Mechanical Engineering Senior Design Project List - South Dakota ...

SOUTH DAKOTA SCHOOL OF MINES AND TECHNOLOGY
DEPARTMENT OF MECHANICAL ENGINEERING
SENIOR DESIGN PROJECT PROPOSAL LIST – FALL 2011
New Project
Project # 1 - ASME Human Powered Vehicle 2012 (ME, IENG, MetE)
Project # 2 - Baja SAE 2012 (ME, IENG, MetE)
Project # 3 - Formula SAE 2012 (ME, IENG, EE, MetE)
Project # 4 - SAE Aero Design 2012 (ME, IENG, MetE)
Project # 5 - SAE Zero Emissions Snowmobile 2012 (ME, EE, IENG, MetE)
Project # 6 - UAV 2012 (ME, EE, CENG, CSC, MetE)
Project # 7 - SAE Supermileage 2012 (ME, EE, IENG, MetE)
Project # 8 - WDTI Partnership in AMD World Championship (ME, MetE, IENG)
Project # 9 - Composite Acoustic Guitar (ME, IENG, MetE)
Project # 10 - ASME SDC – Energy Relay (ME, EE/CENG, ChemE)
Project # 11 - Moonrockers: NASA Lunar Regolith Excavator (ME, EE, CENG, CSC)
Project # 12 - Development of Autonomous Submersible to Explore Extreme Environments
(ME, Chem/ChemE, CENG, EE, IENG)
Project # 13 - Satellite Attitude Dynamics Simulator (ME, CENG, EE)
Project # 14 - Multifunctional Helmet (ME, MetE)
Project # 15 - State of the Art Directional Wave Tank with Wave Makers (ME, EE, CENG, CE)
Project # 16 - Floating Hydro Electric in the Amazon (CE, EE, IENG, ME)
Project # 17 - purePack 2.0 – Portable Water Purification System (ME, EE, IENG, EnvE)
Project # 18 - Robotic Friction Stir Welding of Aluminum Weldments using Linear and Circular
Paths (ME, EE, CENG, MetE, CSC)
Project # 19 - Airflow Enthalpy Monitor (EE, CENG, ME)
Project # 20 - Rehabilitation Device (ME, CENG, EE, IENG)
Project # 21 - ABS Brake Concept Trike (ME, EE, CENG)
Project # 22 - Multi-Axis Robotic CNC MIG Welder (ME, CSC)
Project # 23 - Radiation Hardened Robot (CENG, CSC, EE, ME)
Project # 24 - Bite Force Estimator (ME, MetE)
Project # 25 - Cold Spray Technology (ME, MetE)
Project # 26 - 4-Wheel Tilt Vehicle (ME): This project is tentative
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1

SOUTH DAKOTA SCHOOL OF MINES AND TECHNOLOGY
SENIOR DESIGN PROJECT PROPOSAL
Project Title: ASME Human Powered Vehicle 2012
Proposed/Advised by:
Sponsored by:
Dr. Matejcik, Dr. Ellingson, Kim Osberg, Dr. Dolan, HPV team
CAMP, SA, ASME
Project Description (including objectives and requirements):
A vehicle will be designed, built, and tested for the ASME Human Powered Vehicle Competition.
Information can be found at: http://www.asme.org/Events/Contests/
Project Duration:
2 semesters
Technical Areas Encompassed (e.g., machine design, controls):
machine design, manufacturing, materials, composites, ergonomics, aerodynamics
Any other special requirements:
Senior design members are expected to attend the competition.
Number of Students/Disciplines required (e.g., 2 ME, 1 EE, 1 CS):
3 ME, 2IE, and 1 MetE would be desired
2

SOUTH DAKOTA SCHOOL OF MINES AND TECHNOLOGY
SENIOR DESIGN PROJECT PROPOSAL
Project Title: Baja SAE 2012
Proposed/Advised by:
Sponsored by:
Dr. Dolan, Dr. Muci, Kim Osberg, Baja SAE Team
CAMP, SAE, SA
Project Description:
Baja SAE consists of competitions that simulate real-world engineering design projects and their related
challenges. Engineering students are tasked to design and build an off-road vehicle that will survive the
severe punishment of rough terrain and in the East competition—water.
The object of the competition is to provide SAE student members with a challenging project that
involves the planning and manufacturing tasks found when introducing a new product to the consumer
industrial market. Teams compete against one another to have their design accepted for manufacture by a
fictitious firm. Students must function as a team to not only design, build, test, promote, and race a
vehicle within the limits of the rules, but also to generate financial support for their project and manage
their educational priorities.
All vehicles are powered by a ten-horsepower Intek Model 20 engine donated by Briggs & Stratton
Corporation. For over twenty-five years, the generosity of Briggs & Stratton has enabled SAE to provide
each team with a dependable engine free of charge. Use of the same engine by all the teams creates a
more challenging engineering design test.
Project Duration:
2 semesters
Technical Areas Encompassed (e.g., machine design, controls):
Dynamics, vehicle dynamics, machine and structural design, human factors, manufacturing
Any other special requirements:
The students must be SAE members to attend the competition. All seniors are expected to attend the
competition.
Number of Students/Disciplines required (e.g., 2 ME, 1 EE, 1 CS):
A team consisting of 6 MEs, 2IEs, and 1 Met student would be desired, with an emphasis for one team
member taking ME 428: Finite Element Analysis to focus on frame analysis.
3

