rpi design lab project portfolio

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CELEBRATING TEN YEARS!

Project Portfolio 2009 / 2010

Bob Swanson and Cynthia Shevlin visiting The Design Lab happy to to see all the progress after 10 years.

Photo credit: Rensselaer / Barry Stein

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Copyright © 2010 Rensselaer Polytechnic Institute

All rights reserved. No part of this publication may be reproduced, stored in a retrieval system or transmitted in any form by any means electronic, mechanical, photographic, recording or otherwise without written permission of theRensselaer Polytechnic Institute.

Contents

Director’s Letter

Balance Assist System - General Dynamics

Smart Grid - GE

Structural Wind Turbine Nacelle - GE

Two Piece Wind Turbine Blade - GE

Wind Turbine Interaction - GE

WInd Turbine Tower Concepts - GE

Quantity Sensor Redesign - Hamilton Sundstrand

Parallel Processing for Radar Analysis - Lockheed Martin

Bearing Life - DRS

Camera Study

Automatic Font Identification - Monotype Imaging

Hybrid Actuator - Northrop Grumman

Managing Information Overload - SAIC

Senior Friendly Shopping Cart - Albany Guardian Society

Biometrics - RPI

Design for Sustainabiltiy - RPI

Blind Assembly - NABA

Balance Ball System - RPI

Biomass Scope Study - KNUST

Culturally Situated Design Tools - RPI

Leopard Tracking - Stellenbosch

The Staff and Faculty

About The Design Lab


The entrance to The Design Lab where students meet with their project teams.

Dear Friends:

Thanks to a generous gift from Robert Swanson and his wife Cynthia Shevlin, the O.T. Swanson Multidisciplinary Design Laboratory was built and opened its doors in the Spring of 2001 to a small cadre of students who participated in “real-world” industry sponsored projects. This year we celebrate our ten-year anniversary with this special inaugural issue of the Design Lab Projects Portfolio.

Since its inception, the Design Lab has been a showcase facility for the School of Engineering. In the past ten years the Design Lab has successfully implemented an internationally recognized design program. Over 10,000 students have participated in project-based experiences since The Design Lab was first opened. Every year over 600 sophomore level engineering students take Introduction to Engineering Design in the Design Lab in preparation for their senior level capstone design experience. Drawing upon Design Lab resources, students address some of the world’s major problems, while they learn about teamwork, communication and the design process.

Over 400 senior-level engineering students from biomedical, computer systems, electrical, electric power, industrial, materials, and mechanical engineering work on multidisciplinary capstone design teams each year. The projects highlighted in the following pages show the results of our 2009-2010 projects. As you review each project, I’m sure the level of effort, attention to detail, ingenuity, and overall quality of results from our students will impress you. Underlying the pages, which present the objectives, approach and results for each project, is the excitement and enthusiasm felt by each student as they eagerly engage in important projects with the support of our sponsors, faculty, and staff.

Since its inception, we have conducted over 100 sponsored projects. We employ a team of full and part time faculty and staff who operate the lab and support our students. The Design Lab brings together a multitude of resources, programs, courses, curriculum, and people that have lead to Rensselaer’s recognition by Business Week magazine as one of the top 60 design schools in the world!

As always thank you for your support and best wishes.

MarkMark SteinerDirector, The Design Lab

4 The Design Lab at Rensselaer

Students on the Balance Assist team, perform a system calibration prior to a demonstration.

2010 Project Portfolio 5 5 The Design Lab at Rensselaer

PurposeCurrent Balance System

Medium Weight Shock Machine• Currently equipment is loaded and placed on balance

stands• Load is adjusted manually until system appears

balanced• Process is very time consuming

Technical ResultsDesign: Mechanical

Plunger Balance Stand

Electrical• NI USB-9239 – 4-channel, 24-bit Analog Input Module• Honeywell Model 3270 Load Cell• Requirements

• 5,000 lb. load capacity

Accomplishments

Mechanical

• Manufactured four balance stands for practical application that incorporate

Balance Assist SystemTeam: Ron Carl (ELEC), James Edward Gryzbek (MECL), Matt LaBounty (MECL), Karl Meyer (MGTE), Graham Ostrander (MECL),

Alex Peach (ELEC), John Petsche (MECL), Jonathan Proule (MGTE)

• Process is very time consuming

Semester ObjectivesDeliver a system that:

• Determines shock plate adjustments for one shot balance

• Includes load measuring support stands compatible with MWST

• Includes improved LabVIEW program

Project History

Prototype LabVIEW GUI• Developed proof of concept• Designed and constructed initial prototype• Designed LabVIEW program to operate system• Wrote step by step operation manual

• Maximum of 3 5 inches in diameter• At least 0.1% of full scale accuracy• Output in range of 5 volts

DAQ Enclosure DAQ Load Cell

Analysis• System concept proven via mock stands with digital

scales and two categories of testing• Teeter-totter System Use one scale to give

baseline of compatibility• Four Scale Test Use four scales as a proof of

theory in reducing margin of error(and associated cycle time)

• Repeated proof of concept with load cells to ensure quality of production and applicability of design

practical application that incorporate load cell technology

LabVIEW Software

• New Features:• Visual Aids• Real time System Status

Indicators• Automatic Suggested• Use of Counterweights• Simple GUI • Enables Quick and Easy

Balance Procedure

Project Engineer: Mark Anderson (The Design Lab), Chief Engineer: Richard Alben (Dept. of Mechanical, Aerospace & Nuclear Eng);

Submarine Balancing Equipment

It is necessary to test major pieces of equipment for placement on submarines for the ability to withstand shock.

This equipment, weighing multiple tons, is placed on top of a shock test machine.

Part of this setup involves balancing the equipment to be tested so that it does not damage itself, the machine or nearby personnel.

The students developed a system of load cells to be placed at the machine and a LabVIEW software package that reduced the time needed for this setup by up to 75% during the course of the semester.

The Balance Assist team standing behind their load cell system.

6 The Design Lab at Rensselaer© General Electric Company. Used by permission.

GE student teams including Nacelle, 2-piece Blade, Towerre-design, their professors, project engineers and sponsor mentors.

2010 Project Portfolio 7

© General Electric Company. Used by permission.


Smart Grid - PHEV Impact Study

Robin Lafayette(EPOW), Jia Ma(CSYS), Norma-Ester Medina(MGMT), Justin Metzger(ELEC), Sabrina Moore(EPOW), Sam Ostrow(EPOW), Hao Ruan(ELEC)

Purpose:

To observe and analyze the impact of PHEVs on

the power grid

Research for future project application

Technical Results (Load):

23.6% loaded 1.25x the transformers rated load

9.26% remained overloaded for 5 hours of more

Project History

A plug-in hybrid electric vehicle (PHEV) automobile design

contains:

Electric motor

Internal combustion engine w/ rechargeable batteries

The PHEV is an electric vehicle with a

Gas-tank backup reducing the emissions

The cost of electricity for PHEV

Estimated to be less than one quarter of the cost of fuel

Some models of PHEVs can:

Travel up to 300 miles on a single charge

Be fully recharged in one night

(Ex. Toyota Prius, Ford Escape, Chevy Volt, and Tesla)

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Rated Load: 37.5kW January, Albany NY

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Technical Results (Thermal):

For most scenarios, top oil temperature doesn’t

exceed normal range (120 degrees Celsius)

Project Engineer: Mark Anderson (The Design Lab), Chief Engineer: Cheng Hsu (Dept. of Industrial & Systems Eng.)

Current Semester Objective:

Build a simulation to identify the optimal load

schedule for a transformer and the effect on

the thermal properties.

Next Steps:

Theoretical

•Reduction of modeling assumptions to

improve realism

•Expansion of modeling area

•Better VI to model simulation could be

utilized

Practical

•Physical representation of model

•Improved communication between

utilities, dealerships and vehicle owners

•Modify HMI to include PHEVs

Accomplishments:

Load schedule optimization tool built using excel

User interface constructed using LabVIEW

Output screens for thermal calculations using

LabVIEW

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Power Distribution Systems

As electric cars and hybrid vehicles are adopted by consumers, they will impact the power distribution systems.

Based on consumer patterns, this will likely create different and varying electric loading scenarios that must be accounted for.

The student team successfully developed a simulation tool to help model these variations.

With this tool set, the user can better understand how these loads may impact the grid at the neighborhood level and can thus plan accordingly.




