About The Design Lab - Rensselaer Polytechnic Institute

SCHOOL OF ENGINEERING 

O.T. SWANSON MULTIDISCIPLINARY DESIGN LABORATORY 

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

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 the 

Rensselaer Polytechnic Institute. 

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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. 

Mark 

Mark Steiner 

Director, The Design Lab

4 The Design Lab at Rensselaer 

Students on the Balance Assist team, perform a 

system calibration prior to a demonstration.

Purpose 

Current 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 


Balance Assist System 

Team: 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) 

Semester Objectives 

Deliver 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 

Technical Results 

Design: 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 

• 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 

Accomplishments 

Mechanical 

• Manufactured four balance stands for 

practical application that incorporate 

load cell technology 

LabVIEW Software 

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. 

• New Features: 

• Visual Aids 

• Real time System Status 

Indicators 

• Automatic Suggested 

• Use of Counterweights 

• Simple GUI 

• Enables Quick and Easy 

Balance Procedure 

2010 Project Portfolio 5


GE student teams including Nacelle, 2-piece Blade, Tower 

re-design, their professors, project engineers and sponsor mentors. 

© 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) 

Project History 

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

contains: 

� Electric motor 

� Internal combustion engine w/ rechargeable batteries 

Purpose: 

�To observe and analyze the impact of PHEVs on 

the power grid 

�Research for future project application 

Current Semester Objective: 

�Build a simulation to identify the optimal load 

schedule for a transformer and the effect on 

the thermal properties. 

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 

Technical Results (Load): 

�23.6% loaded 1.25x the transformers rated load 

�9.26% remained overloaded for 5 hours of more 

© General Electric Company. Used by permission. 

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) 

Technical Results (Thermal): 

�For most scenarios, top oil temperature doesn’t 

exceed normal range (120 degrees Celsius) 

Hourly Temperature (C) 

100 

90 

80 

70 

60 

50 

40 

Rated Load: 37.5kW January, Albany NY 

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

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. 

Accomplishments: 

�Load schedule optimization tool built using excel 

�User interface constructed using LabVIEW 

�Output screens for thermal calculations using 

LabVIEW 

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. 

30 

20 

10 

0 

1 2 3 4 5 6 7 8 9 10 11 12 3 14 15 16 17 18 9 20 21 22 23 4 


Average 

Max 

Min 

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 


Present Nacelle Showing Bedplatemounted 

Gearbox, Shaft, generator and 

Yaw Bearing Surrounded by a 

Composite shell 

Project Scope 

1. Develop Structural Nacelle concepts 

•will allow direct mounting of a 

Wind Turbine Drive Train 

Components (Gearbox, Shaft, 

Bearing, generator, Yaw Bearing) 

•Provide protection, and allow 

maintenance, resist wind loads 

2. Down-select 2-3 concepts 

3. Develop CAD Models for selected 

concepts and Baseline (Bedplate 

type design) 

4. Develop Structural analysis models 

5. Perform structural analysis (static) 

6. Develop Design Trade-Off curves in 

design space 

Baseline Loading Model 

Wind Turbine Design 


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) 

Space Frame Design II 

1. 3. 

53,000 kg 

2. 

29,900 kg 

22,900 kg 

14,900 kg 

Bedplate Improvements 

Space Frame Design I 

4. 

Benefits: 

• Even stress distribution 

• Low principal stresses 

• High Stiffness 

• Low weight 

Network Design 

Monocoque (Unibody) Design 


Drawbacks: 

• Manufacturability 

• Weld construction 

• Ball joints 

• Requires a skin 

Ribbed monocoque design 

Corrugated sandwich structure 

Results from panel testing 

CTQs: Critical to Quality 

Stress 

Stiffness 

Weight/Cost 

Vibration 

Fatigue 

Transportability 

Manufacturability 

Maintainability 

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

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 

• Able to sustain weight of 

generator, gearbox, and rotor 

• Able to distribute stress 

throughout nacelle 

• Maximum deflection of the 

shaft is 

• 0-1 degrees 

• Optimized for minimum 

weight through FEA 

• Effects from machinery, yaw 

bearing, nacelle due to winds 

• Able to withstand cyclic 

loading 

• Assess the effects of crack 

propagation 

• Define a process of 

transportation 

• Define a process of 

manufacturing 

• Able to access interior of 

nacelle 

Performance Criteria 

The nacelle should deflect less than 1 degree 

at the tip of the shaft (35 mm) 

