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Thermal Control System for Altair, the New Lunar Lander
Team: Concilium Lunare
Students: Mike Borden (ME), Carina Buck (ME), Clayton Fitzgerald (ME), Nick Norppa (ME), Ian Rokser (ME), Lisa Ruffalo (ME), Chris Schultz (ME), Thomas Simmons (ME), Mark Warwick (ME)
Advisor: Professor Michael Swedish As the United States has renewed interest in returning to the lunar surface, NASA’s Constellation program has significant work to do on Altair, their new lunar lander. Altair will transport up to four American astronauts to the lunar surface while providing a comfortable thermal environment for both personnel and equipment. Previous lunar missions utilized consumable materials to cool the lander. Future lunar missions will require a more robust thermal control approach, one that allows for longer duration missions while minimizing resources. The Lunar Council has been working with NASA to both model and determine the feasibility of several thermal control systems. These systems include: Absorption Refrigeration, Heat Pipes and Magnetic Refrigeration. The Absorption Refrigeration system was determined a feasible design as long as an additional thermal energy input is available. Heat Pipes have been found capable of providing adequate passive thermal control. The Magnetic Refrigeration system was also determined a feasible design, although there are considerable design challenges that must be overcome before a suitable system can be built. A heat pipe was chosen for experimental study during the spring quarter, providing a means to test the numerical models developed during the design process and to demonstrate how this technology might be applied to Altair. Appreciation is extended to: Greg Schunk/EV34/MSFC, NASA’s MSFC, Wisconsin Space Grant Consortium, Orbital Technologies Corp. and Astronautics Corporation of America.
Residential Distributed Energy System
Team: EcoEnergy
Students: Matt Duffy (ME), John Flotterud (ME), Michael Kaiser (ME), Jenny Pfaff (ME)
Advisor: Dr. Christopher Damm
In an attempt to address the growing concerns of carbon dioxide emissions, an energy system for a single family residence located in the We Energies service area was designed. The system meets the energy requirements of the house while minimizing cost and environmental impacts. This was done by implementing a micro combined heat and power (micro-CHP) system in the form of a spark ignition internal combustion engine generator set with thermal energy recovery. This system achieves an efficiency of 90% which reduces the amount of fuel that is needed and thus the emissions that are released. The system was designed and implemented in a laboratory setting for student and university research. Appreciation is extended to: Emerson Process Management Rosemount Inc., Marathon Engine Systems, and Thermal Energy System Specialist
Mini Baja Hydraulic Driveline
Team: Flow Doctors
Students: Elizabeth Weinert (ME), Matt Dudgeon (ME), Charles Ziemer (ME)
Advisor: Professor Thomas Labus
This year our project team was asked to design two variable displacement motors to replace the two current fixed displacement motors on the hydraulic mini baja car. The previous system had a two-speed parallel and series flow circuit that didn’t utilize the full power available from the engine, whereas, the new hydraulic system will operate in a purely parallel circuit. In addition to fitting the variable displacement motors to the car and system, a manual controller was designed. The manual controller will allow the driver, to adjust the angle of the swashplates in the motors by means of a shifter and a push-pull cable to achieve the best performance possible for the desired application. The main applications include a hill climb and a timed endurance run on flat terrain. With variable displacement motors, the vehicle will be able to operate under maximum power for either application. Appreciation is extended to: Mike Benz, Sauer Danfoss; Curt Porter, Orscheln Products; Kevin Strupp, Briggs & Stratton Corp. and Jeff Tayon, Orscheln Products.
Variable Displacement Hydraulic Vane Motor
Team: Full Tilt
Students: Sean Brooks (ME), Matthew Komro (ME), Nicholas Schmidt (ME), Joshua Uelmen (ME)
Advisor: Professor Thomas Labus
The objective of the 2008 Human Powered Vehicle team
was to update the existing hydraulic drive-train on the vehicle. This will be
accomplished using a variable displacement motor and control strategy. This
update will allow the vehicle to obtain a higher speed of 55 mph, and provide a
wider range of control. The motor developed by our team implements a variable
displacement vane concept. The motor will be implemented in the rear drive wheel
of the vehicle, thus eliminating the need for gear reduction and extra drive-train
components.
Appreciation is extended to: Fluid Power Institute™ (MSOE), National Fluid
Power Association.
