EGR 402 eProjects

Professional Design Project II is comprised of students from the BSE Engineering program (with concentrations in Automotive Systems, Electrical Systems, Mechanical Systems, and Robotics Systems) and the BS Manufacturing Engineering program.

EGR 402

Students: Michael Jodat, Alejandro Manzo, Jason Mester, Holden Mitchell

Sponsor: Zero Electric Vehicles

Zero Electric Vehicles

 

 

 

 


Zero Electric Vehicles, or ZEV, requested an auxiliary system for a vehicle that converts the suspension’s potential energy into usable electrical energy. ZEV specializes in the conversion of internal combustion fleet vehicles into fully electric vehicles. ZEV hopes to utilize a suspension harvesting system in their converted vehicles to improve their efficiency. The team took a mechanical approach to address this issue. They utilized a lever arm attached directly to the vehicle’s suspension, which is connected to a bidirectional to unidirectional gearbox. That gearbox is then connected to an electric power generator which can charge the vehicle’s low voltage system.

 

EGR 402

Students: Whitney Foster, Anson Kwan, Jiangtao Li, Aurausp Maneshni, Shannon Mcbreen, Michael Schelp, Isabelle Thalman, Ziyu Wang

Sponsor: Siemens

Siemens

 


The manufacturing industry has experienced rapid technological growth and is moving from industry 3.0 technology to industry 4.0 technology. This growth is leaving behind a workforce without the skills to meet the demands of this new technology and as a result has created a significant labor shortage. Team 18 – 19 has partnered with Siemens and Jerry Gintz, professor of engineering at The Polytechnic School, to refurbish a manufacturing workstation. The workstation aims to serve as an educational manufacturing device that upskills students before they enter the workforce so they have the opportunity to master various industry 4.0 competencies. This solution also has a digital twin component to meet a wide variety of potential user learning needs.

EGR 402

Students: Rocco Francone, Lance Grotelueschen, Michael Mcnerney, Connor Montalban

Sponsor: Discount Tire

Discount Tire

 


Team 25 has been working with Discount Tire to develop a solution that can effectively remove the residue left on wheels by tape weights. The residue leaves behind an irregular surface that not only creates a dirty appearance, but also prevents effective surface bonding between the wheels and additional tape weights. The solution that Team 25 developed is a rounded-edge eraser tool attachment with a quick-change mandrel. This tool piece is designed to allow service technicians easy access to the interior surfaces of wheels for the residue removal, while also being compatible with different types of tooling for effective use.

 

EGR 402

Students: Brayden Dean, Hector Espino, Xingchen Li, Anthony Manriquez

Sponsor: Discount Tire

Discount Tire

 


This team worked with Discount Tire and confronted existing tooling issues. Discount Tire stores currently use a plastic scraper which dulls quickly and eventually becomes ineffective. Students of this team designed a tool with a replacement medium that is more durable and more effective at removing the weights. The group is currently testing two solutions, with a string or composite blade.

EGR 402

Students: Kye Arias-Burmood, Isaac Enriquez, Bradley Gannon, John Lewis

Sponsor: NASA Psyche Mission

NASA Psyche Mission

 

 


ASU Psyche is an ASU-led NASA mission to the asteroid Psyche-16 that is believed to be the remains from a planetary core. This team’s task is to create a system that would be able to sample the hypothesized surfaces for further research of planetary cores. They designed a device consisting of a drill motor attached to a linear actuator with accompanying sensors that will drill down through the surface to collect a sample. The major component of the team’s system is a custom designed drill bit with openings throughout and a hollow core for sample collection and containment.

 

EGR 402

Students: Tyler Jiemback, Austin Kipp, Andrew Meiners, Zach Schley

Sponsor: Lallemander Baking Solutions

Lallemand Baking Solutions

 

 


Lallemand, a yeast manufacturing company, tasked this group with implementing a palletizing robot into their facility, redesigning the production line and implementing real-time data collection. Currently, workers are palletizing 50-pound bags and boxes for 8+ hours per day leading to negative long-term health impacts. This solution is needed to assist the workers and maintain consistent output rates. The team is also redesigning the production line and implementing a system to track the speeds of the conveyors, rejected product quantities and overall weights of the bags and boxes.

