DESIGN MOX 400 2006

Mr NDL Burger, danie.burger@eng.up.ac.za

Room 8-7, Eng 1 Tel.: 012 420 3764

1. Design of a grader (DB,PdW) It is expected of the student to design a detachable grader to be mounted inside the

bucket of a small LHD. The LHD has a breakout force of 4000 kg and the maximum

pushing force of the machine is 4500 kg. The attachment must be fitted to the existing

bucket with the minimum modifications. If the grader attachment is detached the bucket

must still be able to function in its normal way

2. Design of a safe operating platform for Continuous Miner operators (DB) During this design a safe platform must be designed on which the CM operator can be

placed during a shift. The platform must of such a nature that the operator is out of

harms way regarding the shuttle cars, electric cables and roof bolters. The weight of the

remote control must also be supported.

3. Design of a roof rake (DB) This design covers the development of a system that will be able to be mounted on the

inside of the bucket of an eimco loader. The system must be able to rake the roof of a

coal mine to get rid of all loose rock, similar in manner as a plough in a normal

agricultural application.

4. Scrubber for CM (DB/JD) Design a scrubber system to be fitted on a CM for extraction of dust. The dust is

generated during the normal cutting of coal. The dust is also spayed with water during

the cutting process to try and cut down on the amount of dust generated.

5. Design of system to measure ventilation in a shaft (DB/JD) Design a system to measure ventilation in a shaft in a coal mine. The system must be of

such a nature that it can be operated remotely over a distance of 15 m as this is the

distance from the last line of support to the front of the coal face. The wind speed in

question is between 0 and 1.4 m/s

6. Design of a system to extract CM after the goafing operations (DB) During goafing operations the pillars in board pillar mining is also cut and the roof is

allowed to collapse. It happens from time to time that the fall in unpredictable and the

CM actually gets trapped under about 80m of gravel. During the recovery a tunnel must

be dig to the CM to attach a cable to allow recovery of the CM. This is an extremely

dangerous process and a system must be designed that will allow the operators to reach

the machine in safety.

7. Design of a MPV cassette (DB,PdW) Design a MPV cassette to carry a load of 3000 l of lubricants and diesel. The cassette

must be interfaced with an existing MPV vehicle of which the interfacing points will be

provided. The cassette must be lower that 1.2m and not wider than 1900 mm.

8. Design of a ROPS frame for a Toyota Hilux pick up (DB) Design a ROPS frame (roll over protection system) to be fitted to a Toyota Hilux pick-up.

For this design the student will have to get all the relevant specifications as well as to

design the integration points with the vehicle

9. Design of a scissor lift (DB,PdW/JD) Design a scissor lift to be able to lift a weight of 2000 kg over a distance of 2 m. The

working platform must be 3 x 1.6 m with standard handrail all round to protect the

workers from falling off. The base machine is excluded from this design but the

stabilizing legs are included.

10. Design a lifting bucket for 2 persons to be fitted to Eimco loader (DB,PdW/JD) Design a lifting bucket to lift 2 people. The system must be able to be fitted to the bucket

of an Eimco loader in the coal mines. The system will be used to enable routine work

such as light maintenance in the roofs. The system must be able to remain horizontally

over the complete lifting range.

11. Design of a rhome plough 12. Design a gravity tensioning device for a chairlift (PdW) Chairlifts use different devices to keep a minimum tension in the rope. One of the more

popular means is to use a weightstack to tension the rope. Design a tensioning device

using a weightstack and gravity to tension the rope.

13. Design a method for indicating the amount of pre-load on the roof support systems (Burger/Dirker)

The student must design a method that can be manufactured and installed on the roof

support system to give a real time indication of the load on the system. The system must

be able to handle 10 ton.

14. Design a resin tester for testing epoxy resins in a spin to stall application (Burger/de Wet)

Design a system that will allow the quick testing of spin to stall resins to ensure the

quality of the resin. The spin speed must be 250 rpm and the fee must be 100mm/sec

constant. The machine must preferably accommodate standard roof bolts during testing.

15. Develop a system for lowering mine skips remotely from hoisting system (DB)

Hoisting accident is one of the major causes for injuring people during the transportation

of material. One of the major causes is the fact that the skips are constructed with two

decks. The decks are unloaded separately. This means that after the one deck has

been off loaded the skip must be lowered before the second deck can be off loaded.