SOUTH DAKOTA SCHOOL OF MINES AND TECHNOLOGY
SENIOR DESIGN PROJECT PROPOSAL
Project Title: Formula SAE 2012
Proposed/Advised by:
Sponsored by:
Dr. Dolan, Dr. Ellingson, Kim Osberg, Chuck Schilling, FSAE Team
CAMP, SA, SAE, Poet, Ford
Project Description: The Formula SAE competition is for SAE student members to conceive, design,
fabricate, and compete with small formula-style racing cars. The restrictions on the car frame and engine
are limited so that the knowledge, creativity, and imagination of the students are challenged. For the
purpose of this competition, the students are to assume that a manufacturing firm has engaged them to
produce a prototype car for evaluation as a production item. The intended sales market is the
nonprofessional weekend autocross racer. Therefore, the car must have very high performance in terms
of its acceleration, braking, and handling qualities. The car must be low in cost, easy to maintain, and
reliable. In addition, the car's marketability is enhanced by other factors such as aesthetics, comfort and
use of common parts.
The cars are judged in a series of static and dynamic events including: technical inspection, cost,
presentation, and engineering design, solo performance trials, and high performance track endurance.
These events are scored to determine how well the car performs. In each event, the manufacturing firm
has specified minimum acceptable performance levels that are reflected in the scoring equations.
Further information can be obtained at: http://students.sae.org/competitions/formulaseries/
Project Duration:
2 semesters
Technical Areas Encompassed (e.g., machine design, controls):
Dynamics, fluids, aerodynamics, machine and structural design, electric circuits, measurements and
instrumentation, human factors, manufacturing, composites, engines
Any other special requirements:
The students must be SAE members to attend the competition. All seniors are expected to attend the
competition.
Number of Students/Disciplines required (e.g., 2 ME, 1 EE, 1 CS):
A team of 6 MEs, 2 IEs, 2 EEs and 2 Met students would be desired.
4

SOUTH DAKOTA SCHOOL OF MINES AND TECHNOLOGY
SENIOR DESIGN PROJECT PROPOSAL
Project Title: SAE Aero Design 2012
Proposed/Advised by:
Sponsored by:
Dr. Dolan, Kim Osberg
CAMP, SA, SAE, SAE Aero Design Team
Project Description:
The Aero Design® Competition challenges engineering students to conceive, design, fabricate, and test a
radio controlled aircraft that can take off and land while carrying the maximum cargo.
Competition information is posted at: http://students.sae.org/competitions/aerodesign/
Project Duration:
2 semesters
Technical Areas Encompassed (e.g., machine design, controls):
Dynamics, machine and structural design, instrumentation and testing, controls, fluids, aerodynamics,
manufacturing
Any other special requirements:
The students must be SAE members to attend the competition, and seniors are expected to attend.
Number of Students/Disciplines required (e.g., 2 ME, 1 EE, 1 CS):
A team of 4 MEs, 2 IEs and 2 Met students would be desired.
5

SOUTH DAKOTA SCHOOL OF MINES AND TECHNOLOGY
SENIOR DESIGN PROJECT PROPOSAL
Project Title: SAE Zero Emissions Snowmobile 2012
Proposed/Advised by:
Sponsored by:
Dr. Batchelder, Dr. Dolan, Kim Osberg, and the AFV Team
CAMP, SAE
Project Description:
The object of the competition is to provide SAE student members with a challenging project that
involves the planning and manufacturing tasks found when introducing a new product to the consumer
industrial market. Teams compete against one another to have their design accepted for manufacture by a
fictitious firm. Students must function as a team to not only design, build, test, promote, and demonstrate
a zero-emissions snowmobile within the limits of the rules, but also to generate financial support for
their project and manage their educational priorities.
The SDSM&T team will use an electric motor powered by batteries.
Rules are at: http://students.sae.org/competitions/snow/
Project Duration:
2 semesters
Technical Areas Encompassed (e.g., machine design, controls):
Electric power, motors, controls, dynamics, vehicle dynamics, machine and structural design, human
factors, manufacturing
Any other special requirements:
The students must be SAE members to attend the competition. Senior design members are expected to
attend the competition.
Number of Students/Disciplines required (e.g., 2 ME, 1 EE, 1 CS):
A team consisting of 4 MEs, 4EEs, 2IEs, and 1 Met would be desired.
6

SOUTH DAKOTA SCHOOL OF MINES AND TECHNOLOGY
SENIOR DESIGN PROJECT PROPOSAL
Project Title: UAV 2012
Proposed/Advised by: Profs. McGough, Dolan, Batchelder, Weiss, Linde, Hoover, Tolle;
Kim Osberg
External advisors: Jason Howe, Mark Sauder
Grad students: Jaiyi Liu, Jordan Ritz, and UAV team
Sponsored by:
CAMP, SA
Project Description (including objectives and requirements):
This senior design team will work to configure the Unmanned Aerial Vehicle (UAV) Team‘s verticaltake-off-and-landing
(VTOL) sub-vehicle for the interior search mission of 2012. Work will be done on
the control system to provide the jump-drive drop and pick-up system.
This Senior Design Team will coordinate all efforts with the Chief Engineer and Team Manager of the
UAV Team as well as the team at large. All final design decisions will be the collaborative efforts of the
UAV Team leadership, the UAV Team, and the Senior Design Team members. Additionally, it is
desired that Senior Design Team members become and remain SDSM&T UAV Team members in good
standing.
Competition rules and highlights are at:
http://iarc.angel-strike.com/
Project Duration:
1 year
Technical Areas Encompassed (e.g., machine design, controls):
Controls, machine design, composite materials and structures, fluid mechanics, instrumentation and testing,
software engineering, programming
Any other special requirements:
Students would be members of the UAV competition team. Senior design members are expected to attend
the competition.
Number of Students/Disciplines required (e.g., 2 ME, 1 EE, 1 CS):
2 ME, 1 EE, 2 CompE, 3 CSC, 1 MET would be desired
7

