Senior Design

This paper presents a research project with the objective of creating a prosthetic hand solution for upper limb amputees in the United States. This project consists of integrating a pulley-based mechanical design, electrical system optimization, and advanced machine-learning techniques for intuitive control.

The user can command the prosthetic hand through an Android application, which employs voice recognition technology. The mechanical aspect of the design entails the creation of a pulley system that guarantees mobility and strength in the prosthetic hand’s movements. The electrical system is designed to support efficient motor control and positioning, ensuring precise operation.

The voice recognition system is built on a Convolutional Neural Network (CNN) model, utilizing Mel-frequency cepstral coefficients from voice commands as input data. The electrical control system will utilize Pulse-Width Modulation (PWM) techniques to interpret commands from the voice recognition system and translate them to physical movements using various electrical components. The mechanical hand will be designed with 11 degrees of freedom and will be fabricated using 3D printing. Individual components will be modeled using Computer-Aided Design (CAD) tools.

This project’s final deliverable is a fully functional prosthetic hand model controlled by speech recognition via an Android application. The hand is based on a pulley system and will be lightweight, easily 3D printable, and seamlessly integrate electrical components. It should ensure smooth and precise movement while maintaining a minimal size.

This study presents a novel design approach for high-performance, compact heat exchangers suitable for fabrication via metal additive manufacturing. At the core of this innovation lies the utilization of complex geometries, such as space-filling curves and triply periodic minimal surface structures that provide maximal area for heat transfer. The material chosen for this design is Inconel 718, a high-strength, corrosion-resistant nickel-based superalloy.

The overarching goal is to maximize heat transfer, minimize pressure drop, optimize weight, and enhance structural integrity. This is achieved through the utilization of nTop, a generative design software and the incorporation of computational fluid dynamics (CFD) simulation data generated in Ansys.

Building design is first proposed by a developer/building owner. The developer will create an idea of the general purpose and objective of the building, oftentimes consulting with an architecture and engineering firm in the early development stages. This was the initial challenge the PNW Engineering Building Design group faced. In this Senior Design Project, the group will have to act as the developer, architect and engineers.

The PNW Engineering Building Design is dedicated to the engineering students and faculty on the PNW campus; and what better way to design a building than to incorporate multiple engineering disciplines to design the building. This building utilizes three major engineering disciplines consisting of Structural, Mechanical, and Electrical design. The outcome of this design is to incorporate all three disciplines to design three sets of schematics for a building that could be implemented into real life construction.

As the world grapples with the escalating concerns of climate change and the need for clean energy, a noticeable shift is underway, transitioning power generation from fossil fuels to renewable energy sources. However, integrating renewable power generation poses challenges, particularly related to power fluctuations that can negatively affect storage methods used in these systems as well as the grid they are connected to. These fluctuations can lead to issues such as equipment damage—through overheating or failure—system instability, operational disruptions, inconsistent voltage levels, and increased risk of outages due to energy spikes.

This project explores various methods to mitigate power fluctuations in wind turbine systems and hybrid wind/solar photovoltaic (PV) systems. Specifically, it focuses on evaluating how hybridizing renewable energy systems, along with the incorporation of charge controllers and electrical storage devices like batteries and supercapacitors, can help balance power output.

The experimental test plan involved subjecting both systems to different circuit configurations and a range of natural and simulated weather conditions. Wind turbine testing was conducted under conditions categorized as windy, slightly windy, and very windy. For the hybrid system, various combinations of wind speeds and sunlight exposure were applied.

Additionally, the wind turbine underwent testing in different configurations: first as a standalone unit, then with the incremental addition of a charge controller, battery, and supercapacitors. This systematic approach was crucial for understanding how factors like wind speed and sunlight exposure influence power generation in renewable energy systems.

The project concluded that incorporating a battery into the circuit had a significant impact on power generation, with further benefits observed when a hybrid system was employed.

Future iterations of this project could expand by incorporating additional batteries, power generation equipment (such as wind turbines and PV panels), and advanced metering devices. This comprehensive approach would help better identify the role and benefits of each component in stabilizing power output within renewable energy systems.

This extensive approach helps identify the role and benefits of each component and their contribution to stabilizing power output in the observed renewable energy systems.

Roundabouts were created as a form of traffic control in which there is a non-signalized counterclockwise flow around a central island where entering vehicles must yield to circulating traffic. Roundabouts provide a benefit to drivers and pedestrians alike, decreasing wait times, increasing safety and decreasing both vehicle carbon emissions and noise pollution.

During peak traffic volume, the 173rd and NILS parking lot intersection of the Purdue Northwest – Hammond campus faces frequent congestion caused by poor stop light signal timing, and frequent increased volume. This project aims to circumvent these issues by designing, modeling, and proposing a roundabout, as well as an overhead bridge to allow pedestrians to cross the intersection without worrying about oncoming traffic.