This lowering is currently done with signals from the banksman to the driver in the winder

house. A mechanical system must be designed to lower the skip under more controlled

conditions. (Run in combination with Project)

16. Design of an adjustable orifice sphere discharge setup to be used to characterise bridge formation conditions (JD)

The flow of spheres though circular orifices have been well documented. Sphere

blockages are caused due to bridge formations. Design specifications exist to prevent

such blockages for circular orifices. An adjustable set-up is required with which

experimental data can be gathered from which design specifications can be drawn up for

non-circular orifices. The set-up requires accurate time dependent mass balance

measurements during experimental discharging of small spheres. (This project is linked

to a project investigation)

17. Design of a lightweight plastic gearbox to be used with the rock fall roof support

system (Burger/de Wet) Design a gearbox that enables the operator to generate 800Nm of torque to preload the

rockfall roof support system. The gearbox must lightweight, preferably plastic, and the

input must be driven by hand. A time study will be necessary to enable the designer to

determine the allowable ratios.

Mr DJ de Kock djdekock@postino.up.ac.za

Room 9-16, Eng I Tel.: 012 420 2448

Prof KJ Craig ken.craig@eng.up.ac.za

Room 3-32, Eng II Tel.: 012 420 2053

1. Design of continuous caster tundish impact pad for improved transient behaviour (Design and Project)

The previous research on impact pad design optimisation for steady-state performance

is to be extended to design an impact pad (turbostop) with improved transient behaviour

during ladle transitions. The designer will become proficient in the use of CFD software

as applied to transient free-surface simulation.

Project

Build and test continuous caster tundish impact pad for improved transient behaviour

The designed impact pad is to be manufactured and tested in the Columbus Tundish

water model at the University of Pretoria. Results obtained in the design phase are to be

verified experimentally. Further CFD simulations will be required to validate the design

for different casting conditions, including performance with an increased tundish volume.

2. Design of automotive fuel tank for impact and sloshing (Design and Project) The work on fuel tank sloshing optimisation performed during the last few years is to be

applied to a realistic geometry automotive fuel tank. Of interest is the performance of the

fuel tank in full frontal, side and rear impact scenarios as described in the relevant safety

tests. The fuel tank also has to meet low noise emission specifications during stop-and-

go manoeuvres. The designer is expected to use CAD, CFD and dynamic modelling

simulation (LS-DYNA) software as tools.

Project:

Build and test automotive fuel tank for impact and sloshing

The designed automotive fuel tank is to be manufactured (with emphasis on

visualisation) for testing and verification of the design results. The test setup for both

impact and sloshing needs careful consideration for both accurate measurement and

repeatability. Further CFD and LS-DYNA simulations will be required for validation based

on test measurements.

Mr PR de Wet flip.dewet@eng.up.ac.za

Room 8-6, Eng 1 Tel.: 012 420 2428

See NDL Burger

Dr J Dirker jaco.dirker@eng.up.ac.za

Room 8-9, Eng 1 Tel.: 012 420 2465

See NDL Burger

Mr PS Els schalk.els@postino.up.ac.za

Room 10-11, Eng I Tel.: 012 420 2045

1 Mini Baja ride comfort (car 13) (Design and Project) The purpose of this project is to simulate and improve the ride comfort of the Baja. The

student will have to master the ADAMS multi-body dynamics package. This study is of

critical importance for improving the Baja. A diligent candidate is required that can stay

ahead of the Baja schedule.

Design outcome:

Design front and rear suspension with respect to kinematics and strength. The front

suspension must take the steering system into account and the rear suspension must

accommodate the drivetrain.

Project outcome:

Dynamic modelling of ride comfort of the Baja using ADAMS. Verify the simulation model

against test data. The primary goal is to make the car jump over high obstacles and

ensuring a safe landing. This includes optimisation of the spring characteristic, damper

characteristic and centre of mass position.

2 Mini Baja handling (car 13) (Design and Project) The purpose of this project is to simulate and improve the handling of the Baja. The

student will have to master the ADAMS multi-body dynamics package. This study is of

critical importance for improving the Baja. A diligent candidate is required that can stay

ahead of the Baja schedule.

Design outcome:

A hydropneumatic spring-damper system must be designed. The design must be an

improvement on the current component. The redesigned unit must be cheap, lightweight,

reliable and compact. The design must make provision for external adjustability of both

the spring and damper characteristics without opening the unit. Design for mass

production is required to lower cost.

Project outcome:

Dynamic modelling of handling in ADAMS. Verify the simulation model against test data.

The main object is to improve handling of the Baja during the handling test. This includes

optimisation of the spring characteristics, damper characteristics and centre of mass

position.