SOUTH DAKOTA SCHOOL OF MINES AND TECHNOLOGY
SENIOR DESIGN PROJECT PROPOSAL
Project Title: SAE Supermileage 2012
Proposed/Advised by:
Sponsored by:
Dr. Abata, Dr. Dolan, CAMP
Nucor Steel and CAMP
Project Description: The Supermileage® competition provides engineering and technology students
with a challenging design project that involves the development and construction of a single-person,
fuel-efficient vehicle. Vehicles are powered by a small four-cycle engine. The vehicles will run a
specified course with the vehicle obtaining the highest combined kilometers per liter (miles per gallon)
rating plus design segment points winning the event. Students have the opportunity to set a world
fuel economy record and increase public awareness of fuel economy. Engines are donated by Briggs
& Stratton.
Further information can be obtained at: http://students.sae.org/competitions/supermileage/
Project Duration:
2 semesters
Technical Areas Encompassed (e.g., machine design, controls):
Dynamics, fluids, aerodynamics, machine and structural design, measurements and instrumentation,
engines, human factors, manufacturing, composites.
Any other special requirements:
The students must be SAE members to attend the competition. All seniors on the project would be
expected to attend the competition.
Number of Students/Disciplines required (e.g., 2 ME, 1 EE, 1 CS):
A team of 4 MEs, 2 EEs, 1 IE, and 1 Met student would be desired.
8

SOUTH DAKOTA SCHOOL OF MINES AND TECHNOLOGY
SENIOR DESIGN PROJECT PROPOSAL
Project Title:
Proposed/Advised by:
Sponsored by:
WDTI Partnership in AMD World Championship
Dan Dolan, Mike West, Jason Ash, Luke Steinmetz (WDTI), and Mike
Prugh
Prugh Design and Black Hills Harley Davidson
Project Description:
In 2009-2010, Western Dakota Technical Institute partnered with Prugh Design and the Black Hills
Harley Davidson to develop a custom modified Harley for the 2010 American Motorcycle Dealer
(AMD) World Championship of Custom Bike Building that takes place each year during the Sturgis
Rally and features custom motorcycles from around the world. Prugh Design and Black Hills Harley
Davidson are looking to partner again with a collaborative effort between WDTI and the students at
SDSM&T. The scope of the project focuses on the form as well as the function in the mechanical design
of a custom bike and will require in-house parts to be designed and manufactured. Details on the 2010
competition bike can be found at the following:
http://www.amdchampionship.com/bikes/2509-prugh-design-black-hills-harley-davidson-filter.html
Project Duration:
2 semesters
Technical Areas Encompassed (e.g., machine design, controls):
ME: Machine design, vehicle dynamics, product development
MetE: Material selection, product development
IENG: Project management, ergonomics, product development
Any other special requirements:
Number of Students/Disciplines required (e.g., 2 ME, 1 EE, 1 CS):
4 ME, 2 MetE, and 1 IENG would be desired
9

SOUTH DAKOTA SCHOOL OF MINES AND TECHNOLOGY
SENIOR DESIGN PROJECT PROPOSAL
Project Title:
Proposed/Advised by:
Sponsored by:
Composite Acoustic Guitar
Dr. Dolan
CAMP, Gary Santa, Dr. Dolan
Project Description (including objectives and requirements):
A composite (carbon fiber) acoustic 6-string guitar will be designed, built, and tested. It is desired to focus
on the manufacturing technology while assuring a professional sounding guitar. The guitar should have
roughly the shape, size, and sound of a dreadnought guitar.
Project Duration:
2 semesters
Technical Areas Encompassed (e.g., machine design, controls):
machine design, structures, manufacturing, materials, composites, ergonomics, acoustics, vibrations, music
Any other special requirements:
It would be helpful if at least one of the team members were a guitar player.
Number of Students/Disciplines required (e.g., 2 ME, 1 EE, 1 CS):
3 ME, 1 IE, and 1 MetE would be desired
10