 

EGR 402

Students: Seth Forbis, John Socaciu, Tyler Von Ende

Sponsor: Honeywell Aerospace

Honeywell

 


This team partnered with Honeywell to investigate the manufacturing process of reaction wheel assemblies, or RWAs, used in precision satellite positioning and alignment. As a provider of premium hardware built to last, the industrial partners manufacturing process requires precision machining and quality testing for their RWAs. The team’s goal is to identify machinery capable of replacing manual processes while maintaining or improving upon the quality of RWAs produced. The solution was to survey a wide array of companies providing manufacturing equipment and to select the best technology for this process.

 

EGR 402

Students: Petros Magoulas, Roberto Siqueiros, Clark Vidler

Sponsor: Honeywell Aerospace

Honeywell

 


This project was proposed by Honeywell Aerospace, an avionics firm interested in exploring the capabilities of semi-autonomous commercial flight. Pilots are currently an indispensable but costly component of commercial passenger flight. While unmanned aerial vehicles already exist, FAA regulations and a general mistrust by the public currently prevent their use in passenger flights. This project aims to explore a possible stepping stone between an autonomous future and the present, where a pilot in the cockpit operates the aircraft alongside a telepresence co-pilot. This co-pilot observes the cockpit through stereoscopic cameras with pan and tilt capability. The cameras will also provide insightful vision analytics of dashboard instruments and other important signals to allow the co-pilot to make quick and informed decisions.

EGR 402

Students: Isabella Bushroe, Maison Carey, Jordan Johnson, Gino Piccino


Phoenix Sky Harbor Repair and Overhaul Factory currently uses aluminum tape to mask many of the parts they re-work. This process is time consuming and tedious. This team is creating reusable, custom-fit masking solutions for two of their commonly repaired parts, a blade and a nose cone. They are 3D printing molds out of PLA and filling them with flexible polyurethane. The resulting polyurethane components will fit closely over parts of the blade and nose cone to protect them from paint and grit blast. These will reduce repair time and increase productivity.

 

EGR 402

Students: Christopher Brisco, Trenton Clark, Samuel Martin

Sponsor: Paragon Space Development Corporation

Paragon

 


This team is designing and testing a space rated DC-DC converter using GaN FETs. Due to cost and time constraints, their test design will be created using non-space rated components that have space rated counterparts. The students are working with Paragon Space Development Corporation, a company that works with other space and defense companies including NASA. Their solution is a converter with a flyback topology based on its widespread use and the limited number of components compared to other topologies.

EGR 402

Students: Andrew Crouch, Ameil Jones, Hikmat Lawal, Fabian Siqueiros

Sponsor: Intel

Intel

 

 


This team partnered with Intel to develop a modular architecture of an autonomous mobile architecture, or AMR. The scope of the project is to develop a simulation by using MatLab of AMR mobile architectures that allow for various reconfigurations. Along with developing data analysis using Arena, that provides throughput capabilities such as how many models would it take to complete a task, the project includes cycle time — analyzing how long it takes a model to complete a task and how the throughput and cycle time changes between one model and another.

 

EGR 402

Students: Damion Fedler, Aaron Matejcik, Cole Rose, Andrew Sheehan

Sponsor: Northrop Grumman

Northrop Grumman

 

 


This diverse team of mechanical and automotive systems engineering students has partnered with Northrop Grumman’s launch and missile defense systems in Chandler, Arizona, to develop a new rotary actuator test stand. The stand is used in Northrop’s acceptance testing procedures to validate the hardware that supports their portfolio launch vehicles. The company’s existing equipment is quickly reaching the end of its functional life and services only a fraction of the actuators they use. Through a broad range of inertial, torsional and other design constraints, this team has developed a modular prototype that will not only encompass Northrop’s current stock but allow for modifications for future business needs.