3 Mini Baja drivetrain (Project) The Mini Baja is powered by a 7,5 kW Briggs & Stratton overhead cam engine. In 2004,

a hub reduction gearbox was successfully used in conjunction with a continuously

variable transmission (CVT). The hub reduction was redesigned and improved in 2005.

Project outcome:

Manufacture the redesigned hub reduction, implement the design on a Baja and perform

tests to determine the performance. Determine the useful life and efficiency of the hub

reduction gearbox.

4 Mini Baja continuously variable transmission (Design and Project) The continuously variable transmission (CVT) used on the Bajas was investigated

extensively during 2004 and 2005 in an attempt to improve and optimise the

performance and efficiency.

Design outcome:

A cover must be designed using composite materials. The cover must be air-tight. The

design must look at air flow and cooling, and must comply with the equivalency

specification stated in the Mini Baja rules. The emphasis is on weight and the energy

that can be absorbed should any component of the CVT fail at high speed. Cost and

manufacturability is very important.

Project outcome:

Mathematical models of the CVT were developed during 2004 and 2005 using different

approaches. An ADAMS model, as well as an empirical model exists. Both these models

have advantages, but also drawbacks. The aim is to combine these models in an

attempt to develop a useful model. The model must be verified against test data, and

used to optimise CVT performance by determining required spring stiffness, flyweight

sizes and geometry.

5 Mini Baja brake mastercylinder (Design and Project) The Baja rules require two completely independent brake circuits so that at least two

wheels can still be braked if one brake circuit fails. The front and rear brake circuits must

therefore function independently but must be connected to one brake pedal.

Design outcome:

Design a two-channel brake mastercylinder with two independent reservoirs and pedal

assembly. A brake light switch must be incorporated as well as a method to easily adjust

the front/rear brake balance. Weight, reliability and manufacturing are important

considerations.

Project outcome:

Implement the design on a Baja and develop a mathematical model that takes both

hydraulic and mechanical aspects into account. Perform brake tests to determine the

effectiveness of the master cylinder, as well as to validate the model.

6 Pipe profile cutter (Design and Project) When manufacturing a Baja frame or suspension wishbones, many pipes have to be cut

at different angles. These pipes must fit properly onto each other to get a strong weld

joint. Currently each pipe is cut individually on a milling machine using an endmill or hole

saw. Laser cutting is a much more elegant solution, but it is expensive and has a long

lead time.

Design outcome:

Design a piece of equipment to cut pipes quickly and cost-effectively in the Universitys

workshop according to any prescribed profile. The equipment must preferably be

controlled numerically so that pipes can be cut directly from a CAD file.

Project outcome:

Implement and build the equipment. Verify operation of the equipment. Develop an

interface between the CAD system and the equipment.

7 Improvement of ride comfort and handling of car 20 (Design and Project) The purpose of this project is to simulate and improve the ride comfort and handling of

car 20 using ADAMS. The student must become familiar with ADAMS modelling. This

project is of critical importance to the performance of the Baja in the competition. A

diligent and reliable student is required who will stay ahead of the Baja schedule.

Existing suspension and drivetrain components must be preserved. The focus is on

optimising the existing system within the current design. The idea is therefore to

dramatically improve the dynamics, without significantly changing the tried and tested

design.

Design outcome:

Redesign the existing front and rear suspension with respect to kinematics and strength.

The front suspension must take the steering system into account while the rear

suspension must include the drivetrain interfaces.

Project outcome:

Dynamic modelling of the ride comfort and handling of the Baja over rough terrain using

ADAMS software. Verify the ADAMS model against vehicle tests. The focus is on

improving ride comfort and handling during the endurance race. Spring characteristics,

damper characteristics and centre of mass position must be optimised.

8 Mini Baja gearbox (Design and Project) The existing chain drive on car 20 is bulky, heavy and not very reliable. This project must

develop a new gearbox concept not previously used on a Baja, for the 2006 competition

season.

Design outcome:

A new gearbox design that will improve on current concepts in respect of reliability and

weight.

Project outcome:

Implement and test the gearbox design. Determine the effect of the improved gearbox

design on the Bajas performance by comparing test results to a mathematical

performance model of the Baja.

Prof PS Heyns sheyns@postino.up.ac.za

Room10-8, Eng I Tel.: 012 420 2432

dr S Kok schalk.kok@up.ac.za

Room 10-10 Tel.: 012 420

1. Shear test module Design experimental equipment that can be used to perform shear tests on a standard

uniaxial tensile test machine. The experimental apparatus has to be able to provide a

shear stress vs. shear strain curve, from initial elastic loading, though plastic yielding to

final failure. At least force (or moment) and displacement (or angular displacement) have

to be measured.