Dean Baker (MECL), Kaitlyn Calaluca (MS&E), Rima Deveikyte (MECL), Betsy Green (MECL, Bryant Johnson (MECL),Julienne Labrecque (MS&E), Robert Middleton (MS&E), Ethan Rudolph (MECL), Philip Scangas (MECL), Oliver Williams (MECL)

Monocoque (Unibody) Design

Space Frame Design II

Project Scope1. Develop Structural Nacelle concepts

•will allow direct mounting of a Wind Turbine Drive Train Components (Gearbox, Shaft, Bearing, generator, Yaw Bearing)

CTQs: Critical to Quality

Stress

• Able to sustain weight of generator, gearbox, and rotor

• Able to distribute stress throughout nacelle

Stiffness• Maximum deflection of the

shaft is• 0-1 degrees

Weight/Cost • Optimized for minimum weight through FEA

Vibration • Effects from machinery, yaw bearing, nacelle due to winds

Fatigue

• Able to withstand cyclic loading

• Assess the effects of crack propagation

• Define a process of

Network DesignPresent Nacelle Showing Bedplate-mounted Gearbox, Shaft, generator and Yaw Bearing Surrounded by a Composite shell

Benefits:• Even stress distribution• Low principal stresses• High Stiffness• Low weight

Drawbacks:• Manufacturability

• Weld construction• Ball joints

• Requires a skin

1. 3.

4. 2.

53,000 kg

29,900 kg

22,900 kg

14,900 kg

Bedplate Improvements

Baseline Loading Model

Bearing, generator, Yaw Bearing)•Provide protection, and allow

maintenance, resist wind loads2. Down-select 2-3 concepts3. Develop CAD Models for selected

concepts and Baseline (Bedplate type design)

4. Develop Structural analysis models5. Perform structural analysis (static)6. Develop Design Trade-Off curves in

design space

Transportability • Define a process of transportation

Manufacturability • Define a process of manufacturing

Maintainability • Able to access interior of nacelle

Performance CriteriaThe nacelle should deflect less than 1 degree

at the tip of the shaft (35 mm)

Next Semester Plans

Space Frame Design I

Ribbed monocoque design

Corrugated sandwich structure

Results from panel testing

• Fatigue and Vibration analysis

• Honeycomb sandwich structure research and analysis

• Application of sandwich structures to optimize weight reduction and strength

• Exploration of modified spaceframeoptions

• Research on spaceframe shell thickness

• Continuation of network design

Bedplate Improvements

Project Engineer: Scott Miller(The Design Lab), Chief Engineer: Richard Alben (Dept. of Mechanical, Aerospace & Nuclear Eng)

Wind Turbine Design

A wind turbine nacelle is typically an environmental cover protecting the subsystems within the wind turbine machine head. The machine head is the bus sized structure that sits on top of the wind turbine tower.

It supports the turbine rotor and power transmission and generation components such as the rotor shaft, gearbox, coupling, generator, and bearings. The machine head internal components are mounted on a massive metal bedplate, which also holds the composite material nacelle.

The goal was to provide quantitative information on novel nacelle design concepts to help the customer decide whether to launch a commercialization effort.

To this end, GE asked the team to tap a diverse range of mechanical design concepts and fabrication techniques from other industries, while applying wind specific design constraints.

The GE 4.0-110 turbine

2010 Project Portfolio 9 © General Electric Company. Used by permission.


Junction Criteria1. Transfer all loads on blade in such a way

that failure is predicted to occur outside of junction area before junction fails

2. Maintain current performance by minimizing weight addition and additional drag

3. Additional manufacturing costs must be justifiable by transportation and assembly cost savings

Project GoalDesign a one of two feasible junctions for a two piece 50+ meter wind turbine blade

C-Channel + adhesiveWorm Screw Bolt

C-Channel adhesive w/angled dovetails

C-Channel adhesive w/square dovetails

Model Development-CAD/FEA

Two-Piece Wind Turbine BladeJeremy Crouse, (MECL) Jonathan White (MECL), Colin Danek (MECL), Rob Houliston (MS&E), Tricia Kent (MS&E),

Alex Robb (MECL), Charlie Russo (MECL), David Kozak (MECL), Andrew Abrew (MS&E), Manny Lavin (MECL)

Project Engineer: Casey Goodwin (The Design Lab), Chief Engineer: Gregory Hampson (Dept. of Mechanical, Aerospace & Nuclear Eng)

Governing PhysicsFor bolt and adhesive analysis

Physical TestingUsing Instron Machine

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Green Energy Initiatives

The GE Wind Energy business was created as a result of the Ecomagination and Green Energy initiatives at GE Energy. GE currently has over 12,000 1.5MW wind turbines in operation worldwide. The next generation machine, the GE 2.5MW product is expected to grow substantially in market share. GE is continuously striving for creative ways to design, update, or redesign components for improved performance and low cost, and delivers customer value via a cost effective product that meets or exceeds requirements.

Longer wind blades are able to capture more of the wind’s energy than shorter ones. However, large blades are very difficult to transport. Two-piece blade designs, with the ability to assemble them in two halfs in the field would address this problem. However, the biggest challenge is to have a junction design that is structurally robust and aerodynamically equivalent to a pristine “un-jointed”, single piece blade.

10 The Design Lab at Rensselaer © General Electric Company. Used by permission.


Kyle Allen (MECL), Drew Shamyer (MECL), Alex Gage (MS&E), Brian Severino (MECL), CJ Vincent )(MECL),

Michael Hughes (MECL), Tyler Scully (MECL), John Vinueza (MECL)

Analysis Assumptions•All towers are assumed to be 100m tall unless otherwise specified

•Drag force from wind has been simplified to drag on three flat surfaces with the width and length of the blades

•No moment due to Nacelle and blades•Yield Strength of steel 250 Mpa•No torsional load•Specific cost of steel $3.3/kg•Steel Density 7800kg/m3

Lattice With SkinStructural•Modeled as:

• 4 posts with .5” thick skin (skindoes not support bending loads)

• Tower length and width held constant as the dimensions at the center of pressure

• Bending moment calculated using drag on blades as well astower

Modular Panel Design•Friction connections (bolts and plates) instead of welds•Material savings after eliminating ring flanges•Cutting of plates may be less expensive than welding

Structural:•Main Metric is Total Stress•Unless specified otherwise tower height is 100m•Total= Bending Stress Axial Stress•Modeled as:

• Hollow steel cylinder• Constant diameter• Constant wall thickness

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I-Beam LatticeStructural:•Modeled as four vertical I-beams with skin around it•Effects of lattice connection plates and taper neglected • Properties of W27x178 I-Beams used unless specified otherwise

Cost:•The lattice the connection plates and taper were neglected for cost analysis

Hybrid BaseStructural •Modeled as:

•Cylindrical tower of only concrete•Induced stresses assumed to be the same as a 00m tall concrete tower

Cost •Modeled as:

•Cylindrical tower of concrete

Semi-MonocoqueStructural•Properties of W14x99 I-Beam used•Modeled as:

•Vertical I – Beams Only•Beams evenly spaced apart•Beams centroids placed at radius of tower

Cost•Mass of stab lization rings and bolts neglected

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15 Beam Towe 12 Beam Towe 10 Beam Towe

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Steel Y eld St ength

Project Engineer: Casey Goodwin (The Design Lab), Chief Engineer: Daniel Lewis (Dept. of Materials Science & Eng.)

Cost•Lattice neglected in cost model

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Cost vs. Wall Thickness(H=100m, D=3.5m, Wind Speed=20m/s)

• Constant wall thickness•Main factors are wall thickness and height•Torsion and fatigue not considered in initial analysis

Cost•Mass connection plates and bolts neglected

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•Cylindrical tower of concrete with 1’’ thick steel shell

•Concrete estimated to cost $2.78 per ft3

and 2400kg/m3

•Cold rolled steel is estimated to cost $1.5 per lb (Albany Steel)

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Tower of Power

The tower of a wind turbine carries the Machine Head and the Rotor plus the Blade. Typically, large wind turbines utilize tubular steel towers, lattice towers, or concrete towers. Guyed tubular towers are only used for small wind turbines.

More recently, we see Hybrid Towers in use. Each has its advantages and drawbacks.

All towers are required to function under random wind loading (fatigue). They are also required to survive under what is known as “Fifty Year Gust Loads”.

The team proposed a solution to meet the needs of fatigue, life, strength, stiffness, natural frequency, buckling and other requirements.

Some towers are 30 feet in diameter in order to support the machine head, rotor and blades.



GE Wind Turbine Interaction

Vision and ScopeDevelop models for the interaction of wind turbines to improve spacing and operational strategies to maximize power generated from wind farms. These models will strengthen GE s position as a supplier of wind turbine equipment and wind farm design services.

Current Objectives1. Implement improved Cp and higher TSR rotor designs supplied by GE.2. Characterize the performance of the improved model wind turbines in the wind tunnel. Variables tested will be wind speed, TSR, and yaw angle to measure thrust and wake profiles.3. Implement visualization techniques to better understand and analyze wake effects.