 

EGR 402

Students: Maria Espinoza, David Oberan, Alezzandro Ortega, Hailey Suh

Sponsor: Honewell Aerospace

Honeywell

 


The Honeywell Modeling the Factory of the Future capstone project was tasked with developing a digital twin of the T55 engine repair and overhaul line, using Siemens Process Simulate. The objective of this project is to assist Honeywell employees in shortening the learning curve it takes to master the software and build an operational model. The team has provided a process simulate model displaying the assembly process of the T55 rotor compressor assembly. This deliverable includes a methodology that acts as a training guide to understanding process simulate. The methodology includes step-by-step instructions on the fundamentals of building a simulate model as well as information on the interactive human kinematic capabilities available.

 

EGR 402

Students: Angelica Lugo, Kaycee Simpson, Kevin Wagner, Avery Wallace

Sponsor: General Dynamics

General Dynamics

 


This team is working with General Dynamics – Mission Systems to innovate a solution to the existing problems with miniaturized variable heat conductance pipes on a payload equipment designed for space flight. The team took the existing VCHP design and worked on creating a new VCHP design with new materials to find a solution. The team also created a test bench to house the VCHP design, modeled an ANSYS simulation based on the VCHP design to theorize thermal behaviors and will conduct TVAC and dynamic testing in the General Dynamics lab to conclude if the new VCHP design is a successful solution to the problem identified.

 

EGR 402

Students: Serena Baca, Brandon Rojas, Konner Shook, Anthony Tutherow

Sponsor: Honeywell Aerospace

Honeywell

 


With the proliferation of technology today, the potential of extremist groups to use things like drones to deliver dangerous ordinances is a possibility. Along with Honeywell, this team’s goal is to create a man portable armor system that can adapt to a wide range of drones with the intent to take down small hostile drones. They will attempt to accomplish this by 3D printing an armor that mounts on the front of rear motor propelled drones as a basis to focus impact while minimizing the impact for the drone.

 

EGR 402

Students: Kiley Griffin, Justin Janda, Ian Martin, Nathan Neville

Sponsor: Mechanical Systems Startups, LLC

Mechanical Systems Startups LLC

 


The current market of crash safety barriers does not significantly reduce the impact of a crash as they rely on deflection. Mechanical Systems Startups, LLC, has modeled and simulated a crash safety barrier that absorbs the impact and disperses the energy. This team has been tasked with validating these models with a quarter-scale test. They have modified the ASU Hyperloop test track and the test vehicle to complete this testing. The data should validate the models so that further testing can begin.

 

EGR 402

Students: Turki Almudbil, Jose Espinoza, Matthew Jarrell, Priscilla Ramirez

Sponsor: NXP Semiconductor

NXP semiconductor

 


This team was tasked with designing an ergonomic solution for loading stainless steel domes containing semiconductor wafers onto a metal evaporator process tool for NXP Semiconductor. NXP has multiple wafer fabrication facilities across the world and is a major supplier for the semiconductor industry. The team designed a vertical lift which was made from stainless steel and aluminum. It operates via a cam belt linear drive system. The goal of his design was to increase NXP workplace efficiency and safety, while also maintaining the company’s wafer quality.

 

EGR 402

Students: Peter Gregus, Ryan Hyatt, Armando Ramirez, Alejandro Yescas

Sponsor: United States Air Force


The JSTARS is a fleet of highly modified Boeing 707’s maintained and flown by the United States Air Force. One routine JSTARs maintenance procedure is the removal and replacement of the disk brake assembly on the landing gear. This assembly weighs close to 200 pounds and poses a risk of injury to the crew during the removal and installation process. The USAF has requested a tool that can safely and efficiently lift the brake assembly. Team 10 has engineered a hoist that features a simple and robust design that can be adapted to several airframes for brake removal processes.

 

EGR 402

Students: Alexander Olsen, Riley Schaefer, Michael Skalsky

Sponsor: TPI Composites

TPI composites

 

 

 


This team worked with TPI Composites to construct a system capable of taking pictures of a windmill blade cross section, then take measurements based on those pictures. Once each cross section is measured, the measurements are used to construct a 3D model of a completed windmill blade. The purpose of this task is to reduce the amount of time needed to measure the windmill blade and thus increase the rate that windmill blades are produced. The team used a gantry system capable of moving a camera over a cross section — taking pictures of the blade as it traces the perimeter of the blade to capture a measurement.