SOUTH DAKOTA SCHOOL OF MINES AND TECHNOLOGY
SENIOR DESIGN PROJECT PROPOSAL
Project Title:
ASME STUDENT DESIGN CONTEST – Energy Relay
Proposed/Advised by: Mr. Jason Ash and Dr. Michael Batchelder
Sponsored by:
A $500 budget is available from the ASME student chapter with the possibility of an additional $500 depending on
project needs/resources. Travel and hotel expenses will be covered by your ASME student section.
Project Description:
Providing energy to a world with a growing population and rising expectations is a challenge that engineers must
embrace and solve. So many factors must be considered and balanced: cost, efficiency, resource availability,
environmental impact, sustainability, and more. Many different potential solutions are being proposed and
developed. While the winners have yet to be determined, it is safe to assume that the future will include a wide
variety of solutions that together will power our planet.
The goal of the 2012 ASME Student Design Competition is to design four self-propelled devices which can
collectively complete a relay race in the shortest period of time. Each device must contain an on-board energy
source and trigger the motion on the next device. Bonuses will be awarded for devices having different energy
sources and for initiating subsequent devices.
http://files.asme.org/asmeorg/Events/Contests/DesignContest/28571.pdf
Project Duration:
2 semesters
Technical Areas Encompassed (e.g., machine design, controls):
Machine design, mechatronics, controls, programming, and chemical engineering
Any other special requirements:
ASME membership required for 2011-2012 at the $25 student rate.
Competition Prizes:
Number of Students/Disciplines required
Up to 4 ME/EE/CENG/ChemE students (Team cannot exceed 4 students): The ideal team would be 1 of
each discipline or 2 ME, 1 EE or CENG, and 1 ChemE
11

SOUTH DAKOTA SCHOOL OF MINES AND TECHNOLOGY
SENIOR DESIGN PROJECT PROPOSAL
Project Title:
NASA Lunabotics: Lunar Regolith Excavator
Proposed/Advised by: Mr. Jason Ash and Dr.‘s Michael Batchelder, Jeff McGough, and Charles Tolle along with
graduate advisor Mr. Ryan Housh
Sponsored by:
A $5000 baseline funding request has been sent to NASA with positive response for support from the South Dakota
Space Grant Consortium. Additional fundraising may be required.
Project Description:
The Lunabotics Mining Competition is a university-level competition designed to engage and retain students in
science, technology, engineering and mathematics (STEM). NASA will directly benefit from the competition by
encouraging the development of innovative lunar excavation concepts from universities which may result in clever
ideas and solutions which could be applied to an actual lunar excavation device or payload. The challenge is for
students to design and build a remote controlled or autonomous excavator, called a lunabot, that can collect and
deposit a minimum of 10 kilograms of lunar simulant within 15 minutes. The complexities of the challenge include
the abrasive characteristics of the lunar simulant, the weight and size limitations of the lunabot, and the ability to
control the lunabot from a remote control center. This will be the 3 rd year of the competition with the first place
team last year delivering 237.4 kg. Complete details of the competition are provided at the following location:
http://www.nasa.gov/lunabotics
Project Duration:
2 semesters
Technical Areas Encompassed (e.g., machine design, controls):
Machine design, mechatronics, controls, vision systems, and programming
Any other special requirements:
K-12 Outreach required as part of this project.
Competition will be at Kennedy Space Center from May 21-26, 2012.
Competition Prizes:
$5000, $2500, and $1000 for 1 st , 2 nd , and 3 rd place along with VIP Kennedy Space Center launch tickets
Additional prizes for individual and overall competition categories.
Number of Students/Disciplines required
5-7 ME/EE/CENG/CSC students (Ideal would be 2-3 ME, 2 EE/CENG, 1-2 CSC)
12

SOUTH DAKOTA SCHOOL OF MINES AND TECHNOLOGY
SENIOR DESIGN PROJECT PROPOSAL
Project Title:
Proposed/Advised by:
Sponsored by:
Development of Autonomous Submersible to Explore Extreme Environments
Drs. Tolle, McGough, Matejcik, and Mr. Ash
South Dakota Space Grant NASA ($8k is in place to support implementation)
Project Description (including objectives and requirements):
The AUV (Autonomous Underwater Vehicle) team is looking for senior design students from a variety of
disciplines. The team is tasked with the design and development of a submersible capable of autonomously
navigating in confined spaces at pressures of up to 1500 psi for three hours and then returning to its departure point.
This vehicle is intended for use in the Sanford Lab (aka what is to be DUSEL some day) but is being designed for a
variety of applications including open water exploration with Yellowstone lake, deep ocean exploration, and
possible missions to Europa (http://en.wikipedia.org/wiki/Europa_(moon)). This will be the 3 rd year for the team.
In pervious years the team has created and fabricated two frame designs, two different thruster systems, a
transmit/receiver sonar sounder, battery module controller and a designed for the power distribution system. There
are numerous additional needs yet to be accomplished before basic navigation and operation can begin, some
additional projects are listed below:
• A buoyancy system needs to be developed
• A supervisory power system needs to be designed and implemented – utilizing the existing battery module
controller subsystem
• A battery module enclosure subsystem needs to be designed and implemented
• A force transducer feedback system for thruster control must be designed and manufactured
• Low level thruster control systems must be developed and implemented
• An attitude control system must be developed and implemented
• Sensory systems must be developed and implemented, i.e. the sonar sounder needs to complete testing and
integrated to form a full sonar sub-system, a new UV/IR/visual camera system needs to be designed
• A high pressure water and gas sampling system needs to be designed and implemented
• A transportation and deployment system must be designed and manufactured
• Mission planning, guidance, and navigation algorithms must be designed and put in place
• A GUI interface systems for planning system missions needs to be developed
*Note, not all items listed above needed to be solved during this year’s efforts – the actual
team will focus on items that lien towards their knowledge, interest and talents.
Project Duration:
2 semesters
Technical Areas Encompassed (e.g., machine design, controls):
machine design, mechatronics, electronics, and controls
Number of Students/Disciplines required:
This year 1-2 CENG, 1-2 Chem/ChemE, 4-6 EE, 2 IENG, and 4-6 ME are desired – all are welcome.
For more information stop by our lab in EP-335 and contact Dr. Charles Tolle, e-mail: charles.tolle@sdsmt.edu or
Andrew Muxen, e-mail: muxenmi@hotmail.com
13