Kyle Barden (MECL), Alex Field (MGMT), Chris Fiore (MECL), Chris Jones (MECL), Erik Jurgensen (MECL), Hyunkyu Kim (ELEC), Steve Knapp (MECL), Alec Marshall (MECL), Philip Reed (MECL)

Tower System Improvements Rotor Designs and ManufacturingResults

Old TowerOld Tower

New NacelleNew Nacelle Fall ‘09 RotorFall ‘09 Rotor GE Designed Rotor, ABSGE Designed Rotor, ABS

•Enabled thrust measurement•Better aerodynamics

Wind Tunnel SetWind Tunnel Set--upup

FaulhaberFaulhaber 13311331

FaulhaberFaulhaber 22322232

GWS RSGWS RS--385SH385SH

Code Modifications

Circuitry UpgradesFlow Visualization Techniques

Dynamometer Selection

Old TowerOld Tower New TowerNew Tower

Old InterfaceOld Interface New InterfaceNew Interface

Old CircuitryOld Circuitry New CircuitryNew Circuitry

Team Designed RotorTeam Designed Rotor GE Designed Rotor, SLAGE Designed Rotor, SLA Material Deflection ComparisonMaterial Deflection Comparison

Fall ‘09 ResultsFall ‘09 Results

New Smoke New Smoke VisualizationVisualization

•Better aerodynamics•Stronger nacelle

•Higher RPM motors•Higher current motors

•Ability to check motor overheating•Redundant thrust readings•Better signal processing

•Experimenting with more effective visualization techniques

•No voltage interaction between dynos•Increased power capacity•Higher tolerance resistors•Individual power supplies•Modular face plates

4-bladed rotor•Smoke visualization capable•Blade end effects/Axial induction factor•Reduced angular velocity•Theoretical higher Cp

GE rotor•Theoretical higher Cp/TSR

Project Engineer: Scott Miller (Core Engineering), Chief Engineer: Richard Alben (Dept. of Mechanical, Aerospace & Nuclear Eng)

Improving Wind Farms

Wind turbines are typically clustered in “wind farms” of 5 to more than 100 machines. It is desirable to space the turbines widely enough apart that the available wind energy for each turbine is only slightly reduced by the action of other turbines in the wind farm. But widely spaced turbines mean less power for a given land area. These interactions include both wake effects from upwind turbines and also up flow disturbances from downwind turbines.

The goal of this project was to develop an improved understanding of these interactions and, in partiticular, determine if the overall system performance of the wind farm can be improved by accounting for the interactions, instead of just trying to optimize each turbine individually.

GE asked us to study the effects of interaction for other rotors, especially some with higher efficiencies, and also study the physical and data acquisition enhancements to our system.

Each wind turbine has an effect on the ones next to it or behind it.


Students on the Hamilton Sundstrand team presenting designs for measuring the volume inside devices within a space station.


Measuring Volume In Outer Space

Systems that are used in space applications must be stable and reliable while deployed for up to 30 years. It is necessary to measure the volume of fluid in the various systems on the space station platforms.

For approximately ten years the sponsor had been considering various technologies but had not selected an alternative.

One student team successfully identified promising technologies that could be used to replace the current measurement technology. The second student team then found workable and readily available hardware for two of the potential technologies and performed a gage reliability and repeatability analysis on a prototype system they designed and constructed. As a result, they were able to prove that both selected technologies were viable for the application.

Quantity Sensor RedesignCraig Eaton (MS&E), Burton Francis (MECL), Richard Grebe (MECL), Adam Jankauskus (ELEC), Lukas Leinhard (MECL),

Jeffery Musante (ELEC), Arvind Ramachandran (MS&E), Michelle Santospirito (MGMT)

Loop Fluid

(Water, Urine,

Coolant)

Gas Charge

(Air, Nitrogen,

Helium)

BellowsProject Objectives:

1) Create a working prototype of a Hamilton Sundstrand Bellows Accumulator.

2) Test the performance of laser and ultrasonic distance sensors in the accumulator for use as a replacement for their current sensor.

3) Decide which technology best suits the sponsor’s needs and recommend which technology to move forward with.

Background InformationThe Hamilton Sundstrand Bellows Accumulator is a tank used for storing liquid in aerospace life support systems applications. Inside the accumulator, a quantity sensor determines the volume of the liquid present by measuring the displacement of the bellows. The current device, a string potentiometer, fails too frequently because of launch vibrations. A new measurement device is needed.

Hamilton Sundstrand Bellows Accumulator

Figure 1 Figure 2

Measurement Results

Project Engineer: Mark Anderson (The Design Lab), Chief Engineer: Daniel Lewis (Dept. of Materials Science & Eng.)

Results:• The laser is a more precise measuring device.• The ultrasonic sensor is a more accurate, robust, and reliable measurement system.• Both sensors work in the system and greatly surpass the sponsor’s standards in terms of percent error of full scale.

Recommendations:• Hamilton should re-evaluate their error standards.• The sponsor should choose laser for immediate use and precision.• The sponsor should choose ultrasonic and research a calibration method for a more accurate and reliable measurement system.

(a.) 4” x 48” hydraulic cylinder(b.) Ruler mounted to piston(c.) 3/8” threaded rod actuation of piston driven by

power drill(d.) Cylinder mounted on 80 x 20 struts(e.) Sensors mounted directly to cylinder, radially

constrained by cap fitted in cylinder bore(f.) Spring braces used to consistently reproduce holding

pressure of sensor caps to cylinder

(a.) 3/8” threaded rod(b.) Power drill attachment position(c.) Socket ratchet attachment position(d.) Intermediate block connecting

linear actuator to piston

Our Working PrototypeFigure 1 shows a simulation of

ideal experimental output. Figures 2 and 3 show actual laser

and ultrasonic measurements, respectively. Note that the laser most closely resembles the ideal

system.

Figure 3

Students meeting with the mentors at Hamilton Sundstrand.


Parallel Processing for Radar AnalysisTeam: Eric Allen (CSYS), Bryan Bessen (ELEC), Daniel Branken (CSYS), Jonathan Jesuraj (CSYS), Matthew Kloepfer (ELEC),

Jonathan Marini (CSYS), Alexandru Radocea (CSYS), Joseph Sgarlata (ELEC), Daniel Sullivan (ELEC), Brandon Thetford (CSYS)

Project Purpose: Determine how different methods of processing radar signals can speed up the analysis and performance of a radar system algorithm provided by Lockheed Martin. This has been explored by comparing results of single and multiple Graphical Processing Units (GPUs) against a Central Processing Unit (CPU) implementation.

Design

Radar Algorithm:

Technical Requirements:•Examine average run times versus number of objects in scene•Determine average runtime versus CPU/ GPU resources

Semester Objectives Met:•Generation of universal test data

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How a GPU Splits Up Work

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GPU 1 GPU 2 GPU N. . .

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Loops X/N returns until

processed

Each GPU is responsible for an equal number of returns and they all perform calculations in parallel to each other and return the results to the CPU.

Time

CPUAllocate Memory and copy Data for RCS(f)’s

Limited by CPU RAM size

GPU

FFT on s(t)

S(f) x S*(f) x W(f)

Multiply RCS(f)’s * HMF(f)

IFFT on Scp(f)’s and shift

Return Scp(t)’s

Loop until all returns are processed

→ s(t) and W(f) data transfer to GPU →

→ RCS(f) data transfer to GPU →

← Scp(t) data transfer to CPU ←Return to CPU when no more

RCS(f)’s

Pre-computed to save time

How Our Algorithm is Processed

Technical ResultsProvided Algorithm

fft() conj() ifft() ifftshift()

s(t ) S(f) HMF(f)

S(f)

W(f) RCS(f)

scp(t)

HMF(f) • W(f) • RCS(f)

2 500Vector Size vs. Time for CPU vs. GPU GPU vs. mGPU vs. CPU - Time per Return

GPU - 16K

Project Engineer: Mark Anderson (The Design Lab) , Chief Engineer Junichi Kanai (Dept. of Electrical, Computer, & Systems Eng.)