Next Semester Plans 

• Fatigue and Vibration analysis 

• Honeycomb sandwich structure research 

and analysis 

• Application of sandwich structures to 

optimize weight reduction and strength 

• Exploration of modified spaceframe 

options 

• Research on spaceframe shell thickness 

• Continuation of network design 


Project Goal 

Design a one of two feasible junctions for a 

two piece 50+ meter wind turbine blade 

Junction Criteria 

1. 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 

Governing Physics 

For bolt and adhesive analysis 

Bolt Thread shear stress 

Bolt Tensile stress 

Bolt shear stress 

Adhesive shear stress 

Adhesive peel strength 

t 

t 

Pos t on 1 

Loca ion # Loca ion # Lo at on # Loc on # 

1 2 3 4 

cr cal end ng 6 3 0 46 0 0 

m d po nt b nding 0 26 4 2 0 26 4 2 

ax al 13 8 13 8 13 8 13 8 

pre oad 17 6 17 6 17 6 17 6 

jo nt c nt ipe al 0 11 0 11 0 11 0 1 

Total 38 07 36 17 31 77 35 71 

Green Energy Initiatives 

Two-Piece Wind Turbine Blade 

Jeremy 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) 

S ess MPa 

Model Development-CAD/FEA 

Worm Screw Bolt 

Physical Testing 

Using Instron Machine 

2 5 

2 

1 5 

1 

0 5 

0 

0 5 

0 35 

0 3 

0 25 

0 2 

0 15 

0 1 

0 05 

0 

0 

Bo t Material Dens ty vs UTS 

S ress vs St a n or Var ous Prototypes 

0 05 0 1 0 5 0 2 0 25 0 3 0 35 

Stra n (mm) 

A hes ve on Bu t J in in She r 

A hes ve on Dov ta l o nt n T ns on 

B l ed Lap n Shear 

A hes ve on Bu t J in in Ten i n 

Do e ai Shear 

Do e ai Shea 2 

A hes ve She r 

A hes ve She r 2 

B l But Jo nt 

Wo msc ew en ion 

C-Channel adhesive 

w/square dovetails 


C-Channel adhesive 

w/angled dovetails 

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

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. 

t in 


St a n 

St e s (k a) 

C-Channel + adhesive 

Overlap Length 

25 0 

0 000 5 

0 0004 

20 0 

0 000 5 

0 0003 

15 0 

0 000 5 

0 0002 

10 0 

0 000 5 

5 0 

0 0001 

0 000 5 

0 

0 

0 0 5 1 1 5 2 2 5 

eng h (m) 

Bolts in Shear Dovetail Adhesive Shear Adhesive Bolts in Tension 

*Physical Testing was used to confirm results of calculations 

and Finite element analysis 

St ain 

M x Von M es 

St e s X 

St e s Y 

St e s Z 


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/m 3 

Cost ($x1,000,000) 

400 

350 

300 

250 

200 

150 

100 

50 

0 

Stress (MPa) 

$1.60 

$1.40 

$1.20 

$1.00 

$0.80 

$0.60 

$0.40 

$0.20 

$0.00 

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 

•Main factors are wall thickness and height 

•Torsion and fatigue not considered in initial analysis 

Cost 

•Mass connection plates and bolts neglected 

Total Stress vs. Height 

(Diameter =3.5m, Wind Speed = 20m/s) 

Steel Y eld St ength 

80 90 100 110 120 

Height (m) 

Cost vs. Wall Thickness 

(H=100m, D=3.5m, Wind Speed=20m/s) 