SAE Aero Design Competition
Team: Extreme Inferno
Students: Kevin Biederer (ME), Fryderyk Czajkowski (ME), Brian Erickson (ME), Jake Gay (MEM), Elliot Gronland (ME), Andrew Hanson (ME), Peter Kendl (ME), Carl Sarro (ME), Matt Woodruff (ME)
Advisor: Dr. Robert Rizza
This year’s SAE Aero Design Team has designed, built and flown a heavy lift remote control airplane with the goal of lifting the most weight under certain restrictions. The plane is constructed of mostly composite materials, along with other high strength low weight materials. The twin engine design is capable of producing twenty pounds of thrust in order to lift the fifty five pound weight of the plane. The twelve foot wingspan is capable of producing enough lift to take off on a grass field within 200 feet, and the amazing landing gear design is capable of landing in the undeveloped grass field it took off from. Appreciation is extended to: Amalga Composites, Master Lock, and ITW/Devcon for their contributions to the project.
2008 Solar Boat Team
Students: Jason Anderson (ME), Bob Kraft (ME), William Kreuger (ME), Zak Paulus (ME)
Advisor: Professor Thomas Labus
The 2008 Solar Boat Team focused their attention on modifying and upgrading the drive train so that it is capable of operating two unique propeller configurations. The first propeller configuration is a variable pitch propeller that is capable of adjusting the pitch of each blade according to the current speed of the watercraft. This configuration will be used in the sprint race, where maximum speed is desired. The second propeller configuration is a fixed pitch ducted propeller implemented in order to increase the forward thrust of the boat at low speeds. This configuration will be advantageous for the endurance race where the watercraft must travel the longest distance on a single charge of the batteries. Both configurations use the same lower drive unit which has been modified to incorporate a thrust vectoring steering system. The thrust vectoring steering changes the direction of thrust by rotating the entire lower unit and therefore eliminating the need for a rudder while increasing maneuverability. Appreciation is extended to: Handyman Marine Supply, Innovative Machine Specialists, Mercury Marine and Timken Bearing.
Spring Driven Scoliosis Implant
Team: Spine Busters
Students: Toni Cannova (ME), Justin Dworak (ME), Ken Luckjohn (ME), Josh Schermerhorn (ME), Amanda Wilson (ME)
Advisor: Dr. Robert Rizza
Orthopedic surgeons have identified the need for a new system to stabilize scoliosis, a debilitating abnormal curvature of the spine. The systems that are currently used involve fixed rods that are manually adjusted to change spinal curvature. This process requires several surgeries for the patient, often resulting in long and painful recovery periods. The new system is self-driven using a combination of springs and linkages which are completely internal to the device and are controlled remotely. Having external control to elongate the implant limits the number of surgeries needed and subsequently reduces the severity of recovery. Constraints of the human body, forces exerted on the device by the human body, and the small size available to place the implant were used as a basis for the design. This device will greatly improve the quality of life for scoliosis patients. Appreciation is extended to: Faith Engineering Inc. and to Dr. Xue-Cheng Liu.
SAE Baja
Team: Bajaha
Students: Nick Bradley (ME), Peter Chachaj (ME), Chad Dhein (ME), Patrick Dillman (ME), Chris Dominguez (ME), Dan Drew (ME), Nathan Dulmes (ME), Armin Haugg (ME), Adam Hodge (ME), Bryan Huttenlocher (ME), Jeff Kasper (ME), Erik Macias Simeon (ME), Matt Moore (ME), Scott Paul (ME), Tom Puestow (ME), Deana Rousseau (ME), Kyle Rozman (ME), Jeff Wisneski (ME), John Zabel (ME), Jake Zimmerman (ME)
Advisor: Dr. Mathew Schaefer
The objective of this project is to design and build an off-road vehicle which can tackle any terrain from mud pits to rocky inclines. Intended for sale to weekend enthusiasts, this vehicle design must hold paramount driver’s safety and abide by the rules and regulations established by SAE. Once the design is complete, funds are raised, and a prototype is built, the team travels to Montreal, Quebec for an intercollegiate competition with over 100 of the nation’s best schools. Appreciation is extended to: Buell Motorcycle Co., Express Pattern, Hayes Brake, Signicast Corporation, and Timken Co. for supporting this project.