Next Steps:

•Generation of universal test data•Agreement among multiple models of radar systems•Detailed timing and performance analysis•Accuracy analysis

•Summation of RCS before signal chain to improve runtime•Address potential RCS input bottlenecks to keep up with GPU processing•Evaluate effects of different GPUs on performance

Conclusion:•Use of GPUs increases throughput by 2-6 times over our CPU implementation•Algorithm easily parallelized on GPU•Scales linearly across two GPUs

Simulink Model of Algorithm

Input Chirp Signal s(t) W(f) Filter

Output Signal Scp(t)Radar Cross Section, RCS(f)

0 50 100 50 00 2 0 3 0 3 0 400 450 500

2

-1 5

1

-0 5

0

0 5

1

1 5

2

T me s)

Am

pu

de

( )

0 0 5 1 1 5 2 2 5 3 3 5

x 10

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0 1

0 2

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1

Fr quecny

Am

pu

de

W f) F ter

0 0 5 1 1 5 2 2 5 3 3 5

x 10

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-0 5

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1

1 5

Fr quecny

Am

pd

e

RCS ) Noi e

0 0 5 1 1 5 2 2 5 3 3 5

x 10

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x 10

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T me s)

Am

pd

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Sc ( )

System Inputs and Output:

0

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2,000

3,000

4,000

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7,000

8,000

1 8 64 512 4,096 32,768

Retu

rns

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Seco

nd

Number of Returns Processed

GPU vs. mGPU vs. CPU - Returns Per Second

GPU - 16K

GPU - 32K

GPU - 64K

mGPU - 16K

mGPU - 32K

mGPU - 64K

CPU - 16K

CPU - 32K

CPU - 64K

1

10

100

1,000

10,000

100,000

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1 4 16 64 256 1,024 4 096

Tim

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s)


GPU vs. mGPU vs. CPU - Returns vs. Time

GPU - 64K

mGPU 16K

mGPU - 32K

mGPU 64K

CPU - 1 K

CPU - 32K

CPU - 6 K

y = 16.002ln(x) 207.8R² = 0.989

y = 195 44x0 1618

R² 0 9789

0

500

1 000

1 500

2 000

512 4 096 32,768 262,144 2,097 152

Tim

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s)

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GPU

CPU

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Powe F t (CPU)

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GPU - 16KGPU - 32KGPU - 64KmGPU - 16KmGPU - 32KmGPU - 64KCPU - 16KCPU - 32KCPU - 64K

[ Whe e mGPU mu t ple GPUs ( n this c se 2 GPU ) ]

Radar System Performance Improvement

In the design of radar systems it is important to accurately model and simulate various conditions. Modern radar systems utilize computers to analyze the received signals.

Simulation testing is an extremely computer intensive effort and requires significant time investment, thus reducing both the fidelity and the quantity of analysis that can be performed.

The student team was able to study the algorithms used and re-implement them using the processing power found in a typical graphics card (GPU).

The students were able to offer performance improvements of 2-3 times for some cases and much more overall – using a $100 PC card!

Lockheed Martin team standing in front of their poster inside The Design Lab.


Effects of Stray Currents on Bearing LifeLun Chen (ELEC), Dan Frydryk (MS&E), Colin Haynes (MS&E), Nodari Ivanov (MECL),

Seth Jones (ELEC), Jason Livingston (MECL), Bryan Scala (MGMT), Josh Smolensky (MECL), John Velonis (ELEC)

Project Engineer: ScoL Miller (Core Engineering), Chief Engineer: Richard Alben (Dept. of Mechanical, Aerospace & Nuclear Eng)

Design, construct, and deliver anapparatus which will test and analyze theeffects of stray currents on bearing life.

• Max Load: 0-‐950 at 150psi• Voltage Range: 0-‐30v• Amperage: 0-‐10A• Signal Frequency: 60-‐10,000Hz• Rotaôn Speed: 2000 rpm variabledrive

• Safe operaôn with cauôn labels• Custom Labview UI with controls• Easy to assemble 8020 base• Plug and play measurement

devices• Removable collar for easy access• Con^nuous variable drive

• Temperature> Supports J-‐types and many others

• Vibraôn> Accepts analogue and digital inputs

• Oscilloscope> Maximum sampling rate of 50Ms/s,

50MHz bandwith• Acceleraôn

> Range of -‐1.7 to 1.7g, Sensi^vity of1000mV/g, 2kHz bandwith

Purpose Test Capability

System Features

Monitoring and Sensing

Instrumentaôn

• Parallel processing• Communicaôn• Redundancy• Keep It Simple

Technical Design Approach

Transformaôn of Design

Military/Commercial Machinery Systems

DRS Power Technology, Inc (DRS-PTI) provides engineering and manufacturing services for military and commercial machinery systems. This includes mechanical equipment modeling, naval machinery inspection, and the design and fabrication of advanced electric machinery

The goal for the semester was to design and build a test system, and to do initial experiments with that system to understand the effects of stray currents on bearing life. The bearing must be easily removed so that the cumulative damage within the bearing can be measured. A variety of different bearing types were tested in the rig, including journal, roller and ball bearings with both grease fittings and continuous oil lubrication.

Specific values for rotational speed, applied forces and overall scale of the test system were defined as part of the system requirement definition task.

Bearing Life team standing behind their prototype.


Camera Study ProjectTeam: Adam Brooks (BME), Jim Croke (EE), Bill Simmons (EE), Jon Todzia (EE),

Elizabeth Tozer (EE), Tina Verderosa (EE), Harrison Wang (IME), Claire Woot de Trixhe (IME)

Purpose

Chief Engineer: Junichi Kanai PhD (ESCE); Project Engineer: Mark Anderson (Design Lab)

Technical Results

Semester Objec:ves

Ranking1 (best) to4 (worst)

CameraSystem 1

CameraSystem 2

CameraSystem 3

Ex s:ngSystem

S ze(d amete ) 3 1 2 3

L ghOngM n atu eLEDs

None NoneExte nal L ght

Sou ce

ResoluOon(p xels) 1 2 1 3

Came aCost 1 3 2 4

V eweCost 1 3 2 4

Accomplishments  IdenOficaOon of appropriate camera chip

  Proved the chip could be used for surgical applicaOons

  Met or exceeded sponsor requirements

  Developed a system that was cost effecOve

 Developed a tesOng procedure

Design a camera system which meetsor exceeds the following requirements:Camera Sensor Requirements

•  Size – appropriate for surgical applicaOon

•  Type – relevant technology

•  ResoluOon – be[er than exisOng systems

Light Source IntegraOon*

•  Current light source or LEDs (*Not the focus of theproject but necessary for the final system and to

perform the system test on the prototypes.)

IntegraOon with Current Surgical Device

•  Size – appropriate for successful integraOon

•  Safety – for use in surgical applicaOons andsterilizaOon processes currently used.

•  OrientaOon – to provide the correct viewing angle

for the camera system to ensure an unobstructed

view of the surgical site.

Our objec*ve is to develop a camerasystem to replace the current imagingsystem for a surgical device in order toreduce system cost and increase imageclarity and resolu*on.

The decision matrix (tothe right) comparesseveral camera systemsin order to determine thebest one suited to thisproject.

Note: Camera System 3was uOlized due to theunavailability of CameraSystem 1.

Design Progression and Component IntegraOonThe images to the le_ and right followthe progression of the integraOon ofthe camera system s components.

The system components include:• camera sensor•  lighOng source•  lens• casing

To the right is the casing designs arethe CAD renderings of the casingdesign progression.To the le_ are sample lens images anda picture captured during the lighOngsource funcOonality test.

PerformanceRequirement

Confirmed

Came a Ch p Type

Image ResoluOon

L ght Sou ceFuncOonal ty

Ch p FuncOonal ty

Integ aOon w th theCu ent Su g cal System

Image Cla ty N/A

The Performance Requirementtable to the right listed therequirements which we aimedto confirm via tesOng. Allitems with check marks weretested and confirmed. TesOngprocedures for Image Clarityneed further developmentbefore accurate results can befound.

Performance Requirements

Proposed camera system concept

Biomedical Engineering Scope

In many microscopic applications, the current approach to obtaining video is to use an endoscope.

These solid glass rods carry light to the location to be viewed and bring back the image. Endoscopes are fragile and expensive.

New technologies are becoming available to create extremely small cameras – on the order of 3mm in diameter – about three times the size of a mechanical pencil lead.

The students created a prototype package for such a camera and analyzed the technical challenges of bringing light to the viewing area and of obtaining sharply focused images.

Students assembling and bench testing a miniature camera.


Consumer Electronics Devices

Monotype Imaging pioneered mechanical typesetting in the 1880s. Currently, they license typographic solutions to consumer electronics device manufacturers, independent software vendors, creative professionals and leading corporations worldwide. They also provide solutions for software applications and operating systems.

Monotype Imaging asked the team to work on Automatic Font Identification. The goal was to enable a user to take a picture of a word, perhaps on a sign, or on a menu or document, and have a software process that can identify the set of closest matches from a known database of existing fonts.The team will need to work out a classification and matching system that can handle 10’s of thousands of differing fonts, and a user workflow that can enable a user to access this functionality over the web.