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

.025m Wall 

Th ckness 

.030m Wall 

Th ckness 

.035m Wall 

Th ckness 

.040m Wall 

Th ckness 

.045m Wall 

Th ckness 

0.020 0.025 0.030 0 035 0.040 0.045 0.050 

Wa l Thickness (m) 

Tower of Power 

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

Total Stress vs. Wind Speed 

450 

400 

Semimonocoq 

350 

300 

250 

ue Stress 

Lattice w/ Skin 

Stress 

Modular Pane Steel Yield Strength 

200 

Stress 

Hybrid Base 

150 Stress 

I Beam Lattice 

100 

50 

0 

Stress 

0 10 20 

Wind Speed (m/s) 

30 

Stress (MPa) 

Stress (MPa) 

Cost ($x1,000,000) 

120 

100 

80 

60 

40 

Lattice With Skin 

Structural 


• 4 posts with .5” thick skin (skin 

does 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 as 

tower 

Cost 

•Lattice neglected in cost model 

Total Stress vs. Height 

Base W dth 7m 

Base W dth 10m 

Base W dth 13m 

80 100 120 

Height (m) 

4 

3 5 

3 

2 5 

2 

1 5 

1 

0 5 

0 

Cost vs. Base Width 

5 6 7 8 9 10 11 12 13 

Base Width (m) 


Semi-Monocoque 

Wind Speed vs. Maximum Stress in a 

Structural 

467 

4m Diameter Tower 

0.700 

Number of Beams vs. Cost 

•Properties of W14x99 I-Beam 

used 


•Vertical I – Beams Only 

•Beams evenly spaced apart 

•Beams centroids placed at radius 

of tower 

417 

367 

317 

267 

217 

167 

117 

67 

Steel Y eld St ength 

0.600 

0.500 

0.400 

0.300 

0.200 

0.100 

17 

0.000 

Cost 

0 10 20 30 

0 5 10 15 20 

•Mass of stab lization rings and 

Wind Speed (m/s) 

Number of Beams 

bolts neglected 

15 Beam Towe 12 Beam Towe 10 Beam Towe 

I-Beam Lattice 

Structural: 

•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 

•Skin material was assumed to be steel 

Hybrid Base 

Structural 


•Cylindrical tower of only 

concrete 

•Induced stresses assumed to 

be the same as a 00m tall 

concrete tower 

Cost 


•Cylindrical tower of concrete 

with 1’’ thick steel shell 

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

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

Stress (MPa) 

8 Beam Towe 6 Beam Towe 

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

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. 

Stress (MPa) 

Cost($x1,000,000) 

300 

250 

200 

150 

100 

50 

0 

$0.00 

Total Stress vs. Tower Height 

(t=0.25in, D=4m, Wind Speed=20m/s) 

50 60 70 80 90 100 110 120 130 140 150 

Tower He ght (m) 

Cost vs. Height 

(D=4m) 

50 75 100 125 150 

Tower Height (m) 

t=.125 n 

t=.25 n 

t=.5 n 

70 

60 

50 

40 

30 

20 

10 

0 

Stress (MPa) 

Cost ($x1,000) 

160 

140 

120 

100 

80 

60 

40 

20 

0 

Cost ($x1,000,000) 

•Concrete estimated to cost $2.78 per ft 3 

and 2400kg/m 3 

•Cold rolled steel is estimated to cost 

$1.5 per lb (Albany Steel) 

Bending Stress vs. Wall Thickness 

0 0.5 1 1.5 2 2.5 3 

Wall Thickness (m) 

Cost vs. Wall Thickness 

0 0.5 1 1.5 2 2.5 

Wall Thickness (m)

Vision and Scope 

Develop 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. 

GE Wind Turbine Interaction 

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) 


Current Objectives 

1. 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. 

