00 projects 10-18 sp11 - college of engineering ... docs...convert the saturated steam in to dry...

Department of Mechanical Engineering

Application for Sponsorship of a Capstone Design Project Project Sponsor (Company Name): Kellogg Battle Creek Plant

Information Requested:

Technical Contact:

Billing Address/Contact:

Title & Name: Eddie Keene – Plant Manager 425 Porter Street Address:

425 Porter St Battle Creek, MI 49016

P.O. Box 1987

Phone: (269) 965-3350 Email: [email protected]

PROJECT TITLE: (5-10 words) Portable Dry Steam Cleaning System IMPACT OF THIS PROJECT ON YOUR COMPANY (Using approximately 70 words, describe how this project will positively influence your company through, for example, reduced costs, a new product, higher quality, faster production, a healthier workplace etc.) This statement will be printed in the end-of-semester Design Day Brochure. Using 150 pound plant steam and the plant steam distribution system create a portable dry steam unit to clean processing equipment. This system will connect into the distribution system and convert the saturated steam in to dry superheated steam used to spray on mechanical equipment to clean and sanitize. This will improve the production line cleaning sanitation and efficiency of cleaning. There is an important safety component to this project. (Please attach a one page summary describing the project. Indicate if a confidentiality and/or intellectual property agreement will be required.)

PROJECT CHECKLIST: Ideally, your project should …

• use significant creativity to solve a problem where there are many potential solutions Yes No

• require the design of a system, or subsystem rather than a single part Yes No

• require the use of conventional analytical and computational methods rather than specialized equipment and/or software Yes No

• permit our students to display their results at the end-of-semester Design Day, which is attended by the public Yes No

• permit our students to visit to your facilities Yes No

DG10

Objective: Using existing 150 pound plant steam and the steam distribution system, create a portable dry steam cleaning system. Background: 150 pound saturated steam is produced in one area to process food in the manufacturing facility. After different cycle times of food processing, or during product changes, the production equipment must be cleaned and sanitized. Common methods used to clean and sanitize include: manual wiping, blowing, chemical addition and water washing. Each of these methods presents different food safety risks. Cleaning and sanitizing at the same time improves cleaning times, change over times and improves sanitation. Dry steam technology is not new but is limited to small capacity units which convert tap water to dry steam and are not practical when cleaning large equipment or for long periods of time. This project is intended to tap into the current steam distribution system in a safe and simple manner, direct it to various areas of the facility, convert it to dry steam by the use of plant energy sources such as propane or electricity from welding outlets, and safely apply it to equipment to clean and sanitize. The design does not have to be automated and can be a safe manual system. An intellectual property agreement is required. Invention(s) and all Intellectual Property developed during this effort will be owned by Kellogg’s. With sponsor prior approval, the student team has full rights of disclosure to the public during this project. Aspects of a Successful Project:

• Safety is a critical aspect of this project. The equipment used to connect plant steam to the dry steam unit, connections to the portable heat exchanger, the portability of the unit and the procedure to use the equipment must receive plant approval prior to testing.

• Establish the proper type and size hose to use from the plant steam distribution system to the portable dry steam unit.

• Design and construct a heat exchanger and system to convert plant steam into dry steam to be used at rate sufficient to clean and sanitize a coating oven.

• Design a safe transporting system to allow the dry steam unit to be moved to decks and around equipment.

• Using plant testing methods, establish approved levels of cleaning. • Develop safe operating procedures.

DG10


Application for Sponsorship of a Capstone Design Project Project Sponsor (Company Name): Kellogg Battle Creek Plant


Technical Contact:


Title & Name: Eddie Keene – Plant Manager 425 Porter Street Address:

425 Porter St Battle Creek, MI 49016

P.O. Box 1987


PROJECT TITLE: (5-10 words) Electrostatic charging of materials IMPACT OF THIS PROJECT ON YOUR COMPANY (Using approximately 70 words, describe how this project will positively influence your company through, for example, reduced costs, a new product, higher quality, faster production, a healthier workplace etc.) This statement will be printed in the end-of-semester Design Day Brochure. Electro statically charging materials will improve product quality and product yield by improving the adherence of the sprayed material to the original food. Improved yield results in reduced overspray along with reducing drift/waste. Improving the sprayed material control will also improve sanitation and maintenance. Sanitation is required to keep conveying equipment clean and tracking. When the overspray is not properly removed it results in stretched belts which have to be replaced and damage to other equipment in the area. (Please attach a one page summary describing the project. Indicate if a confidentiality and/or intellectual property agreement will be required.)