Automatic Font IdentificationTeam: Lindsay Flynn (MGMT), Karianna Haasch (MGMT), Stephen Mardin (CSYS/CSCI), Brian Michalski (CSYS), Dan Rothschild (CSYS/CSCI)

PurposeIdentify a particular font from a

sample image

Scenario: Customers (i.e. graphic artists) willupload a sample image (screenshot, digitalphoto, etc.) and our system will identify theclosest font Monotype has available

Semester Objectives• Creation of a database to search for font

Technical Results

0.294 0.5835

XOR Based Comparison:

Word Separation:

Accomplishments• Researched many possible methods for font

identification

• Developed 11 python modules to supportprototype and comparison engine

• Implemented XOR comparison method

• Implemented ratio based comparison method

• Developed PIC (character attribute)classification system

• Created prototype program using XOR and ratiomethods

• Designed and populated a database withcharacter information

Project Engineer Junichi Kanai (Dept. of Electrical, Computer, & Systems Eng.), Chief Engineer: Cheng Cheng Hsu (Dept. of Industrial & Systems Eng.)

attributes

• Ongoing population of the database withattributes of different fonts for use in a toolprototype

• Development of an algorithm for separatingcharacters within an image

• Classification of fonts by attributes withindatabase

• Implementation of logic in a prototype tool thatcan identify a font based on attributes

• Determination of tolerances for comparisonmethod(s)

• Evaluation of different comparison methodsand recommendations on these methods

• Final recommendations of project direction anddocumentation on progress made duringcurrent semester

Python GUI:Font Database:

•2410 Fonts

•13 Font Sizes

•1933920 Samples

•1.5GB w/ Indexes

• Implemented character separation for kerningand italics

Next Steps• Continue development of character separation

tool with emphasis on connected characters

• Explore applying ratio tolerance test to inputsample instead of database samples

• Extract PIC attributes from sample characters

• Explore weighted PIC attributes and additionalunique attributes

• Implement PIC-based comparison method

• Expand XOR comparison to weight potions of acharacter

• Optimize database indexes, resolve slowqueries and lookups

Ratio Intervals:Rat o Inte vals fo a ac oss d ffe ent fonts

18 The Design Lab at RensselaerPhoto credit: Rensselaer / Barry Stein

Students meeting with Northrop Grumman before the poster presentation.


Aerospace Engineering & Flow Controls

Flow control is any mechanism or process through which the flow is caused to behave differently than it normally would. In internal flows, flow control is used to delay separation and reduce head losses. There are passive mechanisms like turbulators, vortex generators or surface roughness, which are used to promote turbulent flow and delay separation, and there are active mechanisms such as unsteady blowing, oscillating ribbon or flap, and internal and external acoustic excitations. The objective of this project was to design and build a hybrid “fail-safe” actuator, comprised of a changeable actuated micro-vane with a synthetic jet for Professor Amitay’s transonic inlet duct facility. One fixed synthetic jet geometry will be combined with two interchangeable micro-vane geometries (rectangular and triangular). The team will designed and built test hardware in the wind tunnel to verify and quantify mechanical performance, including accuracy and repeatability of positioning. They also achieved satisfactory aerodynamic fit and finish, practical assembly, and leak tight operation.

Synthetic Jet ModulesProject Engineer: Scott M iller (Core Engineering), Chief Engineer: Richard Alben (Dept. of Mechanical, Aerospace & Nuclear Eng.)

Assembly – Right View

Screw Drive Actuator with Micro Vane Locator

Subassembly

Hybrid Flow Actuators – Isometric View

Semester Objective: Design and fabricate a “fail safe” hybrid actuator prototype with actuating micro-vanes. The assembly should allow for micro-vane positioning by swapping vane locators. It should also allow for switching interchangeable synthetic jets and steady jets modules.

Next Step: Demonstrate current apparatus to Northrop Grumman; submit design for analysis and testing.

Electrical Sensors

Purpose: Create a prototype which includes both passive and active devices that will be tested in a serpentine inlet duct. A reliable flow control actuator in an aircraft intake duct would be beneficial in delaying separation, and promoting turbulent flow.

Micro vane actuation is controlled by a Hall effect sensor. Electrical currents are measured through magnetic fields to calculate vane positioning.

Accomplishments: Designed and modeled a demonstration module of a micro-vane sub-assembly consisting of linear motors, sensory devices, and vane locators. Developed electrical circuitry to control vane actuation. Manufactured prototype completed to demonstrate actuationand to evaluate conceptual requirements.

Screw drive position actuator contains two micro-vane components to demonstrate

actuations accurately. Micro-vane locators can be switch for

positioning.

Subassembly – Exploded View

Micro-Vane Assembly

Hybrid Flow Control ActuatorsErika Schnitzler (MECL), Jeremy Betz (ELEC), Michael Flynn (MECL), Erik Sundberg (MS&E), William

Philippin (MECL), Yau Chan (MGMT), Daniel Johnston (MGMT), Brent Biederman (MECL), Andrew Tergis (ELEC)

Students working together in the shop.


SAIC consulting with the students on the progress of their project.


Computer Science & Communications

SAIC is a FORTUNE 500® scientific, engineering and technology applications company that uses its deep domain knowledge to solve problems of vital importance to the nation and the world, in national security, energy and the environment, critical infrastructure, and health.

Modern tools, such as email, IM, and Twitter, are supposed to improve workers’ connectivity and productivity. Yet, Basex reported that interruptions alone cost companies in the U.S. $650 billion per year.

Many organizations need a means to better manage electrically communicated information.

The SAIC IT group challenged the RPI students to come up with a solutions for engineers, particularly those who participate in multiple engineering projects, to manage their project related communication.

The SAIC team after presenting their power-point presentation.


Seniors find reaching for groceries and pushing a heavy cartmore challenging than it needs to be.


Improving The Lives Of The Elderly

In 2000 there were 18.4 million people ages 65 to 74 years old, representing 53 percent of the older poplulation. According to the US Census Bureau, those 85 years and over showed the highest percentage increase in population.

The mission of Albany Guardian Society is to improve the quality of life for seniors in the Capital District, of New York State.

The team designed, built, tested and refined a prototype shopping cart that improves the shopping experience for senior citizens.

Senior Friendly Shopping Cart Matt Forget (CSYS/ELEC), Matt Guilfoy (CSYS/ELEC), Adam Pasquale (ELEC), Brian Calderon (ELEC), Jim Smith (EPOW),

Jim McKenna (MECH), Jeff Caldwell (MECL), Rob Garstka (MECL, Tommy Cheng (MECL)

Project Overview Our main objective was to lessen the strains that a shopping experience places on a senior citizen by designing, building, testing, and re-fining prototype systems. Our customers (retail stores) need the cart and its subsystems to be cost effective and to improve the shopping ex-perience enough for senior citizens that it influ-ences their store choice.

Unique Handle Bar We found that an ergonomically designed handle bar would address common arthritic problems in seniors and mimic the feel of a walker to allow seniors to feel more comfort-able moving around with the cart.

Different Wheels Using rear wheels with a larger diameter we found we could reduce the average force on the user by up to 95%. This also gives us a smoother and more enjoyable ride.

New Basket Shape and Size To help increase mobility we created a shorter cart. This helps the ease of turning the cart. We also added a platform to rest hand baskets, a shallower main basket for easier reaching, and a slide out basket on the bottom for bigger items.

Braking System A braking system in the cart will provide security and safety for the senior. Having a cart that will not roll away and hit another person or a vehicle is a great plus. After pre-liminary testing, mechanical braking was preferred.

Drive System We experimented with force sensors and electric motors to help assist seniors move their carts around their place of business.

Subsystem Decisions In order to determine what areas to fo-cus on we surveyed many seniors and see what they wanted. Then we took these items, rated them by priority and difficulty, and created our subsystems. We decided to change the size of the carts, increase the mobility, the ergonomics, and general help-fulness of the cart. Our Decision Matrix is on the right.

Storage Box Many seniors wanted a safer place to put their bags or personal items. We decided to design a box to attach to the rear of the cart that can close protecting their items

Barcode Scanner . We wanted to help Seniors with vision problems read labels in the store. We ex-perimented with a barcode scanner to help assist this.