SOUTH DAKOTA SCHOOL OF MINES AND TECHNOLOGY
SENIOR DESIGN PROJECT PROPOSAL
Project Title:
Proposed/Advised by:
Sponsored by:
Satellite Attitude Dynamics Simulator
Drs. Tolle, Bedillion + others potentially
South Dakota NASA Space Grant / AUV Team
($5K is in place to support implementation)
Project Description (including objectives and requirements):
This project is an offshoot of the South Dakota NASA Space Grant AUV team. If we are to travel to
Europa (http://en.wikipedia.org/wiki/Europa_(moon)) our submersible spacecraft rover will need a
communication link back to earth. This project is to design and build a small satellite simulator so that
future students can work on satellite controllers, star pointing algorithms, communication links, etc.
Several such simulators can be seen in Agrawal and Rasmussen paper entitled: ―Air Bearing Based
Satellite Attitude Dynamics Simulator for Control Software Research and Development‖ available at
http://faculty.nps.edu/agrawal/docs/spie-agrawal-rasmussen.pdf. The main goal in this year‘s effort is to
fabricate an air bearing, design a mounting table (similar to a tooling table), design a thruster system and
implement low level thruster electronics.
Project Duration:
2 semesters
Technical Areas Encompassed (e.g., machine design, controls):
machine design, mechatronics, and controls
Number of Students/Disciplines required:
This year 2 ME, 1 CENG, 1 EE are desired, additional students are welcome.
For more information Contact Dr. Charles Tolle, e-mail: charles.tolle@sdsmt.edu or visit our lab in EP-
335.
14

SOUTH DAKOTA SCHOOL OF MINES AND TECHNOLOGY
SENIOR DESIGN PROJECT PROPOSAL
Project Title:
Proposed/Advised by:
Multifunctional Helmet
Dr. Karim Muci, Mr. Brandon Hinz, and Mr. Andrew Brady
Sponsored by:
This senior design project will be part of a research project sponsored by the US ARMY Research
Laboratory (ARL) that involves a close collaboration between the SDSM&T Computational Mechanics
Laboratory (CML) and the SDSM&T Composites and Polymer Engineering (CAPE) Laboratory.
Project Description (including objectives and requirements):
The purpose of this project is to develop a multifunctional helmet for first responders that has a reasonable
cost and can provide adequate protection to the head in a wide variety of scenarios. The following example
illustrates the need for such a helmet. Currently Search and Rescue (SAR) teams across the nation
commonly use different helmets for the different services that they provide like vertical rescue, swiftwater
rescue, vehicle extrication, and building shoring among others. Besides the inherent costs and logistic
problems of having to deal with several different helmets, few if any of them are designed with
multifunctional capability for situations encountered beyond the mission profile.
Arrangements will be made so that the members of the senior design team have the opportunity to interact
with first responders in the Pennington County area to determine the needs that they have for the product
under consideration.
Project Duration: September 2011 – May 2012
Technical Areas Encompassed:
Product development, manufacturing, solid mechanics, fluid mechanics, and dynamics. The work will
include performing computer simulations, manufacturing of prototypes, and experimental testing.
Any other special requirements:
US Citizenship is required to participate in this project.
Number of Students/Disciplines required:
2–3 Mechanical Engineering students.
Optional: 1 Metallurgical Engineering student.
15

SOUTH DAKOTA SCHOOL OF MINES AND TECHNOLOGY
SENIOR DESIGN PROJECT PROPOSAL
Project Title:
Proposed/Advised by:
Sponsored by:
State of the art directional wave tank with wave makers
U.A. Korde, M.A. Langerman, C.F. Schilling
ME Department
Project Description (including objectives and requirements):
Water waves concentrate the sun‘s energy by two orders of magnitude, can travel long distances and last
a long time. Waves have been seen as a source of ‗clean‘ energy for many decades in the worlds of
commercial and academic research and development. Energy conversion from waves usually requires
some form of dynamic mechanical interaction with the waves. This is often achieved by means of a
floating or submerged body oscillating in response to the waves and driving a linear or rotary electric or
hydraulic generator via a suitable power transfer mechanism.
Successful implementation of any such energy conversion scheme depends on rigorous analysis and
model testing. To that end, this project proposes the construction of a wave tank capable of reproducing
at model scale the large variety of wave amplitude and directional spectra encountered in large bodies of
water (such as the Great Lakes or the oceans). The tank will include three essential components: (1) a
tank of dimensions to be specified at project start, (2) wave makers, and (3) wave absorbers (to prevent
multiple reflections from walls). A movable platform allowing access to models being tested and also
providing a place for instruments and model support struts would also be highly desirable. Part (2) will
include mechanical design and construction of the wave makers, design and construction of the drive
electronics, wave maker control system hardware and software (e.g. through Matlab or LabView).
Project Duration:
2 semesters
Technical Areas Encompassed (e.g., machine design, controls):
Fluid mechanics, solid mechanics, dynamics, vibrations, controls, circuits, mechatronics, machine tool
operation, etc.
Any other special requirements:
None.
Number of Students/Disciplines required (e.g., 2 ME, 1 EE, 1 CS):
5/6; MEs, EEs, CENGs, CEs all welcome.
16

