded material transitions to a model which can then be produced using a multi-material 3D printing process. Our second example highlights our solution to the problem of inserting a discrete, off-the-shelf part into a 3D printed model during the printing sequence. Finally, we implement this second example and manufacture two example components.
ContributorsBrauer, Cole D (Author) / Aukes, Daniel (Thesis director) / Sodemann, Angela (Committee member) / Engineering Programs (Contributor, Contributor) / Barrett, The Honors College (Contributor)
Created2019-05
Description
With the growing popularity and advancements in automation technology, Connected and Automated Vehicles (CAVs) have become the pinnacle of ground-vehicle transportation. Connectivity has the potential to allow all vehicles—new or old, automated or non-automated—to communicate with each other at all times and greatly reduce the possibility of a multi-vehicle collision. This project sought to achieve a better understanding of CAV communication technologies by attempting to design, integrate, test, and validate a vehicular ad-hoc network (VANET) amongst three automated ground-vehicle prototypes. The end goal was to determine what current technology best satisfies Vehicle-to-Vehicle (V2V) communication with a real-time physical demonstration. Although different technologies, such as dedicated short-range communication (DSRC) and cellular vehicle to everything (C-V2X) were initially investigated, due to time and budget constraints, a FreeWave ZumLink Z9-PE DEVKIT (900 MHz radio) was used to create a wireless network amongst the ground-vehicle prototypes. The initial testing to create a wireless network was successful and demonstrated but creating a true VANET was unsuccessful as the radios communicate strictly peer to peer. Future work needed to complete the simulated VANET includes programming the ZumLink radios to send and receive data using message queuing telemetry transport (MQTT) protocol to share data amongst multiple vehicles, as well as programming the vehicle controller to send and receive data utilizing terminal control protocol (TCP) to ensure no data loss and all data is communicated in correct sequence.
ContributorsDunn, Brandon (Author) / Chen, Yan (Thesis director) / Wishart, Jeffrey (Committee member) / Engineering Programs (Contributor, Contributor) / Barrett, The Honors College (Contributor)
Created2019-05