Subsystem Priority D fficulty Weight Score Cart Size 9.50 2.88 4 13.19 Mobi ity 8.00 5.88 5 6.80 Storage for Personal Property 4.63 2.50 3 5.56 Reading Lables 6.88 5.63 3 3.67 Outside Mob lity 5.25 7.88 3 2.00 Time Keeping 4.75 2.50 1 1.90 Difficulity Finding Items 5. 8 6.00 2 1.79 arge Gap in Child Area 5.13 2.88 1 1.78 ong Walking Distances 5.50 4.75 1 1.16

Carts Confusing 4.63 8.75 2 1.06 Seperating Carts 5.25 5.88 1 0.89 Multiple People Shopping 3. 8 4.25 1 0.80 Falling Over 4.13 6.25 1 0.66 Reaching High and Low Items 5.13 8. 8 1 0.61 Waiting For Check Out 3. 8 6.63 1 0.51 Transportation to and From Store 3.50 7.75 1 0.45

Project Engineer: Casey Goodwin (The Design Lab), Chief Engineer: Junichi Kanai (Electrical, Computer, & Systems Engineering Dept.)

ALBANY GURADIAN SOCIETY

A L B A N Y N E W Y O R K

Rick Iannello of Albiany Guardian Society discussing the project with Linda Schadler, Associate Dean of Academic Affairs


Students examining biometric circuitry built by the team.


BiometricsTeam: Jesse Herrmann1, Jus4n Toth1, Rob Margolies1, Sean Fleury2, Kevin SwiB2, Shannon Johnson3, Hannah Piontek3, Benjamin Scheiner3

Chief Engineer: Dr. Partha DuLa (ECSE); Project Engineer: Mr. Casey Goodwin (Design Lab)

1Electrical, Computers and Systems Engineering, 2 Biomedical Engineering, 3 Materials Science & Engineering

Objec&ve:To create an easy to use, affordable biometric measuring system thatintegrates mul4ple exis4ng sensors into a single noninvasive unit.

Benefits:Increases availability of physiological self-‐knowledge to all consumers.Removes price/knowledge restric4ons for physiological self-‐awareness.New approach to public health, connec4vity, and device marke4ng.

Accomplishments:Successfully built Microcontroller,Sensor, Power and Packaging systems.Integrated into cohesive device thatrecorded user’s biometric informa4on.Laid framework for future modular systems,adaptable to variety of markets.

Technical Results:Successfully completed major subsystems:

Plan:Iden4fy Target MarketConceptualize DesignBuild and Integrate SubsystemsSystem Tes4ng and Data Collec4on

Luminary Microcontroller

System WiringBaLery and Voltage Convertor

6070809000

110120130140150

60

1 26 51 76 101 126 151 176 201 226 251 276

Hea

rtRa

te(B

eats

/Min

)

Sample Number

Heart Rate

6070809000

110120130140150

60

1 26 51 76 101 126 151 176 201 226 251 276

Hea

rtRa

te(B

eats

/Min

)

Sample Number

Heart Rate

Biometric Subsystem Outline

Real-Time Vital Statistic Processing

The purpose of the Biometrics project was to design and deliver a non-invasive sensor system aimed toward the extraction and acquisition of data regarding the indicators of physical activity in the human body. Vital statistic processing was calculated as a function of output from various physical sensors integrated into a complete upper body article designed for convenience of motion. All data handling was managed by a Luminary microcontroller held in a pocket sewn into a pressure sleeve worn over the clothing and wirelessly networked to an Android based cell phone. The gauged vitals were then streamed to the phone over a Bluetooth link and output to the screen through a pre-installed application, providing a dynamic mechanism to display real-time vital statistics to the user so as to encourage both well-being and performance. The ultimate goal of this project was to make physiological self-knowledge easily accessible to all consumers, regardless of prior training and level of expertise through the communication of physiological process parameters in a logical, easily understandable manner.

Students assembling biometric monitoring circuitry.


Students discussing the sustainability rating of vaccum cleaner parts with their instructor Jeff Morris.



Rating Engineered Parts For Sustainability

“Sustainable development” can be defined as the development that meets the needs of the present without compromising the ability of future generations to meet their own needs [World Commission, 1987]. A sustainable product has a designed life cycle for the purposes of furthering its functional life or reclaiming its value for future products, so that minimal waste is generated.The current challenge for design methodologies is the assessment of measurable design parameters/metrics/attributes, where the designer has empirically obtained, or a priori knowledge of the quantities of these metrics.The current de facto standard is to perform a Life Cycle Assessment (LCA) on the product, which will evaluate the product’s environmental and human impacts from raw material extraction to its end of life treatment.Current research has addressed new product architectural design metrics that may better assess a product’s sustainability, but will need to support and baseline these metrics against current life cycle assessment methods (LCA), within the framework of an improper linear model (Dawes, 1979)

Design for SustainabilityKate Biagiotti (MGTE), John Cannarella (MECL), Pete Cassellini (MGTE), Andy Dubickas (MGTE), Maggie Exton (MS&E),

Michelle Pelersi (MS&E), Chasidy Perrin (ELEC), Saadia Safir (MECL)

PurposeTo provide product designers with a tool to use a guide during the design process that

accurately assesses a product’s overall sustainability

Previous Work: Fall 2009 MetricTotal Sustainability = Durability [Source + Manufacture + Transport + Disposal] + Use

MSI Material source indexMI Manufacture IndexTI Transportation IndexRI Reclaim IndexUI Use Index

Current Metric

Accomplishments• Improved the previous semester’s scorecard• Reverse engineered two products• Compared/contrasted scorecard to existing LCAs

Next Steps • Develop “serviceability” equation• Design an interactive web-based design tool

Project Engineer: Jeffery Morris (School of Engineering), Chief Engineer: Cheng Hsu (Dept. of Industrial & Systems Eng.)

Semester Objectives • Revise and validate previous model• Complete reverse engineering case studies• Develop a customer-friendly way of displaying

model results on products• Research ways of developing an absolute

model that can adapt with time (measured in dollars, stars, etc.)

UI Use Indexm Mass

Total Sustainability = Serviceability * [MSI + MI + TI + RI] + UI

UI = Product Specific Serviceability = To be determined

Left to right: Jeff Morris, Mark Steiner, Florine Cannelle of Northrop Grumman, Cynthia Shevlin and Bob Swanson.


Above: The Blind Assembly Team and sponsors, assemble for a photo. Below: The Students present to the Faculty and Sponsor, The Northeast Association of the Blind


Out Of Sight Solutions

The Northeast Association of the Blind at Albany (NABA) operates a small manufacturing facility employing blind and visually impaired workers, producing goods purchased by the State of New York.

These products include the orange safety vests used by workers during the 9/11 cleanup. Their mission is to increase the employment of blind and visually impaired while improving workforce productivity. Students studied the manufacturing facility and, working with the NABA staff, identified key areas to focus on.

The students then analyzed various machines and processes, selecting the most opportunistic for further work. Fixtures were then created to improve worker safety or to permit blind workers to perform tasks previously limited to sighted workers, thus extending employment opportunities.opportunities. The team will also complete projects started by previous teams.

Blind AssemblyMark Abrajano (MGTE), Omar Aguero (MECL), Ishan Gaur (MECL), Mike Gigliotti (MECL), Alex Lamparski (MECL),

Bradley Nelson (ELEC), Timothy Piemonte (ELEC), Joseph Skomurski (MGTE), and Spencer Wehnau (MECL)

Northeastern Association of the Blind at Albany

Floor LayoutFloor Layout

Deliverables• Electronic management system• 2D/3D Modeling management

system• Floor Layout Assessment• Work flow plans

Percent Floorspace

Necktab

702 Vest

Othe Vest

Othe Proposal• Vertical (stream-lined) work flow• Incorporation of 702 vest line• Improved space management• Enhanced maneuverability

0

50

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Cu ent P oposed

Annual Product on (Units n Thousands)

0

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Cu ent

Necktab Production(Units Per Day)

Opportunity• Inefficient production line layout• Horizontal, scattered product lines• Prolonged idle time between

processes

JUKI FixtureJUKI FixtureAllows a blind laborer to side-seam a necktabPrevious Design Flaws• Back plate was warped and too thick• Back plate was poorly attached• Latch was large and obtrusive

Solutions• Construct a thinner back plate from Kydex plastic• Use adhesive to attach back plate• Fabricate a smaller latch

Project Engineer: Mark Anderson (The Design Lab), Chief Engineer: Richard Alben (Dept. of Mechanical, Aerospace & Nuclear Eng)

New Press for New Press for TyvekTyvek Line & Electrical Line & Electrical Process Opportunities Process Opportunities

Tyvek Press • Create documentation for new pneumatic Tyvek press• Palm button safety feature for new Tyvek press

Necktab Quality Control• Uses Labview software to measure necktabs• Program will be connected to webcam • Will enable blind worker to manage quality

control for necktab line.