DG11

Objective: Improve the adherence and over spray of flavor enhancing ingredients to food through electro-statically charging. Background: Base grains produced and dried are enhanced by spraying ingredients onto the product. Spraying is typically done in flow through drums and spray booths in order to control drift and over spray. This project is intended to improve the usage or yield by reducing the waste from overspray. Controlling the overspray can result in improved usage/improved product cost, less equipment wear from the drift onto other moving parts and cleaning of the drift into other areas. An intellectual property agreement is required. Invention(s) and all Intellectual Property developed during this effort will be owned by Kellogg’s. With sponsor prior approval, the student team has full rights of disclosure to the public during this project. This project will:

• Calculate the current usage and yield to determine the amount of waste in the current system.

• Design and install a method to charge the food exiting a dryer and oppositely charging the flavor enhancing ingredients being applied after the dryer.

• Calculate the yield after the electro statically charging of materials and the associated system improvements.

• Establish maintenance plans and costs for the modification.

DG11


Application for Sponsorship of a Capstone Design Project Project Sponsor (Company Name): Student Alumni Foundation / MSU Alumni Association


Technical Contact:


Title & Name: Director-SAF; Dan DiMaggio Address:

333 Union Building East Lansing, MI 48824

All same as technical


PROJECT TITLE: (5-10 words) The “Cool” Sparty Project

PROJECT CHECKLIST: Ideally, your project should … Yes or No

• use significant creativity to solve a problem where there are many potential solutions __

• require the design of a system, or subsystem rather than a single part __

• require the use of conventional analytical and computational methods rather than specialized equipment and/or software

__

• permit our students to display their results at the end-of-semester Design Day, which is attended by the public

__

• permit our students to visit to your facilities __

IMPACT OF THIS PROJECT ON YOUR COMPANY (Using approximately 70 words, describe how this project will positively influence your company through, for example, reduced costs, a new product, higher quality, faster production, a healthier workplace etc.) This statement will be printed in the end-of-semester Design Day Brochure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

Please attach a 1 page Project Summary to be distributed publicly to students and faculty advisors when they choose projects. Indicate if a confidentiality and/or intellectual property agreement will be required.

DG12

1 page Project Summary

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DG12


Application for Sponsorship of a Capstone Design Project Project Sponsor (Company Name): MSU Center for Orthopedic Research


Technical Contact:


Title & Name: N. Peter Reeves, Assistant Professor Same Address:

2727 S. Pennsylvania Aveʼ, room 230 Lansing, MI, 48910

Same

Phone: 517-975-3303 Same Email: [email protected] Same

PROJECT TITLE: (5-10 words) Force neuromuscular control of the head.


• use significant creativity to solve a problem where there are many potential solutions _Y_

• require the design of a system, or subsystem rather than a single part _Y_


_Y_


_Y_

• permit our students to visit to your facilities _Y_

IMPACT OF THIS PROJECT ON YOUR COMPANY (Using approximately 70 words, describe how this project will positively influence your company through, for example, reduced costs, a new product, higher quality, faster production, a healthier workplace etc.) This statement will be printed in the end-of-semester Design Day Brochure. There is growing evidence that people with neck pain have impaired neuromuscular control of the head. This project will develop a new method to assess force neuromuscular control of the head. Future research studies will use this new method to understand the mechanism for neuromuscular impairment in the neck pain population and evaluate the efficacy of treatment options.


DG13

1 page Project Summary The goal of the project is to develop new methods to assess neuromuscular control of the head. Students will be asked to design and develop a system, which will allow for the evaluation of force control of the head during target tracking and stabilization tasks.

With the approach, we will use objective performance measures typical for control systems. Fig 1 depicts the generalized system for evaluating neuromuscular control. The plant, denoted by P, is a function of the plant parameters T, which could be affected with injury. The collection of the control processes, denoted by K, is a function of controller parameters Q, which also could be affected by injury or pain. The error signal e is defined by the difference between the output of the system y and the reference signal r (i.e., e=r-y). The disturbance signals is denoted by d.