 

EGR 402

Students: Alexander Burck, Kevin Crowley, Cole Mcduff

Sponsor: Honeywell Aerospace

Honeywell

 


Honeywell has recently transferred a testing facility to their avionics manufacturing site in Deer Valley, Arizona. Due to environmental differences, the relocated test chambers periodically experience undesirable moisture levels during operation. This team was tasked with restoring and ensuring a controlled screening environment. They developed a cost effective, automated and non-invasive SCADA system that easily integrates with existing infrastructure. Functionally, the device detects critical events and appropriately delivers CDA, while communicating with a central hub.

 

EGR 402

Students: Cortney Batt, James Seifert, Liam Snider, Spencer Wheat

Sponsor: Honeywell Aerospace

Honeywell

 


This team partnered with Honeywell Aerospace to investigate a production improvement study in their thermal spray process at the Honeywell maintenance, repair and overhaul, or MRO, facility. Honeywell currently uses aluminum tape and silicone putty to protect areas of jet engine components not requiring metal spray application. The tape and putty process is a time-consuming hand operation that Honeywell would like this group of students to improve from a time and simplicity standpoint. The team will explore the possibility of creating hard-shelled, high-temperature refractory masks using Honeywell’s internally developed 3D printed ceramics to replace the tape and putty.

 

EGR 402

Students: Taylor Bollinger, Payten Chicci, Jax Jimenez-Jones

Sponsor: Discount Tire

Discount Tire

 


This team was tasked with designing and creating a new air chuck for Discount Tire. The two current air chucks have problems they hope to remedy in order to be more efficient and cost-effective. The main concerns they have with these chucks are that they wear easily and the same type of chuck cannot be used on every type of vehicle rim. Some rims, seen on trucks in particular, have recessed valve stems that can be hard to insert the air chucks into. This team have created a shorter, more durable and reliable air chuck that aims to solve these issues.

 

EGR 402

Students: Logan Garland, Emmanuel Machado, Eden Ochoa Ramos, Nicole Van Handel

Sponsor: Honeywell Aerospace

Honeywell

 


Honeywell Aerospace conducts the maintenance, repair, and manufacturing for aircraft in the public and private sectors. Repair processes for complex parts, such as impellers, rely on CMM and proprietary programs which there is decreasing expertise in. There is an opportunity to modernize and streamline the scanning, digitization and toolpath creation process, making it broader and more adaptive. In collaboration with industry partners Jason Floor and Dr. Ben Peterson, Team 45 has developed an updated process that utilizes structured light scanning and Siemens NX to adaptively determine repairability of parts and generate machining toolpaths based on scans.

 

EGR 402

Students: Jason Dabney, Zachary Schwartz, Hunter Silvey

Sponsor: Andersen Windows and Doors

Andersen Windows and Doors

 


Team 13 partnered with Andersen Windows and Doors to help them solve the problems they are experiencing with their french door assembly workstation. Their current workstation has inefficient cycle times, places stress on the workers due to poor ergonomics and damages the surface of doors that are built on it. This team’s solution is a redesign of the ergonomic flow of the station by modifying the dimensions of the table, adding an extension component that is self supporting and creating a table surface that protects the product.

 

EGR 402

Students: Jacob Delacruz, David Harden, Jerred Hermogino, Akhil Johnson, Hala Mayyas, Andrew Peavler, Matthew Seddon, Logan West

Sponsor: National Fluid Power Association

National Fluid Power Association

 

 

 

 


The National Fluid Power Association (NFPA) tasked this group with fabricating and improving a trike that consists of an integrated hydraulic power system to compete against multiple universities in the Fluid Powered Vehicle Challenge (FPVC). The design objective is to design, build, test and validate a human-powered hydraulic trike that will achieve a speed of at least 10 mph at a maximum weight of 210 pounds. The team’s solution is to integrate, while meeting competition design constraints, a human powered trike while utilizing a hydraulic power system to propel the wheels.