ISO 9001ISO 9001ISO 9000 Gap Analysis StepsISO 9000 Gap Analysis Steps• Plan out a Gap analysis • Schedule the Gap Analysis • Conduct the Gap Analysis• Summarize the findings and create a repor• Fill the gaps where the criteria is not met

Quality Management System (QMS) Pyramid

Proposal• Create Quality Management System• Help design Quality Manual• Improve existing Standard Operating

Procedures

Gap Analysis Checklist• Quality Management System• Management Responsibility• Resource Management• Product Realization• Measurement, Analysis and Improvement

• Work flow plans

Sponsors and Faculty critique the students at the presentation.


One of the students on the team, that designed a mechanism to balance a ball at a specific position, quickly and smoothly.


Engineering Students On The Ball

The goal of this project was to develop a series of laboratory experiments that will provide instructors with an outline for the teaching of mechatronics topics through hands on activities.

The team was to design and build a ball balancing system prototype, capable of bringing a ball to rest within 5 millimeters of a specified point, measured from the specified point to the point of contact between the ball and plate, in no more than 2 seconds.

The intent of the assignment was to have the device be used as is, or tailored to the instructor’s preferences and aid in the teaching of mechatronics subjects.

Ball Balance System

Joshua Hurst (Dept. of Mechanical, Aerospace & Nuclear Eng)

Purpose and Objectives

Purpose

The team aims to provide a set of educational tools for the study of mechatronics by

producing an intuitive Ball Balance System that can reliably bring a ball to a desired

position quickly and smoothly, as well as by creating a series of laboratory experiments.

Current Semester Objectives

• Create a ball balance system prototype

• Write 4 laboratory experiments that can be completed within a two-hour class period:

• Introduction to microprocessors

• Introduction to encoders

• Open loop position and speed control

• Closed loop position and speed control

Physical System

Accomplishments

LabVIEW Controls

Camera

A camera is used to track the ball using object tracking algorithms

then position algorithms translate the image of the ball into relative

coordinates on the plate. The properties of the tracked object can be

changed depending on the object.

Touch Screen

A resistive touch screen is used to track the position of the ball. The

pressure from the ball creates a resistance on the touch screen which

then in turn creates a change in voltage which can be translated into

the current position.

Interactive Wii Remote control

A Wii Remote can be interfaced to a computer

using Bluetooth™. A LabVIEW interface is

used to read the movement of the remote.

X and Y plane actuation of the plate can be

controlled with a Wii Remote through the roll

and pitch, respectively, by directly changing

the angle of the motors.

Next Steps and Design Changes

• Electrical failsafe cutoff switches

• Rework mathematical models and simulations with design changes

• Optimize design (mechanical and control systems)

• Potential add-ons (similar to Wii Remote)

Technical Results

Mathematical models were derived for both [1] the motor/

plate dynamics and [2] the ball dynamics:

Motor properties were tested to accurately model the system.

This plot shows the torque of the

motor vs. the velocity. Using this

graph we derived the viscous and

coulomb friction coefficients.

The time constant of the motors were also derived by testing

and finding the step response of the motor.

Base plate dimensions 20” x 20”

Plate dimensions: 13.875” x 11”

Camera Arm Height: 26.5”

Stephen Andrus (MECL), Bennett Bishop (CSYS), Andrew Calcutt (CSYS), Robert Chang (ELEC), Joseph Internicola (ELEC), Jonathan Prout (MECL), Lord Tamas (MECL),

Laboratory Experiments

Four laboratory experiments were completed using the Teensy

ATmega32U4 microprocessor.

These labs were implemented to teach students about open and

closed loop control system responses.

Close-up view of actuation system

National Instruments LabVIEW is

used to implement the control

system and interface all sensors

using NI software and NI DAQs.

A GUI was also created to input the

desired ball position.

[1]

[2]

Underside view of the Ball Balance Apparatus.


Above: Student reviewing the posters at the 10th anniversary celebrationBelow left: Professor Eglash teaching students in Ghana. Lower right: The Actual Biomass Scope Device.


Energy For Global Impact

KNUST University was interested in researching the energy potential of biomass streams within regions of Ghana. A quantitative and qualitative analysis provided data for educational purposes to the university as well as the local residents. The goals for this project were to design a portable device which evaluates the energy content of biomass and waste streams for energy production while providing educational value to local students and citizens of Ghana. The device was cost effective to build, operate, and maintain and data was collected though calibrated instruments that provided accurate readings of tested materials. These instruments were selected based on their availability in Ghana and for ease of replacement. Considerations were given to cultural, environmental, and socio-economic impact, including but not limited to profit, religion, and politics. Summer students implemented the device in Ghana and tested various biomass streams in the region; this information was then applied to a waste to energy conversion process for future educational use. Upon the return of the summer students, KNUST was able to continue ongoing testing.

Biomass Scope StudyAlex Camhi (MGTE), Eric Chapin (MECL), Linda Donoghue (MECL) , Jesse Kenyon (MECL), Zachary Loya (MECL),

Christine O'Rourke (ELEC), Raymond Pinto (MECL), Alex Updegrove (MECL)

Our job is to design a portable testing device which evaluates the energy content of biomass and waste streams for energy production while providing educational value to the local students and citizens for development in Ghana. The device should be cost effective to build, maintain, and operate, and meet cultural, environmental, and socio-economic requirements.

KNUST & RPI

Gas Generation Gas Collection and Delivery Gas Analysis

•Gas Production (dry wood): 330-340 L/kg•Operating Temperature: 400-500°C

•Rotameter Range: 0-4 L/min Air•Orifice Size: 0.089”

Project Engineer: Gregory Hampson (Dept. of Mechanical, Aerospace & Nuclear Eng), Chief Engineer: Daniel Lewis (Dept. of Materials Science & Eng.)

Accomplishments:•Fully functioning testing device•O&M Manual•Test Plan

Next steps:•Testing and Data Acquisition•Field testing in Ghana

Full System

•Operating Temperature: 400-500°C•Volume: ~71 in^3•Input Fuels: agricultural, municipal, wood waste

•Capacity: 1.357 Liters• Check Valve Required Pressure: ≥ 0.1psig•Flow rate: 1.5L/min for 54 seconds, 1.3 psig• Bucket: Height adjustment offers variable flow rate

•Orifice Size: 0.089”•Sustained Flame Height (H2): 0.7” @ 1.5L/min• Flame Shield: Protection from wind

Visitors from KNUST listening to Professors Steiner .


Learning Design From Ancient Cultures

The goal of this project was to design and create at least one device which uses concepts presented in Ron Eglash’s Culturally Situated Design Tools website.

The focus for this semester was on the development of a device that can help demonstrate and teach the mathematical aspects of the arcs used by the Anishinaabe Native American tribe to make wigwams. The learning opportunity also included an attempt to develop a similar device or method relating to shapes and patterns found in pre-Columbian pyramids. This project targeted middle to high school students, especially those of particular ethnicities, in an attempt to connect with them through culture in order to illustratemathematical concepts inherent in the work of Native Americans and the builders of the pyramids.The project ultimately produced a unique type of learning instrument.

Culturally Situated Design Tools: Anishinabe ArcsTeam: Hannah Porteous(MECL, DIS), Ruby Ramirez(ELEC), Andrew Dobras (MGMT), Jason Bernardo(MECL, DIS)

Purpose:To combine software and congruent physical modeling to create a hands-on learning experience that integrates cultural backgrounds and mathematics

Project History:The Culturally Situated Design Tools website uses web based design tools to teach arithmetic through the identification of mathematical concepts pre-existing in indigenous cultures.

Semester Objectives :To create system capable of converting the Anishinaabe

Technical Results :Functioning Java Applet Set of equations which

converted output into useful form

Predrilled plastic base Styrofoam base that make be kept by the user

converting the AnishinaabeArcs software designs to physical models.

Accomplishments:Devised a working method of taking the arc data received by the original software and converting it into a printable document that provides the information necessary to build the physical model. The system was able to be tested on students and resulted in a noticeable gain in knowledge.

Next Steps:• Further testing and implementation into classroom use• Create the fixed base to be more user friendly and individualized

• Smaller bases and lesser costs• A program for kids to design and drill their own boards

• Create a working model that integrates the LED design concept into the fixed base model

• Begin to create systems that convert that convert other CSDTs into physical models

Project Engineer: Junichi Kanai (Dept. of Electrical, Computer, & Systems Eng.) , Chief Engineer: Ron Eglash (Dept. of Science & Technology Studies)


Tracking & Preserving Predatory Species

In the conservation areas within South Africa, there have been issues in monitoring and tracking the movement of various predatory species such as the leopard.