Several methods were used to achieve these goals, such as thorough data collection, research on designing a roundabout and pedestrian bridge, creating a CAD (computer-aided design) model of the initial conditions of the intersection and performing a land survey of the existing intersection. CAD software was then used to create a set of proposed engineering plans that can be implemented to construct the roundabout, and the pedestrian bridge was developed using similar software through rigorous work and research. Two other objectives were completed throughout the project: a total cost/time estimate for construction and a physical 3D model of the completed roundabout made to scale.

This project provided valuable insight into the planning and processes of designing a roundabout and pedestrian bridge, deepening our knowledge of transportation, structural and civil engineering.

This project aims to redesign and build the powertrain and battery mount for a battery-powered electric vehicle. These systems will be built following the Shell Eco-Marathon 2025 Official Rules handbook specifications to pass technical inspection. These actions were
done in order to compete in the Shell Eco-Marathon Americas competition at Indianapolis Motor Speedway in Indianapolis, Indiana.

While finishing up Senior Design I in Spring 2024, the American Society of Mechanical Engineers, also known as ASME, created a work plan based on the results of the technical inspection from the 2024 competition.

The following was the plan created by the ASME and the advisors of the project on what needs to be done:

• Front brakes
• Body design fabrication
• Frame modification
• Powertrain
• Battery mount
• Front-wheel guard
• Horn, internal emergency stop
• Horn mount

These tasks were delegated to various people and groups. In our Senior Design II, we are tasked to take on the powertrain and battery mount. The new Senior Design I team will work on a new body design and fabrication while the rest will be given to ASME members to work on.

Background

A crucial step in steel production is the reheating of steel products, which is necessary for processes such as tempering, rolling, etc. The process begins with heating a steel slab through a furnace (most popularly combustion or induction) to make it more malleable. However, combustion reheating poses significant environmental challenges compared to induction reheating.

Therefore, we will be focusing on batch induction heating (where the steel slab remains stationary during the process) and examine the effects it has on the steel product in an effort to highlight the potential of induction reheating under the assumption that it is a more eco-friendly and sustainable alternative in steel production.

Objective

The objective is to enhance our understanding of the performance of steel within an induction reheating furnace. Additionally, other relevant factors, such as but not limited to pricing, practicality, efficiency, performance, etc.

Approach

Having a design, our approach is to simulate a model of an Induction Heating Line under various conditions to record and analyze results. Key factors to be considered include the temperature the steel reaches, the time to reach the desired temperature, speed, product size, and energy required.

Outcome

The outcome would be a Computational Fluid Dynamics (CFD) simulation and corresponding data that would allow us to compare induction to combustion heating methods. This analysis will address questions such as: Which method will be overall more productive and eco-friendly? Will induction yield favorable results in terms of cost, efficiency, and environmental impact?

The design and implementation of the 36V E-bike system focus on delivering a reliable, efficient, and user-friendly pedal-assisted e-bike solution tailored to diverse users. Emphasizing efficiency, affordability, and accessibility, our project aims to achieve optimal performance and reliability.

Key components, including a 36V (BRUSHLESS DC) BLDC motor and gear reduction mechanism, are carefully selected and tested to ensure seamless operation in various conditions, achieving a maximum speed of 8 MPH on electric power alone. Targeting exceptional value, the e-bike system is priced under $1,000, making this technology accessible to a wider audience, including individuals with disabilities.

A user-friendly interface featuring a digital display enhances usability by providing essential information such as battery percentage and speed. Ultimately, the 36V E-bike system aspires to deliver outstanding performance, reliability, and affordability, contributing to a more sustainable and inclusive transportation ecosystem. This innovative approach not only enhances user satisfaction but also promotes active mobility for all.

Decarbonizing the steel industry is important due to the high amounts of carbon dioxide (CO2) emissions generated, which have long-term impacts on the environment and human health. One way to do so is by using hydrogen in place of the current industry standard of methane (CH4) as fuel in reheating furnaces. Hydrogen combustion does not produce carbon dioxide emissions, unlike methane combustion, but greenhouse gas emissions are not entirely removed. Nitrogen oxides (NOx) are produced at high temperatures from the nitrogen in air, and hydrogen typically burns much hotter than methane. This can be controlled with proper design of the combustion process, which this project will explore.

The objectives of this project are to investigate the advantages of having an existing reheating furnace use hydrogen fuel and/or hydrogen-methane fuel blends instead of the industry standard methane and inquire how costly the fuel change would be. The furnace geometry will be simulated with hydrogen and hydrogen/methane blend combustion in the Computational Fluid Dynamics (CFD) software Ansys Fluent. Multiple simulations will be performed that make use of different amounts of hydrogen and methane fuel. These different parameters will be applied to 2 different common types of burners seen in a reheating furnace, a flameless burner, and a typical swirl burner.