Tower System Improvements 

Results 

Rotor Designs and Manufacturing 

Old Tower New Tower 

•Ability to check motor 

overheating 

•Redundant thrust 

readings 

•Better signal 

processing 

New Nacelle 

•Enabled thrust 

measurement 

•Better aerodynamics 

•Stronger nacelle 

Code Modifications 

Old Interface 

Circuitry Upgrades 

•No voltage interaction 

between dynos 

•Increased power 

capacity 

•Higher tolerance 

resistors 

•Individual power 

supplies 

•Modular face plates 

New Interface 

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Wind Tunnel Set Set-up up 

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Faulhaber 1331 

Faulhaber Faulhaber 2232 

GWS RS-385SH RS 385SH 

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Fall ‘09 Rotor 

Dynamometer Selection 

GE Designed Rotor, ABS 

Team Designed Rotor GE Designed Rotor, SLA Material Deflection Comparison 

•Higher RPM motors 

•Higher current motors 

Old Circuitry New Circuitry 

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

Improving Wind Farms 

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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 up-wind turbines and also up-flow disturbances 

from down-wind 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. 

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4-bladed rotor 

•Smoke visualization capable 

•Blade end effects/Axial induction 

factor 

•Reduced angular velocity 

•Theoretical higher Cp 

Flow Visualization Techniques 

Fall ‘09 Results 

New Smoke 

•Experimenting with 

Visualization 

more effective 

visualization techniques 

GE rotor 

•Theoretical higher Cp/TSR 

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 

Quantity Sensor Redesign 

Craig 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) 

Background Information 

The 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. 

Measurement Results 

Figure 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 1 Figure 2 

Figure 3 

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. 

Loop Fluid 

(Water, Urine, 

Coolant) 

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. 

Hamilton Sundstrand Bellows Accumulator 

Bellows 

Gas Charge 

(Air, Nitrogen, 

Helium) 

Our Working Prototype 

(a.) 4” x 48” hydraulic cylinder 

(a.) 3/8” threaded rod 

(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 

Project 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. 

(b.) Power drill attachment position 

(c.) Socket ratchet attachment position 

(d.) Intermediate block connecting 

linear actuator to piston 

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

Students meeting with the mentors at Hamilton Sundstrand. 



Parallel Processing for Radar Analysis 

Team: 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. 

Technical Requirements: 

•Examine average run times versus 

number of objects in scene 

•Determine average runtime versus 

CPU/ GPU resources 

Radar Algorithm: 

W(f) RCS(f) 

s(t ) S(f) HMF(f) scp(t) fft() conj() ifft() ifftshift() 

H 

S(f) 

MF(f) • W(f) • RCS(f) 

Provided Algorithm 

Simulink Model of Algorithm 

System Inputs and Output: 

Amp ude 

Amp de 

2 

1 5 

1 

0 5 

0 

-0 5 

1 

-1 5 

2 

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

1 5 

1 

0 5 

0 

-0 5 

( ) 

T me s) 

Fr quecny 

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

RCS ) Noi e 

1 

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

Fr quecny 

x 10 

Radar Cross Section, RCS(f) 

4 

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

x 10 4 

W f) F ter 

1 

0 9 

0 8 

0 7 

0 6 

0 5 

0 4 

0 3 

0 2 

0 1 

0 

Amp ude 

Amp de 

4 

x 10 

6 

5 

4 

3 

2 

1 

Sc ( ) 

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

x 10 4 

0 

T me s) 

Output Signal Scp(t) How a GPU Splits Up Work 

Doing the parallel calculation 

V1 VR = V1 * V2 

V2 1 2 3 4 . . . 

1 2 3 4 . . . 

V R [1] = V1[1] * V2[ ] 

Returns Per Second 

2 500 

2 000 

1 500 

1 000 

500 

0 

7,000 

6,000 

5,000 

4,000 

3,000 

2,000 

1,000 

0 

* 

* 

* 

* 

* 

* 

1 2 3 4 . . . 

VR * 

* 

* 

* 

* 

* 

V R [4] = V1[4] * V2[4] 

GPU P ocesso 

GPU vs. mGPU vs. CPU - Returns Per Second 

8,000 

GPU - 16K 

GPU - 32K 

GPU - 64K 

mGPU - 16K 

mGPU - 32K 

mGPU - 64K 

CPU - 16K 

CPU - 32K 

CPU - 64K 

y = 16.002ln(x) 207.8 

R² = 0.989 

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

Number of Elements (log8 scale) 

1 8 64 512 4,096 32,768 

Number of Returns Processed 

Radar System Performance Improvement 

Loops X/N 

returns until 

processed 

Design 

Splitting Work Between Multiple GPUs 

X RCS(f)’s on CPU 

X/N Returns X/N Returns X/N Returns 

GPU 1 GPU 2 . . . GPU N 

X S cp(t)’s on CPU 

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. 