2. Wheelchair swing Design a wheelchair swing for wheelchair bound children. The swing must accommodate

the child in his/her wheelchair. Provide a lockdown mechanism to prevent the wheelchair

from falling out/off the swing. The safety of the child is the most important design

criterium. Wheelchair bound persons cannot comfortably and safely reverse, therefore

the swing has to be entered from the rear and exited at the front. If at all possible, design

the swing such that an able-bodied companion is not required for the swing to function

properly.

3. Reconfigurable wheelchair Design a wheelchair that can reconfigure to a standing position. This allows the

occupant to occasionally take weight on his/her legs (which prevents osteoporosis) and it

helps to prevent bedsores (skin lesions due to sustained pressure on the same point).

Consider manual (preferable) or hydraulic actuation of the system. The seat of the

wheelchair reconfigures to provide support at the hips. After reconfiguration, the

occupant is in a standing position, with his/her feet still in the footrests of the wheelchair.

Combined topics: Design and Project

4. Mini-baja frame The existing frame on the Mini-baja has to be replaced. A new lightweight frame, on

which the other components are mounted and which possesses the required structural

properties has to be designed. The frame has to comply with all the 2006 Mini-baja rules.

The frame has to be built and subjected to an impact test.

Design outcomes:

A new frame has to be designed that complies with all the Mini-baja rules. The impact

test has to be analyzed.

Project outcomes:

Build a prototype of the designed frame. Verify the results of the impact analysis. Subject

the frame to an impact test and implement improvements. Build the improved frame for

use in the Mini-baja.

5. Pipe bending machine A pipe bending machine has to be designed and built, which can be used to bend pipes

required for the Mini-baja frame. The machine has to capable to bend 32mm outer

diameter mild steel pipe with a 1.6mm wall thickness, without buckling or pinching.

Design outcomes:

Design a pipe bending machine that satisfies the user requirements.

Project outcomes:

Analysis of the bending process, material properties, plasticity models and springback.

Verify these analyses with experiments. Bend pipes for use in the Mini-baja frame.

6. Beam bending experiment Design experimental equipment that permanently deforms a thick plate. The deformation

mechanism must be as simple as possible, to allow accurate modelling of the test.

Design the system such that the effects of friction are negligible. Allow for the

measurement of at least force and displacement. Ensure that the elastic springback can

also be measured accurately. Incorporate some mechanism to visualize the deformation

e.g. a fine grid of points on the surface of the beam.

Design outcomes:

Design of the experimental apparatus.

Project outcomes:

Analysis of the bending process, material properties, plasticity models and springback.

Verify these analyses with experiments.

1. Prof L Liebenberg lieb@up.ac.za Room 9-9, Eng 1 Tel.: 012 420 2192

1. Design of a Wind-powered Model Gyrocopter To design wind-powered model gyrocopter for use as a toy. The gyrocopter should be able to operate at low wind speeds and be line-

controllable. Design process to make use of commercial-strength wing simulation package,

Profoil, as well as simulation packages X-Foil, DesignFoil, and the Virtual Wind

Tunnel software. Complete design drawings of the aircraft body and rotor system are required.

2. Design of Human Powered Vehicle (HPV) To design a recumbent bicycle for an HPV capable of reaching 125 km/h, wind-

unassisted. This project will only focus on the design of the bicycle, and not on the fairing

(which has already been designed). Complete drawings of the specialised geartrain will be required. In addition,

complete design drawings of the tubular framework are required. The Cheetah HPV, designed and built by MIT, holds the previous 200m-world record: 110.6 km/h

3. Design of a High-Speed Alternator Design of a high-speed (120,000 min-1) alternator for coupling to a 5 kW gas

turbine (turbo-shaft). The design will involve the selection of robust, high-magnetism permanent

magnets, rotor design, bearing design/selection, and shaft design. FEM analysis of the rotor is a pre-requisite. Detail drawings of the rotor and shaft are required.

4. Design of a 5 kW turbo-shaft gas turbine Design a small (10kW) turbo-shaft type of gas turbine, to be employed as prime

mover for a high-speed electrical generator.

The design will concern itself with the full analytical detailing of the gas turbine (i.e. compressor and turbine sections), and detail drawing of the turbine section (an off-

the-shelf compressor unit will be used). An off-the-shelf combustor will be used.