SOUTH DAKOTA SCHOOL OF MINES AND TECHNOLOGY
SENIOR DESIGN PROJECT PROPOSAL
Project Title:
Proposed/Advised by:
Sponsored by:
Floating Hydro Electric in the Amazon
Tom Fontaine, Casey D. Heinrich, Michael S. Heinrich, Aaron Costello,
Rebekah Dargatz, and Jason Ash (tentative)
World Micro Power
A $2,500 base budget has been provided by World Micro Power in addition to the 6 Kilowatt generator
head. World Micro Power is a non-profit organization administered by an all volunteer group of engineers
and technical specialists whose goal it is to use renewable resources to power remote villages in the
Amazon jungle. Specifically, to create durable, light weight, low maintenance ―zero head‖ hydro-electric
power at an affordable cost.
Project Description:
World Micro Power has a basic design for a zero head hydro-electric generator that is compatible with the
very harsh conditions of the Amazon River. It is hoped that he completed design will light all 100
dwellings at night and power a water filtration system during the day. The design requires fresh ideas and
many engineering and technical enhancements.
Designing a zero head generator for the remote Amazon jungle is an extremely challenging task. The
village of Santa Maria de Fatima is a remote village on the Amazon River outside Iquitos, Peru and is
accessible only by boat. The village has no source of light after dark and no way to power a water filtration
system.
The project would take the base design and improve it for: 1. Durability 2. Maintainability/Simplicity 3.
Efficiency 4. Minimum shipping weight 5. Compactness of disassembled components. 6. Low cost
The completed device will be required to pass a 24 hour duration test without failure.
Project Duration:
2 Semesters
Technical Areas Encompassed (e.g., machine design, controls):
Machine Design, Mechatronics, Controls, Fluids, Circuit Design, Hydro, and Programming.
Any other special requirements:
The device will be installed in the Santa Maria del Fatima, Peru in the Summer of 2012.
Number of Students/Disciplines required
8 ME/EE/CE/IENG
17

SOUTH DAKOTA SCHOOL OF MINES AND TECHNOLOGY
SENIOR DESIGN PROJECT PROPOSAL
Project Title:
Proposed/Advised by:
Sponsored by:
purePack 2.0 – Portable Water Purification System
Mr. Lucas Haan and Jason Ash (tentative)
Labrusca Scientia, LLC
Project Background:
Last year (Spring 2010 – Fall 2011) a group of interdisciplinary senior design students at SDSM&T
worked to develop a prototype of a portable water purification system that produces clean, drinkable
water for contaminated fresh water locations and is powered by renewable energy. The group of students
then traveled to Chile to test and implement the prototype at an orphanage construction site in the Andes
Mountains where the prototype is currently in use. Due to the success of the project, these students have
now created a limited liability company (Labrusca Scientia, LLC) to develop even better portable water
purification system technologies. Labrusca Scientia, LLC aims to work with senior design students at
SDSM&T to help with the design of this development.
Project Description:
Labruscsa Scientia, LLC is developing a portable water purification system that produces clean, drinkable
water for contaminated fresh water locations and is powered by renewable energy. The entire system is
being revisited to optimize the product for movement into production. The main objectives of this project
are detailed below:
Objective 1: Design and develop a lightweight containment for entire system that is ergonomic and
fits the carry-on size constraints of airline travel
Objective 2: Optimize the pump/filtration system
Objective 3: Optimize the power storage and generation
Objective 4: Integrate more sensors and improve user interface system
Project Duration: 2 semesters (Fall 2011 – Spring 2012)
Technical Areas Encompassed (e.g., machine design, controls):
ME: structural integrity design, manufacturing, materials, ergonomics, fluid dynamics,
EE: alternative power generation, storage, and sensing (electrical circuit design)
IENG: ergonomics
Any other special requirements:
Previous experience in travel abroad or an interest in such is recommended but not necessary
Number of Students/Disciplines required (e.g., 2 ME, 1 EE, 1 CS):
2 ME, 2 EE, 2 IENG, 1 ENVE
18

SOUTH DAKOTA SCHOOL OF MINES AND TECHNOLOGY
SENIOR DESIGN PROJECT PROPOSAL
Project Title:
Proposed/Advised by:
Sponsored by:
Robotic Friction Stir Welding of Aluminum Weldments using Linear and
Circular Paths
Chris Thompson, Johnathan Borrego, & Joshua Merry - Space Exploration
Technologies, Dr. Kalanovic, Dr. Widener (tentative)
Space Exploration Technologies – Hawthorne, CA
Project Description:
Chris Thompson is the Vice President of Production Development at Space Exploration Technologies
(SpaceX). SpaceX has a desire to enter into robotic friction stir welding on their Falcon family of launch
vehicles and Dragon capsule that is used to transport equipment to and from the International Space
Station. The goal of this project is to develop a robotic friction stir welder using a common industrial
robot like those offered from ABB or FANUC. The robotic friction stir welder needs to perform and
control weld operations in 6061-T6 aluminum with material thicknesses ranging from 0.0625‖ up to
0.500‖. The proposed system must be all electric – no hydraulics. The end goals of this project are –
design and simulation of the proposed system, and demonstration of simple lap and square butt welds in
linear and circular motions time permitting.
Project Duration:
2 semesters
Technical Areas Encompassed (e.g., machine design, controls):
Machine Design, Friction Stir Welding, Robotic Programming and Control, System Engineering
Any other special requirements:
None that I am aware of at the moment
Number of Students/Disciplines required (e.g., 2 ME, 1 EE, 1 CS):
4-6 ME, EE, CENG, CSC
19