The objective of the control system in Fig 1 is to attenuate the error signal in spite of the time-varying reference input and disturbance signals. The control process with the time-varying reference signal r(t) will be referred to as the tracking task with respect to r(t). In this case, zero tracking error e(t)=0 implies perfect tracking y(t)=r(t). The control process with the reference signal r = 0 will be referred to as the stabilization task. In terms of stabilization, zero error e(t)=0 implies perfect rejection of disturbances,

Target tracking performance will be evaluated by the smallness of the error signal e, when the reference signal r(t) is time-varying. Different reference signals will be used such as pseudorandom, chirp, and step inputs.

Stabilization performance will be measured by the smallness of the error signal e under the disturbance signal d (applied to the trunk as shown in Fig 2). The RMS measure can be used to represent the size of error signal e.

The project will involve developing methods to display targets and measure force in real-time.

Fig 2. (A) Force control of a head-neck system under the trunk perturbation. (B) Real-time display of the target force and the output force of the subject on a screen.

(A) (B)

Fig 1. The generalized system.

e(t) y(t)

P(T)

K(Q)

d(t) r(t)

DG13


Application for Sponsorship of a Capstone Design Project Project Sponsor (Company Name): Louis Padnos Iron & Metal Co.


Technical Contact:


Title & Name: Craig Schrotenboer Accounts Payable Address:

117 W. 7th Street Holland, MI 49423

P.O. Box 1979 Holland, MI 49422-1979


PROJECT TITLE: (5-10 words)

High Speed Compressed Air Product Diverter PROJECT CHECKLIST: Ideally, your project should … Yes or No

• use significant creativity to solve a problem where there are many potential solutions _Yes_

• require the design of a system, or subsystem rather than a single part _Yes_


_Yes_


_Yes_

• permit our students to visit to your facilities _Yes_

IMPACT OF THIS PROJECT ON YOUR COMPANY (Using approximately 70 words, describe how this project will positively influence your company through, for example, reduced costs, a new product, higher quality, faster production, a healthier workplace etc.) This statement will be printed in the end-of-semester Design Day Brochure. Development and proper design of a compressed air diverting system will allow us as a recycling company to be able to further separate and recover additional materials from the recycled products stream. This in turn allows for a more sustainable operations platform for our recycling company.


DG14

1 page Project Summary

High Speed Compressed Air Product Diverter

As a metals recycling company Padnos Iron & Metal employs high speed metal separating equipment to

separate valuable materials from a stream of mixed materials. Our current system uses induction sensors to be

able to locate pieces of metal traveling on a high speed conveyor belt. We then use a mechanical diverter to

remove the selected material from the product stream. The project entails development and design of a material

diverter that would remove the desired metal with a precise, high speed “jet” of compressed air. The project

scope encompass’ all aspects of the design starting directly after receiving a timed PLC signal that would

indicate when to “fire” the jet of compressed air. All aspects of mechanical control and delivery of compressed

air to the product would be included; with a critical emphasis on design of the “airbar” itself. This project

would very likely include the production of one or more prototypes for testing. As we operate a fabrication and

machine shop production of these prototypes could very easily be a joint effort.

DG14


Application for Sponsorship of a Capstone Design Project

Project Sponsor (Company Name): Pepsi Beverages Company


Technical Contact:


Title & Name: Eric Curtis/ Engineering Manager Eric Curtis Address:

730 Isbell St Howell, MI 48843

3400 Auburn Rd Auburn Hills, MI 48326

Phone: 248-670-8182 248-670-8182 Email: [email protected]

PROJECT TITLE: Mechanical Layer Picking Design for Shell Handling IMPACT OF THIS PROJECT ON YOUR COMPANY This project will positively influence Pepsi by increasing the efficiency of our Direct Store Delivery network. Not only will labor costs and workers compensation claims be reduced, but overall loading accuracy will be increased. By redesigning the existing mechanical layer pick device to handle more of our existing SKU’s, we will now be able to build more orders via machine in layer quantities versus building manually case by case. (Please attach a one page summary describing the project. Indicate if a confidentiality and/or intellectual property agreement will be required.)







DG15

Current State: In all of our larger distribution centers, a mechanical layer device is mounted onto a forklift and uses the already existing hydraulic controls to palletize custom built pallets for our customers. The constraint of the existing design is that it can only handle a limited number of our existing SKU’s. It currently can only handle 12oz cans, 2 Liter, and some 16.9oz and 20oz packages depending on their secondary packaging configuration. The goal of this project is to gain the flexibility to handle all 20oz, 24oz, 16.9oz, 1 Liter SKU’s in full layer quantities via the mechanical layer pick device.

Currently able to handle these SKU’s.