5. Design of the landing gear for a Robust Mini-Unmanned Aerial Vehicle Detailed analysis and design of the landing gear for a re-usable mini-UAV that

should be able to take-off and land in a rugged terrain. The mini-UAV will be used

for wildlife management.

The aircraft will have a wingspan of around 2m, with about the same fuselage length; it will weigh around 5 kg.

The aircraft payload will comprise of sensitive electronics and camera equipment.

6. Design of a modular biltong drying machine Design a beef biltong drying machine, based on a vapour compression cycle. There is a need for a machine that can produce safe and nutritious biltong in a

fast and energy-efficient manner.

The machine must be able to accommodate 180 kg of beef at any one time. The design should include the detail specification of the vapour compression cycle

(e.g. compressor, condenser, expansion valve, evaporator, solenoids, tubing,

refrigerant), as well as the design of the cabinet and associated support structure.

Dr AG Malan arnaud.malan@eng.up.ac.za

Room 9-17, Eng I Tel.: 012 420 2193

The topics listed entail thermo-fluid designs for which computational fluid dynamics may be utilized as a design tool.

Water Propelled Rocket Launching Mechanism Water propelled rockets are finding increased industrial application due to their inherent safety, short time intervals required to recharge and unrivaled cost efficiency of the propellant used.

Design topic 1: Launch mechanism

The aim here is the design of a cost effective launch mechanism for a water propelled rocket. Of importance are speed of release, weight implications on the rocket and applicability to various nozzle shapes. Furnish detailed drawings of your design.

Design topic 2: Fuselage design Of critical importance to the maximum height attainable is the weight of the fuselage. The objective is to design an ultra-light fuselage that is capable of withstanding large internal pressures. The use of stress analysis software in your design is highly recommended. Furnish detailed drawings of your design.

Heat Exchanger Internal Leak-prevention Design Shell-and-tube heat exchangers designed for use in extreme conditions, such as nuclear power plants, are to offer safety with regards to a number of aspects. Of critical importance is the prevention of a leak internal to the exchanger (e.g. in one of the tubes) which may result in contamination of one fluid stream with another. In the case of modern packed bed nuclear reactors, this will result in steam entering the reactor with serious safety related implications:

Generate and evaluate a number of leak prevention mechanism concept designs. Select the most appropriate mechanism. The main assessment criteria are to be

safety, durability and manufacturability. Conduct a detailed design of the most suitable mechanism. Use appropriate

equations in your calculations. Design a test-bed-heat-exchanger which will be used to test the selected leak

prevention mechanism. Furnish detailed drawings of the designed test-bed-heat-exchanger.

Design of a Device by which to allow Visualization of the Void Space in a Packed Bed of Spheres

The heat transfer in randomly packed-beds of spheres is of importance in both the chemical reactor industry as well as the nuclear power generation industry. Of importance to the heat transfer is the shape of voids between spheres. Unfortunately, no correlation currently exist which offers an indication of the extent of elongation of the voids near to reactor walls. This project tasks the student with the design of a set-up with which the geometry of the voids between the spheres may be quantitatively measured. Generate a number of concept designs, select the most appropriate one and do a detailed design of the latter. Of importance is cost effectiveness, functionality for repeated use and environmental friendliness. Furnish detailed drawings of your design.

Design a Novel Airship As compared to conventional fixed-wing aircraft, airships are relatively slow. This renders them less suitable for applications, such as inter-continental business travel. There are however a number of important modes of transport where the intrinsic characteristics of an airship render them superbly effective e.g. delivering of relief to disaster areas where local infrastructure has been severely damaged. The advent of modern non-rigid materials now make it possible to design airships with unique shapes. This has opened up a new era in airship design, where drag as well as the quantity of required helium may be significantly reduced. Generate two concept designs of a novel and improved airship and compare this to the classical ellipsoid design. Your airship is to have a maximum payload of 20ton and is to offer low drag and fast cruising ability (use software such as xfoil for your calculations). Furnish detailed drawings of the most suitable design.

Wind-Surfer Guide-fin Characterization Experiment Wind-surfers depend on the guide-fins located underneath the board for much of their stability and control. Unfortunately, cavitation occurs at reasonably low velocities and can have a detrimental influence on sail-ability. This project tasks the student with the design of an experiment with which to measure the fluid flow related forces on a fin undergoing cavitation. Cost effectiveness and repeatability is of paramount importance. Furnish detailed drawings of your design.