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

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! 

Time (ms) 

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

GPU - 16K 

GPU - 32K 

GPU 

GPU - 64K 

mGPU - 16K 

CPU 

3,500 

mGPU - 32K 

Log F t (GPU) 

y = 195 44x0 1618 

R² 0 9789 

3,000 

mGPU - 64K 

CPU - 16K 

Powe F t (CPU) 

CPU - 32K 

2,500 

CPU - 64K 

Time (µsec) 

1,000,000 

Time (ms) 

2,000 

1,500 

1,000 

500 

0 

100,000 

10,000 

1,000 

100 

10 

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

1 

1 8 64 512 4 096 32,768 


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

GPU - 64K 

mGPU 16K 

mGPU - 32K 

mGPU 64K 

CPU - 1 K 

CPU - 32K 

CPU - 6 K 

1 4 16 64 256 1,024 4 096 


Time � 

How Our Algorithm is Processed 

CPU 

GPU 

Allocate Memory and 

copy Data for RCS(f)’s 

Limited by CPU RAM size 

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

FFT on s(t) 

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

→ RCS(f) data transfer to GPU → 

Loop until all Multiply RCS(f)’s * HMF(f) returns are 

processed IFFT on Scp(f)’s and shift 

← Scp(t) data transfer to CPU ← 

Return Scp(t)’s Pre-computed 

to save time 

Return to CPU 

when no more 

RCS(f)’s 

Semester Objectives Met: 

•Generation of universal test data 

•Agreement among multiple models of 

radar systems 

•Detailed timing and performance 

analysis 

•Accuracy analysis 

Conclusion: 

•Use of GPUs increases throughput by 

2-6 times over our CPU implementation 

•Algorithm easily parallelized on GPU 

•Scales linearly across two GPUs 

Next Steps: 

•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 

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

Effects of Stray Currents on Bearing Life 

Lun 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) 

Purpose Test Capability 

Design, construct, and deliver an 

apparatus which will test and analyze the 

effects of stray currents on bearing life. 

Technical Design Approach 

• Parallel processing 

• Communicaôn 

• Redundancy 

• Keep It Simple 

Transformaôn of Design 

Instrumentaôn 

• Max Load: 0-‐950 at 150psi 

• Voltage Range: 0-‐30v 

• Amperage: 0-‐10A 

• Signal Frequency: 60-‐10,000Hz 

• Rotaôn Speed: 2000 rpm variable 

drive 

System Features 

• 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 

Monitoring and Sensing 

• 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 of 

1000mV/g, 2kHz bandwith 

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

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. 


Purpose 

Our objec*ve is to develop a camera 

system to replace the current imaging 

system for a surgical device in order to 

reduce system cost and increase image 

clarity and resolu*on. 

Semester Objec:ves 

Design a camera system which meets 

or 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 the 

project 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 and 

sterilizaOon processes currently used. 

• OrientaOon – to provide the correct viewing angle 

for the camera system to ensure an unobstructed 

view of the surgical site. 

Biomedical Engineering Scope 


Camera Study Project 

Team: 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) 

The decision matrix (to 

the right) compares 

several camera systems 

in order to determine the 

best one suited to this 

project. 

Note: Camera System 3 

was uOlized due to the 

unavailability of Camera 

System 1. 


Ranking 

1 (best) to 

4 (worst) 

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

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. 

Camera 

System 1 

Camera 

System 2 

Camera 

System 3 

Ex s:ng 

System 

S ze 

(d amete ) 3 1 2 3 

L ghOng 

M n atu e 

LEDs 

None None 

Exte nal L ght 

Sou ce 

ResoluOon 

(p xels) 1 2 1 3 

Came a 

Cost 1 3 2 4 

V ewe 

Cost 1 3 2 4 

Design Progression and Component IntegraOon 

The images to the le_ and right follow 

the progression of the integraOon of 

the camera system s components. 