Layer collapses in middle when trying to handle by full layer.

DG15


Application for Sponsorship of a Capstone Design Project Project Sponsor (Company Name): O G Services


Technical Contact:


Title & Name: Owner-Glenn Shedrick Address:

2268 Hetzner Drive Saginaw, MI 48603

Phone: 989.755.6322 Email: [email protected]


The Interchangeable Bottle and Cap IMPACT OF THIS PROJECT ON YOUR COMPANY: The OG Services Value Cap and Bottle project is aimed at providing a more efficient design solution to a problem that is found with pump dispense lotion and soap bottles. Pump dispenser lotion and soap bottles are not designed to enable the consumer to retrieve the entire product from the bottle. Because it is difficult to retrieve the remaining product; as a result, many consumers simply discard the container with useful product left in the bottle. The team challenge is to design an interchangeable bottle and cap that would enable the user to retrieve the remaining product while eliminating waste. (Please attach a one page summary describing the project. Indicate if a confidentiality and/or intellectual property agreement will be required.) PROJECT CHECKLIST: Ideally, your project should …

• use significant creativity to solve a problem where there are many potential solutions Yes

• require the design of a system, or subsystem rather than a single part Yes

• require the use of conventional analytical and computational methods rather than specialized equipment and/or software Yes

• permit our students to display their results at the end-of-semester Design Day, which is attended by the public Yes

• permit our students to visit to your facilities No

DG16

The Interchangeable Bottle and Cap Design

The purpose of this bottle and cap model is aimed at providing the company with a design solution to the problem that lotion and other pump bottles are not designed to enable the consumer to retrieve the entire product. The pump will fail to continue dispensing product, even though there may be a substantial amount remaining. It is my goal to design a bottle and cap that receives a range of lotion bottles and fully dispenses the remaining product left in the bottle.

When a consumer uses a pump dispense bottle, they utilize the pump dispenser to easily dispense the product. However, when the bottle nears empty, there is typically a significant amount of product that remains in the bottom of the bottle that can no longer be retrieved by actuating the pump. Typically, it is difficult to try to retrieve this remaining product, and in result, a consumer may discard the container with useful product still left in the bottle. With this problem in mind, challenge is to design bottle and pump dispenser coupled an attachable cap. This cap will snap at the bottle of the bottle and dispense pump. Once the dispense pump can no longer call for the product in the bottle, the cap will then be used to replace the dispense pump. The bottle must have the ability to be turned upside down; therefore the cap must support the bottle new position. The bottle should have a two-sided label. One side is for when the bottle is right size up, while the other label is when the cap is used after the pump dispenser can no longer call for the product inside the bottle.

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DG16


Application for Sponsorship of a Capstone Design Project Project Sponsor (Company Name): Small Engine Research Laboratory (SERL) at Wright Patterson AFB


Technical Contact:


Title & Name: Dr. George Zhu Address:

148 ERC South Michigan State University East Lansing, MI 48824

Phone: 517-884-1552 Email: [email protected]


A flexible testbed for optimization of a small scale engine ignition system


• use significant creativity to solve a problem where there are many potential solutions Y_

• require the design of a system, or subsystem rather than a single part Y _


Y _


Y _

• permit our students to visit to your facilities Y _

IMPACT OF THIS PROJECT ON YOUR COMPANY (Using approximately 70 words, describe how this project will positively influence your company through, for example, reduced costs, a new product, higher quality, faster production, a healthier workplace etc.) This statement will be printed in the end-of-semester Design Day Brochure. The design of a flexible testbed which can accommodate a wide range of small scale engines and advanced ignition systems will enable the testing and optimization of a new generation of advanced propulsion systems for unmanned aerial systems (UASs) in the Air Force. The ability to test new ignition systems will result in advanced engines which are capable of integrating a wide range of alternative and renewable fuels as well as dramatic improvement in thermal efficiency and power output.