 

EGR 402

Students: Jessica Dirks, Brooklyn Johnson, Bridget Koehl, Spencer Sillanpaa

Sponsor: Becton Dickinson

Becton Dickinson

 

 


In this project, sponsored by Becton Dickinson, students have teamed up to explore avenues for introducing new innovative twists into a traditional medical device. Over the course of the project, the team was asked to undertake the following tasks: Evaluate current technology and techniques of production, identify appropriate needs to address and integrate the solution into a prototype to demonstrate successful operation.

 

EGR 402

Students: Mohammed Bawareth, Deborah Eisenberg, Wendy Lara, Rebekah Wagen

Sponsor: IDEA Lab

IDEA Lab

 


Becoming educated in STEM fields during high school and secondary education isn’t common. Daniel Aukes, assistant professor of engineering at The Polytechnic School leads the IDEA Lab and has hopes to change that. Team 14 has been working in conjunction with Aukes to develop a five-day summer camp geared towards students aged 11-13. The camp will teach a basic introduction to electronics, programming and how robotics relate to biology. Using the knowledge obtained in the camp, students will be able to construct their own foldable robot that will be presented on the final day of camp.

 

EGR 402

Students: David Altamirano Leon, Samuel Andersen, Marcus Dopilka, Nathan Fonseca

Sponsor: Able Aerospace Services Inc.

Able Aerospace

 

 


This team partnered with Able Aerospace Services Inc., a company that provides resourceful component repairs, overhaul and approved replacement parts solutions for aircraft operations. Students were tasked with validating manufacturing repair techniques for worn or damaged aluminum components. They are also assisting Able Aerospace in validating their state-of-art repairing methodologies using cold spray and shot pen and show an increase in the fatigue life of the aluminum samples. The long term goal is to use this new method and meet the Federal Aviation Administration (FAA) regulation with a more cost-effective repair methodology.

 

EGR 402

Students: Lee Brown, Joseph Bruder, Adrian Ramirez, Edward Taylor

Sponsor: AbTech Industries

AbTech Industries

 

 

 


AbTech Industries is a company dedicated to the treatment of wastewater, whether that be in the form of industrial runoff water or storm water. Monitoring the state of any given storm drain filter around the world through a cloud network of IoT sensors is of substantial interest to AbTech Industries. To address this, this group of students developed a solution that uses load cell sensors and ultrasonic sensors. The load cells are used to measure the weight of the filter and the ultrasonic sensor is used to determine whether or not there is standing water in the UUF box created by clogging. These sensor readings are managed by a microcontroller and sent to a WiFi module.

 

EGR 402

Students: Sergio Ramos, Jun Kai Yeo

Sponsor: Summit Automation

Summit Automation

 


Team 11 Base Motor (Vail Motor) worked with Summit Automation to develop an upgrade to their current door animation system. The problem with their current door automation system is the high cost and extensive installation process. This combination makes their product not accessible to the elderly which are the target audience. Students worked on developing a safe, low cost and easy to install solution by using a smaller motor that can fit in the frame of any door to make it more accessible.

 

EGR 402

Students: Faisal Alyousif, Matthew Gargan, Rachel Hayden, Richard Nguyen

Sponsor: Heitek Automation

Heitek Automation

 


Heitek is an independent company located in Phoenix, Arizona, and distributes automated systems. Heitek’s various vendors and suppliers had products they wanted showcased through Heitek, however, the company did not have a system built to display product integration or showcase those products’ capabilities. To address this concern, Heitek Automation and ASU partnered to design and develop a demonstration featuring a three-axis machining center. Utilizing approximately $30,000, the teams’ goal revolved around implementing different control systems and displaying how they interact with one another to both train employees and educate customers.

 

EGR 402

Students: Isaiah Finney, Shams Hassan, Simon Pavlick, Jorge Perez

Sponsor: Moog Broad Reach

Moog Broad Reach

 

 


Team 32 is worked with Moog Broad Reach to bring automated optical inspection, or AOI, to the PCB production line. Their aim is to incorporate a new inspection system into the current infrastructure found at Moog’s workspace, effectively reducing the time for inspections from hours to minutes. The existing circuit boards can have up to 1400 components per side and are currently inspected manually by technicians — some of these components can be as small as a grain of sand and require a microscope. The team ensured AOI was properly installed into the production line and that there was labor required to ensure the quality of the manufactured board was maintained.