The system components include: 

• camera sensor 

• lighOng source 

• lens 

• casing 

To the right is the casing designs are 

the CAD renderings of the casing 

design progression. 

To the le_ are sample lens images and 

a picture captured during the lighOng 

source funcOonality test. 

The Performance Requirement 

table to the right listed the 

requirements which we aimed 

to confirm via tesOng. All 

items with check marks were 

tested and confirmed. TesOng 

procedures for Image Clarity 

need further development 

before accurate results can be 

found. 


� 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 

Students assembling and bench testing a miniature camera. 

Performance Requirements 

Performance 

Requirement 

Confirmed 

Came a Ch p Type � 

Image ResoluOon � 

L ght Sou ce 

FuncOonal ty 

� 

Ch p FuncOonal ty � 

Integ aOon w th the 

Cu ent Su g cal System 

� 

Image Cla ty N/A 

Proposed camera system concept

Purpose 

Identify a particular font from a 

sample image 

Scenario: Customers (i.e. graphic artists) will 

upload a sample image (screenshot, digital 

photo, etc.) and our system will identify the 

closest font Monotype has available 

Semester Objectives 

• Creation 

attributes 

of a database to search for font 

• Ongoing population of the database with 

• 

attributes of different fonts for use in a tool 

prototype 

Development of an algorithm for separating 

characters within an image 

• Classification 

database 

of fonts by attributes within 

• Implementation of logic in a prototype tool that 

can identify a font based on attributes 

• Determination of tolerances for comparison 

method(s) 

• Evaluation of different comparison methods 

and recommendations on these methods 

• Final recommendations of project direction and 

documentation 

current semester 

on progress made during 

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 ten’s of thousands of 

differing fonts, and a user workflow that can enable a user 

to access this functionality over the web. 

Automatic Font Identification 

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


XOR Based Comparison: 

0.294 

Word Separation: 

Font Database: 

•2410 Fonts 

•13 Font Sizes 

•1933920 Samples 

•1.5GB w/ Indexes 

Ratio Intervals: 

0.5835 

Python GUI: 

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


• Researched many possible methods for font 

identification 

• Developed 11 python modules to support 

• 

prototype and comparison engine 

Implemented XOR comparison method 

• Implemented ratio based comparison method 

• Developed PIC (character attribute) 

• 

classification system 

Created prototype program using XOR and ratio 

methods 

• Designed and populated a database with 

• 

character information 

Implemented character separation for kerning 

and italics 

Next Steps 

• Continue development of character separation 

tool with emphasis on connected characters 

• Explore applying ratio tolerance test to input 

sample instead of database samples 

• Extract PIC attributes from sample characters 

• Explore weighted PIC attributes and additional 

unique attributes 

• Implement PIC-based comparison method 

• Expand XOR comparison to weight potions of a 

character 

• Optimize database indexes, resolve slow 

queries and lookups 

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



Students meeting with Northrop Grumman 

before the poster presentation. 


Erika 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) 

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. 

Hybrid Flow Actuators – Isometric View 

Screw Drive Actuator 

with Micro Vane Locator 

Synthetic Jet Modules 

Subassembly – Exploded View 

Subassembly 

Next Step: Demonstrate current 

apparatus to Northrop Grumman; 

submit design for analysis and 

testing. 

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

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 microvane 

geometries (rectangular and triangular). The team has 

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. 

Hybrid Flow Control Actuators 

Micro-Vane Assembly 

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 actuation and 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. 

Students working together in the shop. 

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 

Assembly – Right View 

and steady jets modules. 

Electrical Sensors 

Micro vane actuation is controlled by a 

Hall effect sensor. Electrical currents are 

measured through magnetic fields to 

calculate vane positioning. 



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 cart 

more challenging than it needs to be.