SOUTH DAKOTA SCHOOL OF MINES AND TECHNOLOGY
SENIOR DESIGN PROJECT PROPOSAL
Project Title:
Proposed/Advised by:
Sponsored by:
Airflow Enthalpy Monitor
Lance Weaver/Bernt Askildsen
Lloyds Systems LLC
Project Description:
Develop an Enthalpy sensor that will also display wet bulb and dry bulb temperatures of airflow on a
LCD screen. The design will be focused around a low power microcontroller to ensure that a miniature
windmill will power the sensor system. The measured signals will also be transmitted to a wall box that
is connected to 120VAC. A successful outcome of project will be rewarded by stipends.
Project Duration:
2 semesters
Technical Areas Encompassed (e.g., machine design, controls):
Airflow dynamics, measurements, instrumentation, testing, software engineering, programming, wireless
communcations, SolidWorks, mechanical design of housings.
Any other special requirements:
No
Number of Students/Disciplines required (e.g., 2 ME, 1 EE, 1 CS):
A team consisting of 1 EE, 1 CENG and 1 ME student is desired
20

SOUTH DAKOTA SCHOOL OF MINES AND TECHNOLOGY
SENIOR DESIGN PROJECT PROPOSAL
Project Title:
Proposed/Advised by:
Sponsored by:
Rehabilitation Device
Ryan Swenson, Doctor of Chiropractic, Jason Ash (tentative)
Ryan Swenson, Doctor of Chiropractic
Project Description:
Ryan Swenson is a Chiropractic Doctor here at Black Hills Chiropractic. He has identified a need for a
rehabilitation therapy device whose goal is to strengthen and retrain neck muscles for patients suffering
from neck pain. Ryan would like to collaborate with SDSM&T and senior design students in the
development of a prototype that could be used in pursuing a patent. The students would be recognized
along with Ryan as the creators of the device, while Ryan would retain ownership of the patent.
Project Duration:
2 semesters
Technical Areas Encompassed (e.g., machine design, controls):
Machine design, mechatronics, controls, human-factors, ergonomics, electrical circuit design
Any other special requirements:
Signing a non-disclosure statement would be required for this project to maintain confidentiality
Number of Students/Disciplines required
Ideally 4-6 EE, CENG, IENG, ME students (3 students minimum are needed and would not have to be
multidisciplinary)
21

SOUTH DAKOTA SCHOOL OF MINES AND TECHNOLOGY
SENIOR DESIGN PROJECT PROPOSAL
Project Title:
Proposed/Advised by:
Sponsored by:
ABS Brake Concept Trike
Gary Hamilton, Lehman Trikes Advisor, Dr. Bedillion
Lehman Trikes
Project Description (including objectives and requirements):
Add an ABS brake system to a 3-wheeled motorcycle for purposes of testing feasibility. The objective is to
produce a mule or first prototype to explore the possibility of adding ABS brakes to Lehman‘s product line.
The goal is to add to the basic engineering knowledge base at Lehman Trikes. This is a first stage design
for use in house and not intended as a final product for sale.
Project Duration:
2 semesters
Technical Areas Encompassed (e.g., machine design, controls):
machine design, oil hydraulics, electronic controls
Any other special requirements:
System would be designed as a test or demonstration on a Lehman model Trike. Lehman would provide a
trike, funding for purchase of parts ($2000) as well as welding and machining time (40 hours) at Lehman‘s
shop. Lehman would provide qualified engineers and operators to plan and conduct all dynamic testing.
Tests would be conducted on a closed track. Lehman accepts liability for testing conducted by Lehman
personnel. A more detailed agreement final must be written before this project starts.
Number of Students/Disciplines required (e.g., 2 ME, 1 EE, 1 CS):
3-5 ME, EE, CENG
22

SOUTH DAKOTA SCHOOL OF MINES AND TECHNOLOGY
SENIOR DESIGN PROJECT PROPOSAL
Project Title:
Proposed/Advised by:
Sponsored by:
Multi-Axis Robotic CNC MIG Welder
Steven Franker
Steven Franker & Team along with Fundraising
Project Description (including objectives and requirements):
This project would entail designing and building a multi-axis robotic arm with low load actuators for CNC
MIG welding. The goal is to produce a practical device that could be easily used in small welding and
machine shops for repetitive welding tasks. No lengthy programming or computer skills required. Perfect
for consistently welding parts that can be mounted in a fixture or jig. It is also our goal to pursue the
marketability and possible patents of this project if it is successful. According to our research this would be
a unique product that no other company currently offers.
Project Duration:
2 semesters
Technical Areas Encompassed (e.g., machine design, controls):
machine design, oil hydraulics, electronic controls
Any other special requirements:
Number of Students/Disciplines required (e.g., 2 ME, 1 EE, 1 CS):
4-6 ME, CSC
23