DG17

1 page Project Summary Design of a flexible testbed for optimization of a small scale engine ignition system Unmanned aerial systems (UASs), also widely known as drones, are increasing being deployed as a key component of our aerial defense and combat strategy. A class of UASs, group 1-3, are dedicated to small scale, highly maneuverable aircrafts which can carry out reconnaissance missions with small payloads (up to 5 lbs.). This project is dedicated to the design and construction of a flexible testbed which can accommodate a wide range of small scale UAS engines specifically for the task of optimization advanced ignition systems for the Air Force. Next generation of small-scale propulsion systems in our Air Force will continually push the boundaries of size, speed, and fuel type such as the Scan Eagle shown in Figure 1. Smaller combustion geometries inherently present higher surface area to volume ratios. The significant rise in heat transfer decelerates the chemical energy conversion rates, ultimately leading to flame extinction. As the engines are routinely pushed near their performance limits, a more advanced and energetic ignition system will be required to maintain stable and reliable operation. Recently, the introduction of more advanced ignition systems, such as a non-equilibrium plasma discharge, have opened new research fields in engine technology which can greatly benefit the performance of the small scale engines discussed here. The integration of a new and more energetic ignition system can enable combustors to operate outside the normal flammability regime, such as ultra lean combustion for reduction of harmful byproducts. Additionally, such technology can eventually make possible the integration of new alternative and renewable fuels to be used in the next generation of advanced internal combustion systems. The specific goal of this project is to design and assemble a comprehensive testbed for small scale engines (up to 7.5 hp), with the ability to monitor engine performance such as power, torque, fuel consumption, and chamber pressure. To date, no suitable test facility exists that is entirely dedicated to the requirements of testing solely small scale engines. The main design challenge of this project will be to build flexibility into the system so that many different configurations of engines and ignition systems can be tested and compared with relative fast turn around and with high sensitivity. Each engine mount and integration assemble with a dynamometer is different and this testbed should be flexible enough to accommodate a broad range of engine shafts and geometries. The control system should also be flexible enough to provide control for both the engine and the ignition system. The students will be provided with specific requirements for the test engine specs and ignition systems as well as assistance in electronic control systems for the testbed.

This project will be integrated into the Capstone undergraduate design project at Michigan State University as well as graduate level research project and exhibited at the University Capstone Project Demonstration Day in the Small Engine Research Laboratory (SERL) at Wright Patterson AFB. The goal is to promote engineering education, design, and application of fundamental science in a capstone educational environment, leading to innovations and advances for both Michigan State University and the Air Force.

Figure 1 Air Force small scale UAS: Scan Eagle (1.5hp engine).

DG17

Summary "Solar Heated Vermicomposting Bin”

for Woodcreek Magnet Elementary School

Woodcreek Magnet Elementary School is an official Green School in the Lansing Public School District. It presently has two outdoor mid-scale vermicomposting bins approximately 7 feet across by 4 feet deep. Generally, the annual food waste that is composted is over 600 pounds. This is taking into account that the food composted is lunch waste only, vegetables or fruit and basically just collected 8 months out of the year. There is space to accommodate much more composting.

The 5th graders would like to offer composting to the local community as well as their own families. This is a possibility if we can get the wormbins or at least one of them running year round. The challenge is the winter months more than anything.

Our 5th graders learn about solar energy and will be involved in a solar energy unit of study after the beginning of next year. It would benefit the learning experience tremendously if they could work with MSU student engineers to design, build and implement a type of solar collector that would effectively heat wormbins during the cold months so the worms won't freeze. Both bins are backed up against the school building so perhaps mounting a rooftop collector is a possibility. At any rate, the unique solar powered worm compost bin would allow the worms to continue to produce compost year-round.

An aspect of the partnership with MSU College of Engineering students is their direct interaction with our students. Sharing their expertise in crafting such a system as well as their knowledge of alternative energy, specifically solar energy, is important. The Woodcreek students should end up understanding the design process first hand as they are actively engaged in the whole process.

Another note about the system: it would need to be self-sufficient and require minimal maintenance. The students will be responsible for keeping the worm bin operational.

Impact of the Solar Heated Vermicomposting Bin Project on Woodcreek Magnet Elementary School, Lansing

Our fifth grade class has made a tremendous shift from traditional teacher instruction to partnering with MSU College of Engineering students and tapping into their expertise. The Solar Heated Vermicomposting Bin Project has given our fifth graders the opportuni1y to think and work alongside 'real' engineers. This project has captured the imagination and interest of students by actively involving them in the design process. It's a positive experience that builds not only their understanding of the elements of engineering but gives them practice in teamwork and helps them to see that they can indeed work together to find solutions to help our environment.

The solar heated bin will allow the red worms to continue to consume organic material during the cold Michigan winters and the carefully designed system, which emphasizes simplicity, and can easily be duplicated at other school sites in Michigan.

DG18

00 projects 10-18 sp11 - college of engineering ... docs...convert the saturated steam in to dry...

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