Prof JP Meyer jmeyer@up.ac.za

Room 9-26, Eng I Tel.: 012 420 2590

1. Drive train for a human powered aircraft Design a drive train for a human powered aircraft. The most important components are

peddles, gears, chain and propeller. The system must not only be very safe but very light

and very efficient. Fundamental calculations need to be done to determine a realistic

power input, the estimated mass of the aircraft, speed required, and power output

required keeping it in the air.

Mr M Morris mmontres@postino.up.ac.za

Room 9-13, Eng I Tel.: 012 420 4743

PELTON TURBINE DEMONSTRATION UNIT Design: It is required to design a small and portable experiment for one of the 4th year subjects that can be used to demonstrate the principles of a Pelton turbine. The Pelton turbine is a widely used example of an impulse machine where kinetic energy is converted into rotational power. Thesis: As part of the thesis the design must be manufactured and tested. It is also required to develop a practical guide to the setup. This will require that the setup be equipped with electronic sensors to a computer. The numerical interface must also be generated so that all the data can be logged.

Example of the FM32 demonstration unit

GAS TURBINE DEMONSTRATION UNIT

Design: It is required to design a small and portable experiment for one of the 4th year subjects that can be used to demonstrate the principles of axial flow turbo machinery such as compressors and turbines. As part of the design a test bench with all the associated instrumentation must be designed for a small gas turbine engine capable of providing 120 N of thrust and rotating at 100000 rpm. Thesis: As part of the thesis the design must be manufactured and tested. It is also required to develop a practical guide to the setup. This will require that the setup be equipped with electronic sensors to a computer. The numerical interface must also be generated so that all the data can be logged.

CENTRIFUGAL PUMP DEMONSTRATION UNIT

Design: It is required to design a small and portable experiment for one of the 4th year subjects that can be used to demonstrate the principles of centrifugal pumps. The experiment will be used to demonstrate the concept of pump performance curves. The setup must be designed so that different impellers can be tested and compared. Although not a requirement, it would also be useful to investigate the onslaught of cavitation at low pressures. Thesis: As part of the thesis the design must be manufactured and tested. It is also required to develop a practical guide to the setup. This will require that the setup be equipped with electronic sensors to a computer. The numerical interface must also be generated so that all the data can be logged.

Example of the PumpLab experiment

Prof NJ Theron njtheron@eng.up.ac.za

Room 10-5 Tel.: 012 420 3309

1. Cooling system for shape memory alloy actuators

The department has a number of shape memory alloy actuators whose high to the low

temperature phase change response times are quite large. These response times may be

reduced if better cooling of the actuators can be effected.

Project: Design a cooling system to significantly reduce the high to the low temperature

phase change response time of the available shape memory actuators as installed in a

typical application.

2. Mini-mechanical analogue computer

Before the dawn of the digital computer age, analogue computers were often used to

perform simulations and in control systems of various kinds. These analogue computers

were mostly of an electric nature, with electric summers, gain blocks, integrators and the like.

Most of these elements, however, also have mechanical counterparts, and theoretically it is

quite possible to also construct a mechanical analogue computer. The mechanical analogue

computer in various forms was in fact used (and in very simple forms are still widely used

today) in the control of numerous systems. The reliability and slower degradation in

performance offered by electronics, however, have made electric analogue systems more

popular in recent years, that is, wherever a digital solution was not preferred. The current

interest in micro and nano mechanics, however, may present new opportunities to utilize

mechanical analogue computers.

Project: Perform a detailed study into the components and elements of the mechanical

analogue computer and ways to miniaturized these. Using this study, implement a design of

a control system on the mini to micro mechanical level to control the position of the piston of

a typical hydraulic cylinder as used in the SASOL laboratory. No electronic component is to

be used in this control system, as a goal, or otherwise such usage should be minimized.

Estimate both the cost and the dynamic response of the proposed system and compare

these with the currently used electronics based systems.

3. Turntable for a house

Household energy consumption in areas with high percentage daytime sunshine may be

reduced if the orientation of the house can be made to track the movement of the sun

relative to the house. Furthermore, the occupant may wish to change the orientation of the

house from time to time for reasons other than energy preservation, such as utilizing a nice

view or reducing the effect of an unpleasant wind on an outdoor area.

Project: Design a turntable system to support a medium sized house comprising three

bedrooms, two bathrooms, a kitchen, lounge, dining room, living room, study and small

outdoor reception area. The design should include the drive mechanism, bearing system

and supply of all services to the house. The construction material of the house may be

negotiated with the client, but you also need to advise on this matter. The specification

needs to be determined as part of the project. Cost should be kept a low as possible, with

the aim of making such a system feasible for middle class people.