Results are to be validated against published values in literature, when available. They will also be evaluated theoretically with mass and energy balance. Both the Swirl Burner and Flameless Combustion will be using the same combustion mechanism to facilitate more accurate comparisons. Current results are proving to be realistic but appear to be leaning toward a flameless burner for effectively reduced pollutant amounts.

Once a modern marvel, the Kentucky and Indiana Terminal Bridge now lies in decaying disarray as it is used for a fraction of its potential. Despite the rough history of the bridge, appeals have been made to restore the bridge to its former glory and full potential. The restoration and expansion project proposed was approached via steel beam design which promises to bring the bridge back to life. The current semester’s research span was based on finishing blueprints of our new bridge designs and the calculation package. These blueprints are made to help set dimensions to determine what material should be used and thus make calculations based on the type of material.

The creation of the steel bridge redesign for the K&I Bridge can be divided into two steps: drawing and modeling. The primary tool this semester for the design used was Revit. Revit allows for drawing the plan, elevation, and section views. These new designs feature variations in width to incorporate lanes for both vehicles and pedestrians, altering the current layout of the K&I Bridge. The calculation package for a bridge requires the use of the LRFD for Highway Bridge Substructures AASHTO Standard. The plans will also include a small-scale 3D-printed model of the bridge.

Our team has successfully completed the first phase of our senior design project, culminating in a comprehensive geotechnical report for an existing warehouse building in University Park, IL. For the second phase, we will be developing detailed structural and foundation designs of a newly constructed warehouse using AutoCAD, Revit, and RISA, complemented by a 3D printed model.

Our warehouse design will encompass a variety of detailed drawings, including floor plans, foundation layouts, columns, beams, trusses, and other essential components that ensure the building’s structural integrity. Alongside these designs, we will provide calculations to validate the stability and effectiveness of our approach.

Upon project completion, we will present a 3D virtual walkthrough and a physical 3D printed model. The physical model will consist of detachable parts, allowing for an in-depth exploration of the structure. Our goal is to tangibly demonstrate the design’s reliability and functionality, showcasing what the final structure will entail.

In conclusion, our senior design project has made significant strides, transitioning from a thorough geotechnical analysis to the upcoming development of detailed structural and foundation designs. By employing advanced tools like AutoCAD, Revit, and RISA, we are committed to creating a robust design that prioritizes safety and functionality.

The integration of a 3D printed model and a virtual walkthrough will enhance our presentation, providing a clear visualization of our work and its practical applications. We are excited to demonstrate the reliability and structural integrity of our design, ultimately contributing to the field and showcasing our efforts in this comprehensive project.

Power transformers are critical assets in power distribution networks, and their reliability is essential for uninterrupted power supply. However, failures due to overheating, oil leaks and corrosion can lead to costly repairs, unexpected outages and safety hazards. This
project presents the development of an AI-based system utilizing the YOLO (You Only Look Once) object detection algorithm to predict potential transformer failures by identifying visual signs of overheating, oil degradation, and mechanical wear.

By leveraging a dataset of transformer images annotated with fault areas, the YOLO model is fine-tuned to detect issues that might lead to catastrophic failures. The system processes real-time image data to continuously monitor transformers, providing early
warnings for maintenance teams to take preemptive action. Furthermore, data augmentation techniques are employed to improve model generalization and performance under varying environmental conditions.

This proactive maintenance approach offers significant benefits, including reducing unplanned downtime, optimizing resource allocation, extending the lifespan of transformers, and enhancing overall network reliability. The results of this project demonstrate the effectiveness of computer vision techniques in industrial applications for enhancing predictive maintenance systems in power distribution networks.

Grid power is not always available. There is a real need for a portable battery device that does not rely on the grid for charging and can run any normal appliance. The device must be big enough to fit the parts, yet small enough to be portable.

There are seven parts total in the system: solar panels, two DC-DC boost converters, a battery, a DC-AC inverter, and a microcontroller.

The solar panels need to have a DC-DC Boost converter to output a voltage high enough to charge the battery. The battery needs to have another boost converter to output a voltage high enough to drive the inverter. An inverter is needed to power standard 120VAC appliances. Through sensors and gate drivers, a microcontroller will change how the boost converters and inverter behave to keep the operation of the device nominal.

The three most important circuits – the two boost converters, and the inverter – were designed and simulated in the first semester. The second semester was thus about the physical prototype.

First, implement the boost converters. Second, implement the control program for those boost converters. Third, implement the inverter, which requires tandem development of control program for proper operation. Finally, make the prototype fit into a case, and refine until deemed adequate by the group members.

The Paint Night Inspiration Bot leverages the creative abilities of generative AI to gamify Paint Night. First, upload a picture of your painting. Then, type in any key elements you want to be added to the new picture. Finally, a generative AI will create a new image using any key elements and the description of the painting.

Because generative AI outputs are so bizarre, the challenge to the painter is to incorporate at least one element of the AI image into their painting.