As the proximity of man to leopard increases there have been issues where livestock has been killed by the animals. Simply killing leopards does not provide a sound ecological solution to the problem. Scientists thus require research tools while farmers may require systems to help protect their farms. Rensselaer students worked in collaboration with Stellenbosch University in South Africa to understand the problem and identify areas for study.

A team of Rensselaer students created two prototypes – one to indicate the proximity of leopards and another to both warn the livestock and deter the leopard.

Team: Chris Brown (ELEC), Jack Gibson (ELEC), Morgan Graybill (ELEC), Adam Karlewicz (ELEC), Zack Kaye (ELEC), Stephanie Livsey (ELEC, CSYS), TJ Reale (CSYS, CSCI), Dennis Zhang (ELEC)

Wild Animal Detection and Repellant Systems

Predatory animals, specifically leopards and jackals, pose a threat to livestock on farms in South Africa. Current methods for controlling the predators rely on firearms and traps reducing the population. These detecting and repelling solutions provide a base system in providing proof of concept to repel predators from farm areas.

System Visualization

Detecting Unit

Detection Threshold

Repellant BeaconsFarm Area

Infrared Detection System oDetect animals up to 100m awayo Program for user interaction and

Ultrasonic Repellant Systemo Output noise level of 120dB at 50mo Adjustable output frequency band

Semester Objectives:Ultrasonic Repellant System

A Chebyshev high pass filter and op

10 15 20 25 0 35 40 45 50 55 60

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Max Ra ge f Tr nsmis ion f ) vs R ce ver O fs t in Deg ees

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One ra sm t ng IR LED

Two Tr nsm t ng IR LEDs

Th ee Tra sm t ng IR LEDs

Transmitting IR LED& Circuitry

IR detector & Circuitry

Measuring Tape (Length varied by tester)

θ

Technical Results:

Infrared Detection SystemA test bed was created to characterize detector and emitter performance.

Background investigation on current practices using RF collars lead to a creative alternative approach combining first the detection of the animals and then the use of repellant systems to manage their behavior.

Detection System Block Diagram Repellant System Block Diagram

o Program for user interaction and visualization of predators in the areao Cost less than $200.oo USD

o Adjustable output frequency bando Power consumption of less than 500Wo Cost less than $300.00 USD per unit

Infrared Detection System oDetect an object up to 22.6m awayo Program for user interaction o Cost less than $100.00 USD

Ultrasonic Repellant SystemoOutput noise level of 100dB at 10m (calculated)o Adjustable output frequency bando Power consumption of 13W for systemo Cost approximately $100.00 USD per unit

Accomplishments:

Project Engineer: Mark Anderson (The Design Lab), Chief Engineer: Partha Dutta (Dept. of Electrical, Computer, & Systems Eng.);

Ultrasonic Filter Frequency Response

A Chebyshe high pass filter and op amp power amplifier were successfully developed and implemented.

Future System DesignLong term enhancements of the system will yield power efficient and accurate repellants and tracking systems such that the system can enhance the performance of the system including:

•Increased species variability for tracking and repelling systems•Increase the tracking and repelling range•Integrated tracking and repelling systems•Explore alternative attachment methods of the infrared transmission system•Use alternative sources of energy such as solar or wind•Network the repellant systems for increased control and variability•Adapt the systems to different environmental factors.


DESIGN LAB STAFF

Mark Steiner, Ph.D.Director, Clinical Professor

Junichi Kanai, Ph.D.Associate Director, Clinical Associate Professor

Barry SteinBusiness Development Manager Guest Lecturer

Mark AndersonProject Engineer

Charles “Casey” GoodwinProject Engineer

Aren PasterProject Engineer

Scott MillerProject Engineer

Rich Alben, Ph.D.Clinical Associate Professor

Valerie MastersonAdministrative Specialist

Jeff Morris Technical Manager, CAD/CAM/CAE

Scott YerburyElectromechanical Technician

Sam ChiapponeManager, SoE Fabrication and Prototyping Facilities

Biomedical Engineering

Eric Ledet, Ph.D.Assistant Professor

Electrical, Computer & Systems Engineering (ECSE)

Lester Gerhardt , Ph.D.Professor

Biplab Sikdar, Ph.D.Associate Professor

Partha Dutta, Ph.D.Professor

Ken Connor, Ph.D.Professor

Industrial & Systems Engineering

Charles Malmborg, Ph.D.Department Head, Professor

Cheng K. Hsu, Ph.D.Professor

William J. Foley, P.E., Ph.D.Clinical Associate Professor

Mechanical, Aerospace&Nuclear Engineering (MANE)

Michael Amitay, Ph.D.Associate Professor

Michael K. Jensen, Ph.D.Professor

Deborah A. Kaminski, Ph.D.Associate Professor

Matthew A. Oehlschaeger, Ph.D.Assistant Professor

Materials Science Engineering

Daniel Lewis, Ph.D.Assistant Professor

Rahmi Ozisik, Ph.D.Associate Professor

John LaGraff, Ph.D.Adjunct Professor

AFFILIATED FACULTY

Left to right: Partha Dutta, Dan Lewis and Casey Goodwin.

Sam Chiappone


About The Design Lab

Our Mission The O.T. Swanson Multidisciplinary Design Laboratory (The Design Lab) is to provide clinical real-world experiences for undergraduate students that build confidence and teach integration of discipline-specific knowledge with practice on challenging multidisciplinary design projects. The Design Lab joins together a multitude of resources, programs, courses, curriculum, and people that have lead to Rensselaer’s recognition by Business Week magazine as one of the top 60 design schools in the world!

Providing Real World Experiences for StudentsOver 400 senior engineering students from aerospace, biomedical, computer systems, electrical, electric power, industrial, materials, and mechanical engineering work on sponsored projects each year. Sponsors bring their problems to us and we match students to their projects. Every semester students work on a vast array of multidisciplinary design projects involving product concept and prototype development, design analysis and optimization, process improvement, automation and test equipment, energy and health systems, logistics management, entreprenuerial ventures, and information technology.

Integrating the Social Sciences into the Engineering CurriculumWe continue to play a leadership role in the Interdisciplinary Program in Design and Innovation (PDI). Faculty and staff affiliated with the Design Lab teach in studio courses, mentor future entrepreneurs, and serve as academic advisors for most of the students who are currently enrolled in this exciting program.

Bringing Cutting Edge Software to the InstituteThe Design Lab continues to lead the Institute’s PACE initiative by providing the entire campus community with advanced engineering, design, and management related software through our affiliation with the Partners for the Advancement of Collaborative Engineering Education (PACE).

Turning Ideas into RealityThe Manufacturing Network at Rensselaer (see http://www.eng.rpi.edu/manufacturing/ ) is an integral part of the Design Lab at Rensselaer. Every semester students in The Design Lab have hands-on experiences in the Haas Tech Center and Advanced Manufacturing Laboratory.

Changing the World for the BetterEvery semester over 330 engineering students help to “Change the World” for the better in the Design Lab by participating in team projects as part of the Introduction to Engineering Design course. Working in collaboration with Rensselaer’s Archer Center for Student Leadership, the Design Lab prepares students for their capstone design experience, teaching them about teamwork, communication and the design process.

A Forum for Invention and EntrepreneurshipEvery semester engineering students learn about business and innovation in the Design Lab on their projects. Our projects have planted the seeds for numerous patents and entrepreneurs who have started new businesses.

Supporting the Research Mission through Innovation & DesignWe continue to magnify the impact of our corporate sponsorship by uniting with research centers and faculty on campus. Our affiliations include The Center for Automation Technologies and Systems and the Lighting Research Center at Rensselaer.

Our VisionOur vision is to become a “A leading world class engineering design program, acclaimed for producing exceptionally resourceful graduates, who are driven to achieve technical excellence and innovation.”


Special Thanks To Our Sponsors For Their Generous Support

• Albany Guardian Society• Albany International Corporation• Barclays• Boeing• Comfortex• DRS Power Technology• General Dynamics / Electric Boat• General Electric• General Motors• Gerber Technology• Hamilton Sunstrand / UTC• Harris Communications• Hearst Corporation• IBM• Lockheed Martin• MicroAire• Monotype Imaging• Morgan Stanley• National Instruments• Northeastern Association of the Blind (NABA)• Northrop Grumman• NY State Department of Environmental Conservation• New York Independent System Operators (NYISO)• Pitney Bowes• SAIC• Schick/Energizer• St. Peters Healthcare• WMS

Rensselaer Polytechnic InsitiuteSchool of Engineering

O.T. Swanson Multidisciplinary Design Laboratory110 8th Street

JEC 3232Troy, N.Y. 12180-3590 ISA

http://DesignLab.rpi.edu

518.276.6746

Photo credit: Rensselaer / Barry Steinrev. 02102011

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