4. Practical Test Bench: Control Systems

The Department owns a test bench that is used in two control systems practicals. The

system can be used to investigate the control of the level of water in a water tank with the aid

of a water pump. The bench is however considerably larger than the unit on which the

Department has decided to standardize in future.

Project: Design a new test bench that meets the latest Departmental requirements but at

least also retains the functionality of the current system. It should however also be

attempted to improve the functionality of the present system.

Mr F van Tonder fvantonder@postino.up.ac.za

Room 10-6, Eng 1 Tel.: 012 420 3724

1. Design of serial robot manipulator The student must design a serial robot manipulator which can move an 8kg object

between various shelves. The shelves are located randomly and are at different heights.

The design includes a dynamic analysis, structural design, design of the drive

mechanism and the control system.

2. Design of a multi-axial fatigue test bench Multi-axial fatigue is the phenomenon where a complex stress state exists due to the

applied load on a component. The applied loading is cyclic of nature and fatigue failure

is likely to occur. The student must design a multi-axial fatigue test bench that can be

used for testing components and material specimen under multi-axial fatigue conditions.

3. Design of a load cell tester Loadcells are used to measure forces that are exerted on various components and

before usage a loadcell must be calibrated. Calibration is the process by which a

loadcell, or any other measurement sensor, is verified against a know quantity. For

loadcells the known quantity can be calibrated weights or another calibrated loadcell.

During the calibration process care must be taken not to exceed the allowable limits of

the loadcell since it can be damaged permanently. You are requested to design a

mobile loadcell calibration unit capable of calibrating loadcells in the range of 40kN to

250kN.

4. Design of a plane bearing connecting hydro-pulse actuators to test specimen Hydro-pulse actuators are used in the Sasol laboratory to perform various endurance

tests on different mechanical components. The hydro-pulse capability varies from 5kN

to 630kN. With every test the engineer faces interfacing challenges between the

actuators and the test specimen. Usually plane bearings are used in the test set-up, but

most of the commercially available plane bearings fail before the endurance test is

finished. The main reason for the plane bearings is to protect the actuator from lateral

loads that can cause permanent damage. The student is requested to design a plane

bearing capable of sustaining a dynamic load of 250kN for an infinite fatigue life.

5. Design of a kingpin test bench Kingpins form the connection between the horse and the trailer on big road haulers.

Various codes require endurance testing of the kingpins before commercial usage. One

such code specifies that the kingpin must be capable of sustaining a load of 60% of the

gross weight of a loaded trailer for 2 million cycles before it can be commissioned. You

are requested to design a kingpin endurance test bench capable of sustaining infinitely

large numbers.

Dr PE Uys petro.uys@postino.up.ac.za

Room 10-13, Eng 1 Tel.: 012 420 2254

1) Tyre evaluation: (Design and Project) For the project, the best tyre for different soft soil conditions (where the tyres tread profile

and dimension play an important role) and lacking tyre characteristics must be

determined. In order to recommend on tyre applications a study of the terra-mechanical

characteristics of tyre profiles and an investigation into the roll of tyre pressure and size on

performance will be necessary. From this background an optimal tyre must be determined

for different soil conditions (gravel, mud, sand, etc) and functions (skid pull, acceleration,

obstacle course) given the products commercially available. To obtain additional tyre

characteristics the test equipment needs to be modified to be able to measure braking and

traction coefficients. The equipment needs to be modelled in ADAMS software and the

test model validated against measured data.

Design outcome:

Redesign test equipment to overcome existing shortcomings and in order to measure

braking and traction.

Project outcome:

Implement design recommendations and apply the equipment to obtain the required

results. Model the equipment is the multi-body dynamics software ADAM and validate the

model with test results.

2,3,4) Solar cycle challenge: (Design and project) The design of a lightweight solar powdered vehicle that will be able to compete in an

interuniversity solar cycle challenge race must be improved and implemented. Electrical

assistance will be provided by an electric motor powered by solar panels and batteries. A

functional low weight structure must be designed for the optimal position of batteries,

motor, driver and solar panels to obtain the maximum average speed over the prescribed

track. In addition a steering system and driveline must be integrated with the electric

motor to ensure effective traction and handling. Due to the low power available and high

efficiency required, material selection and aerodynamics will be very important.

Design outcome:

Chassis

Redesign the structure to comply with safety requirements and to save on weight.