 

EGR 402

Students: Jeremy Batson, Alexandria Bisher, Bryan Carlton, Nicolo Hamilton

Sponsor: NXP Semiconductor

NXP semiconductor

 


At NXP Semiconductors the current process of moving lot boxes onto the storage rack is inefficient as it takes one person two minutes per box to move them from the AMHS stocker to the storage rack. NXP requires a robot that moves the boxes to the storage rack, safely, so that associates may simply grab the box from the rack. This team designed a robot that will take the lot boxes from the output port of the AMHS stocker and store the lot boxes on a staging rack. This will allow the associate on the factory floor to quickly take lot boxes from the staging rack to the machines saving the company valuable time.

 

EGR 402

Students: Awab A Salam Mohamed, Jay Godin, Borna Mansoormoayad, Aaron Saltou

Sponsor: The Air Force Research Laboratory


The Air Force Research Laboratory has proposed a challenge for university students to develop a prototype for a backpackable, covert and highly mobile device. The main purpose of the device is for moving supplies over rough and rocky terrain from one location to another. During a variety of missions, there are circumstances where troops require supplies from other members of their team. This team designed and prototyped an unmanned aerial system to perform this task. The UAV utilizes coaxial flight techniques for efficiently generating the maximum thrust.

 

EGR 402

Students: Eric Elkassab, Granville Smith, Malcolm Smith, Malik Townsend

Sponsor: Raytheon Technologies

Raytheon

 


In Raytheon’s factories and warehouses they use automated guided vehicles, or AGV’s, used to transport loads within their facilities without human interactions. They are looking for their AGV systems to be more efficient and more environmentally friendly by reducing the wear and tear of the AGV’s suspension system. This team was tasked with providing a prototype AGV suspension system for the company to adapt into their current system that will allow them to be more efficient by reducing slippage on factory floors, reduce cost of maintenance, increase stability over uneven floors and bumps and to be able to carry a load of 500 pounds.

 

EGR 402

Students: Marshall Botta, Erick Duarte, Derek Marshall

Sponsor: Raytheon Technologies

Raytheon

 


This team worked with Raytheon Technologies to develop a mechanical system that will allow an automated guided vehicle, or AGV, to dock consistently and reliably. The students’ target tolerances are +/- 4 mm in the x and y dimensions and to be within +/- 1 degree of perpendicular. For the sake of simplicity, they developed strictly a mechanical system. The cart they used to simulate an AGV will successfully dock only when it is within the target position. Undocking the cart is done with the aid of two pneumatic air cylinders.

 

Summit Automation

Students: Trenton Gutowski, Kyle-Christopher Kelley, Brittany Tews

Sponsor: Summit Automation


This team worked with Summit Automation, a company specializing in the design and manufacturing of automated doors and windows, to design a new and improved version within one of its already existing product lines. The product is a wall “switch” that provides a user interface between the customer and their Summit Automation automated doors/windows. Previous versions of this wall switch were either too basic (mechanical) or too unrefined (missing features) for the company’s product goals. Summit’s customers desire a more sleek design that blends in rather than stands out in their home or office. This team’s solution is a touchscreen with a minimal bezel, featuring multiple menus for setup or installation and operation. The design also features motion sensing, light sensing, background customization and wireless control via WiFi.

 

Honeywell

Students: Micah Nagel, Jeffrey Papesh-Jacobs, Bella Recato, Avery Wenta

Sponsor: Honeywell Aerospace


Honeywell Aerospace partnered with this team to determine if their aircraft products could be made lighter utilizing a material called shape memory alloys, or SMA’s. The team was tasked with discovering a replacement to one of its heavier components, the solenoid valve. The solenoid valve is currently their most common form of actuation used in commercial and military aircraft and the chosen component to be innovated upon. The goal is to improve system optimization to conclude whether or not Honeywell should continue to develop this technology. The team is seeking a patent for using resistive heating to actuate the SMA and operate the valve.