Redesign of the TRAXX Gripper
Students: Thomas Lowisz (ME), Eddie Rodriguez (ME)
Advisor: Professor Thomas Labus
Danger is present in trying to clear rubble from collapsed buildings. Such an environment is too dangerous for people to traverse. The solution is to deploy a robot that can clear out the dangerous area. The design specifications for such a robot are that it is to be wirelessly operated and is able to grip and lift irregularly shaped objects of up to 250 lbs. Such a gripper system was designed and incorporated into the TRAXX robot. Due to weight versus power considerations, a system of cylinders was chosen to create the gripping force necessary to lift such objects, while a motor is utilized to allow the gripper to rotate which allows for easy maneuverability and orienting. Appreciation is extended to: Enerpac for donating their cylinders for the gripper and FORCE America for their willingness to provide their products for the team.
TRAXX Driveline
Team: TRAXX
Students: Darrell Hesse (ME), Lucas Steiner (ME), John Vacca (ME), Stephen Vossen (ME)
Advisor: Professor Thomas Labus
In this senior design project the intent was to update the hydraulic and electrical controls of a pre-existing rescue vehicle; capable of functioning in a destroyed building while removing rubble. The new components will render the implement arm functional inside a building for demonstration during the International Fluid Power Expo 2008. The set constraints to function the radio frequency controlled vehicle indoors required an external hydraulic power unit and DC power supply, utilizing a 120 volt 20 amp wall outlet instead of the onboard 13 HP gasoline engine. The control system allows for linear and non-linear metering control of the implement arm functions. The non-linear metering allows for improved control of the implement arm functions, thus making the machine more user-friendly. After the show the vehicle’s hydraulic drive circuit was updated to allow the gasoline engine to start without pressure induced load from the vehicles pumps. The completed control system provides torque summation for the five hydraulic pumps preventing the gasoline engine from a torque stall, allowing the vehicle to remain functional. Appreciations is extended to: Enerpac, MSOE’s Fluid Power Institute™, Gates Corp., Husco International, Hydro Electronic Devices Inc., JM Grimstad, National Fluid Power Association, Oilgear, Sun Hydraulics
Autonomous Lunar Regolith Excavator
Team: Crater Raiders
Students: Abdullah Al Olayan (EE), Jason Beck (ME), Steve Bothe (ME), Jon Campbell (ME), Jonathan Clark (ME), Matt Fastelin (ME), Karl Henke (EE), Hendrik Jaeger (ME), Matthew Jakymiw (ME), Nathan Jarosinski (ME), Justin Kuffel (ME), Jean-Luc Kunicki (EE), Patrick McDermott (EE)
Advisor: Dr. William Farrow
To compete in the NASA Centennial Regolith Excavation Challenge 2008, a safe, fully autonomous lunar regolith scraper excavator was designed and built within the strict rules of the competition. With limited time and power, the robot was designed to collect regolith using a modified Fresno scraper system in combination with a cleated conveyor belt. Regolith stored within the rover during the excavation process will be delivered autonomously to a marked collection bin, and the entire process will be repeatable. Electric drive motors were used to power the skid steer tracks that provide the driving ability of the robot. Electric linear actuators were used to raise and lower the scraper blade and move the on board storage bin for regolith dispensing. The robot will also use a sensory array including bump sensors and infrared sensors to help in autonomous decision making, navigation and safety. Appreciation is extended to: Plexus Corp.
Design of Classroom experiments for the Study of Fluid Mechanics
Team: CK Raiders
Students: John Kaminskas, Ethan Perez, John Simons
Advisors: Dr. William F. Carnell Jr. ’99 and Dr. Robert A. Kern
The current design project entails the development of a laboratory experiment for use in the Aerodynamics (ME-481) and Computational Fluid Mechanics courses at the MSOE. The experimental apparatus consists of a cylinder in cross flow in the MSOE wind tunnel. Static pressure taps are located around the circumference of the cylinder and connected to a transducer/data acquisition system, which allows for measurement of the pressure distribution around the cylinder. An extensive Computational Fluid Dynamics (CFD) investigation of the experimental setup has been conducted and the experimental pressure distributions were compared to model results. A laboratory experiment has been developed that utilizes the data produced from the experiment for validation of various standard turbulence models as implemented in the CFD calculations.