Placement and mounting of batteries, motor, driver steering brakes, wheels, the

aerodynamic shell etc. should be taken into account. Safety and driver comfort should

receive special attention.

Shell:

Investigate causes of high aerodynamic resistance in the existing vehicle. Redesign for

improvement. Take mounting and dismounting, drive train, accessibility of subsystems

mounting of solar panels availability of funds and materials into account.

Drive train:

Efficiency of energy transmission and management is a main concern. In this respect co-

operation with electronic engineering will be necessary with respect to speed and torque

control, regenerative braking and characterising and mounting of solar panels, motor(s),

switches etc. A drive train must be designed which will ensure optimal performance

Project outcome:

Perform baseline tests on the existing vehicle. Develop a theoretical model of the

subsystem. Implement the design and integrate it with other subsystems. Develop an

experimental rig and perform tests for comparison to modelling results and base-line tests.

5) Inner wheel load cell: Design and Project The purpose of the project is to design a load cell that can be mounted within the wheel

rim so that moments and forces developed in the wheel can be measured as the vehicle is

driving. Standard components should be used and provision must be made for connection

to data telemetry.

Design outcome:

Design a load cell that can be mounted within the wheel rim of a vehicle

Project outcome:

Manufacture the designed load cell, install and test. Model the working of the load cell in

ADAMS multi-body dynamics software. Compare results.

6) Toothed belt gearbox: (Design and Project) The purpose of the project is to design a toothed belt gearbox for a Mini-Baja vehicle, to

manufacture it and to conduct tests to determine its lifetime and efficiency.

Design outcome:

Design a toothed belt gearbox that meets the requirements of the vehicle.

Project outcome:

Manufacture the gearbox. Determine its lifetime and efficiency by means of a dedicated

test rig and compare it with that of an existing gearbox.

Mr AJ van Wyk kobus.vwyk@eng.up.ac.za

Room 8-11, Eng 1 Tel.: 012 420 2194

1. Design of an Epidural needle placement assist device The placement of epidural needles during epidural anaesthetics remains a difficult and

potentially dangerous procedure. In order to assist the anaesthetist performing the

procedure a device which supplies a constant backpressure via a syringe pump is

proposed. The design will focus on the mechanical design of such a device as well

considering the product, ergonomic and aesthetic design aspects of this product.

2. Design of a Peg (Percutoneous Endoscopic Gastrostomy) tube placement device for the placement of a PEG tube in patients.

Patients recovering from a stroke sometimes have the inability to eat (swallow).

Intravenous feeding strategies are sometimes used for the treatment of this condition but

do suffer from certain complications. A PEG tube is a tube inserted into the stomach

wall of the patient, which enables feeding via the tube that leads directly into the

stomach of the patient. The current placements of these tubes are difficult procedures

and require a lot of skill from the medical practitioner while positioning and pose a severe

infectious risk. The design will focus on the design of the PEG tube.

3. Design of a leaf drying apparatus for fast drying of leave samples Design a leaf dryer consisting of compartments for the rapid drying of leaves. The dryer

will typically incorporate heating elements for the control of the drying air temperature.

The design will require a study into existing drying technologies (i.e. tobacco dryers, etc.)

and adapting the theories for the specific application.

4. Design of a redundant tangential flow filtration and throttling system. A Tangential flow filter is currently used for the filtration of an emulsion from a plasma

mixture. These filters tend to clog up after a certain time period which necessitates the

replacement of the filter, which is a very difficult procedure considering the sterility

considerations. A Backup (standby) filter is to be incorporated into the system to

facilitate the easy and sterile switching of one filter to the other. At the same time the

outlet flow must be throttled to a specific pressure depending on the pressure drop

across the filter. The whole unit must be designed taking into consideration the existing

operating environment.

5. Design of a femur lengthening device. During bone fractures of the femur, the femur sometimes does not recover to its original

length. This might be due to loss of original bone during the trauma incident. The

design and development process will focus on the design of such a device that will be

implanted in the patient and attached to either ends of the femur, spanning the fracture

area. The controlled elongation of the device over a 3 month time period will lead to the

lengthening of the bone while supporting the bone for the same time period. The design

will focus on the concept generation, and detail design of the actuation mechanism of

such a device.

6. Design of a parachute deployment mechanism for a home rocket kit Private rocketeers build and fire their own rockets. The return of the reusable rocket

body must be decelerated by making use of a parachute mechanism. The design will

focus on the design of such a mechanism.