SOUTH DAKOTA SCHOOL OF MINES AND TECHNOLOGY
SENIOR DESIGN PROJECT PROPOSAL
Project Title:
Proposed/Advised by:
Sponsored by:
Radiation Hardened Robot
Los Alamos National Lab, National Security Technologies (contractor),
Texas Instruments, Drs. Bedillion, McGough, and Tolle
Los Alamos National Lab
Project Description (including objectives and requirements):
LANL would like a radiation hardened robot to drive down the beam line in an accelerator during
operation, perform diagnostics, and send back video.
Project Duration:
2 semesters
Technical Areas Encompassed (e.g., machine design, controls):
ME: Robotics, machine design, controls
EE/CENG: Electrical circuits, controls
CSC: Programming, GUI Interface
Any other special requirements:
Number of Students/Disciplines required (e.g., 2 ME, 1 EE, 1 CS):
4-6 ME, EE, CENG, CSC
24

SOUTH DAKOTA SCHOOL OF MINES AND TECHNOLOGY
SENIOR DESIGN PROJECT PROPOSAL
Project Title:
Proposed/Advised by:
Sponsored by:
Bite Force Estimator
Don Esker (Mammoth Site)/Dr. Marius Ellingsen
Mammoth Site/AMP (MTS measurement time)
Project Description:
Since its discovery in 1986, the presence of the giant short-faced bear (Arctodus simus) in the Hot Springs
sinkhole has been attributed to the great ursid preying or scavenging on trapped mammoths. Despite this,
only one bone has ever been found with any bite marks or feeding traces: the rib 93HS031. This rib bears
two round depressions, interpreted as puncture marks from the canines of a large carnivoran. Determining
which carnivoran has been tricky, however. While the distance between the marks is consistent with intercanine
spacing of an A. simus, they could also indicate a Panthera atrox (American lion), depending on
whether the canines were maxillary or mandibular.
We would like to design and test a mechanical apparatus that could answer the question once and for all.
In 2010, Gignac et al built a device to determine the bite force of an extinct animal. It operated by using a
hydraulic loading frame to press a hardened steel replica of the tooth into a cow bone, while a 25 kN load
cell measured the force applied. The force required to press the tooth into the cow bone to the same depth
as seen in the fossil gave an approximate bite force for the animal when alive. We‘d like to do essentially
the same here, and determine how much force was needed to puncture our rib. From there we‘ll compare
that force with published data on bite force estimates and our own finite element analysis to determine who
was chewing on mammoth bones in the sinkhole 26,000 years ago.
Project Duration:
2 semesters
Technical Areas Encompassed (e.g., machine design, controls):
Machine design, solid mechanics, mechatronics, and measurements
Any other special requirements:
Number of Students/Disciplines required
3 or more ME/MET students
25

SOUTH DAKOTA SCHOOL OF MINES AND TECHNOLOGY
SENIOR DESIGN PROJECT PROPOSAL
Project Title:
Cold Spray Technology
Proposed/Advised by: Christian Widener
Sponsored by:
AMP
Project Description:
This is a tentative project through discussions with Christian Widener. He is interested in having students increase
the pressure capabilities of the current cold spray system. There are also additional design related items (nozzle
design, portability, etc.) with the current system that should be sufficient for a senior design project.
Project Duration:
2 semesters
Technical Areas Encompassed (e.g., machine design, controls):
Machine design, solid mechanics, mechatronics, controls, measurements, and fluid mechanics
Any other special requirements:
Number of Students/Disciplines required
3 or more ME/MET students
26

SOUTH DAKOTA SCHOOL OF MINES AND TECHNOLOGY
SENIOR DESIGN PROJECT PROPOSAL
Project Title:
Proposed/Advised by:
Sponsored by:
4-Wheel Tilt Vehicle
Dr. Dolan
David Dieziger
Project Description:
Provide drawings and specifications for the construction of a vehicle based on US Patent 7,722,063 B2. Vehicle
will have 4 wheels, tilt and steer like a traditional motorcycle, be all-wheel drive, and have 250 to 400
horsepower.
The suspension system divides the vehicle into leaning and non-leaning components. The passenger
compartment and wheels lean together like a traditional motorcycle, and the rest of the vehicle (the drive train
and suspension system) remains upright like a standard automobile. It allows for a smoother ride than a
motorcycle because the suspension system, unlike a traditional motorcycle, does not experience any lateral or
turning acceleration. It allows for a smoother ride than a traditional automobile because it does not require
torsion bars, that negatively affect ride quality, to prevent body roll and weight transfer to the outside tires.
The most important feature of the design is that it solves a problem that no previous design for a tilting fourwheel
vehicle has solved: the transfer of power from the differential to the wheels. In my design the differential
does not tilt, and consequently the system of axles and u-joints is the same as a typical front wheel drive car (a
proven technology) avoiding the considerable expense and inefficiency of the technology involved in current
tilting four-wheel power train designs (extreme u-joint angles, long axle slip joints or multiple chain or shaft
drives).
Designing and building this entire vehicle in one year is probably not feasible, and thus this year‘s project will
involve choosing, designing, and building a subset of the vehicle is an option.
Project Duration:
2 semesters
Technical Areas Encompassed (e.g., machine design, controls):
Dynamics, vehicle dynamics machine and structural design, electric circuits, fluids, manufacturing
Any other special requirements:
Number of Students/Disciplines required (e.g., 2 ME, 1 EE, 1 CS):
4 ME students
27