Improving The Lives Of The Elderly 

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 refining 

prototype systems. Our customers (retail 

stores) need the cart and its subsystems to be 

cost effective and to improve the shopping experience 

enough for senior citizens that it influences 

their store choice. 

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. 

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. 

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 

In 2000 there were 18.4 million people ages 65 to 74 years 

old, representing 53 percent of the older poplulation in the 

US. 

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. 

Subsystem Decisions 

In order to determine what areas to focus 

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 helpfulness 

of the cart. Our Decision Matrix is 

on the right. 

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 comfortable 

moving around with the cart. 

Barcode Scanner 

. We wanted to help Seniors with vision 

problems read labels in the store. We experimented 

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 

Drive System 

We experimented with force sensors and 

electric motors to help assist seniors move 

their carts around their place of business. 

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 preliminary 

testing, mechanical braking was 

preferred. 

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

Rick Iannello of Albany Guardian Society discussing the project with 

Linda Schadler, Associate Dean of Academic Affairs 

ALBANY GURADIAN SOCIETY 

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



Students examining biometric circuitry built by the team. 


Biometrics 

Team: Jesse Herrmann1 , Jus4n Toth1 , Rob Margolies1 , Sean Fleury2 , Kevin SwiB2 , Shannon Johnson3 , Hannah Piontek3 , Benjamin Scheiner3 1Electrical, Computers and Systems Engineering, 2 Biomedical Engineering, 3 Materials Science & Engineering 

Objec&ve: 

To create an easy to use, affordable biometric measuring system that 

integrates 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. 

Plan: 

Iden4fy Target Market 

Conceptualize Design 

Build and Integrate Subsystems 

System Tes4ng and Data Collec4on 

Biometric Subsystem Outline 

Real-Time Vital Statistic Processing 

Technical Results: 

Successfully completed major subsystems: 

Luminary Microcontroller 

System Wiring 


Successfully built Microcontroller, 

Sensor, Power and Packaging systems. 

Integrated into cohesive device that 

recorded user’s biometric informa4on. 

Laid framework for future modular systems, 

adaptable to variety of markets. 

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

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. 

BaLery and Voltage Convertor 

Heart Rate (Beats/Min) 

60 

150 

140 

130 

120 

110 

00 

90 

80 

70 

60 

Heart Rate 

Sample Heart Rate Data 

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

Sample Number 



Students discussing the sustainability rating of vaccum 

cleaner parts with their instructor Jeff Morris. 


Design for Sustainability 

Kate Biagio4 (MGTE), John Cannarella (MECL), Pete Cassellini (MGTE), Andy Dubickas (MGTE), Maggie Exton (MS&E), 

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

Purpose 

To 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 Metric 

Semester ObjecAves 

• 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 Pme (measured in 

dollars, stars, etc.) 

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) 

Current Metric 

Total Sustainability = Durability [Source + Manufacture + Transport + Disposal] + Use 

MSI Material source index 

MI Manufacture Index 

TI TransportaPon Index 

RI Reclaim Index 

UI Use Index 

m Mass 

UI = Product Specific Serviceability = To be determined 

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


• Improved the previous semester’s scorecard 

• Reverse engineered two products 

• Compared/contrasted scorecard to exisPng LCAs 

Next Steps 

• Develop “serviceability” equaPon 

• Design an interacPve web-‐based design tool 

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

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 

28 The Design Lab at Rensselaer

Percent Floorspace 

Necktab 

702 Vest 

Othe Vest 

Othe 

ISO 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 

Gap Analysis Checklist 

• Quality Management System 

• Management Responsibility 

• Resource Management 

• Product Realization 

• Measurement, Analysis and Improvement 

Proposal 

• Create Quality Management System 

• Help design Quality Manual 

• Improve existing Standard Operating 

Procedures 

Blind Assembly 

Mark 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) 

Floor Layout 

Opportunity 

• Inefficient production line layout 

• Horizontal, scattered product lines 

• Prolonged idle time between 

processes 

Proposal 

• Vertical (stream-lined) work flow 

• Incorporation of 702 vest line 

• Improved space management 

• Enhanced maneuverability 

Deliverables 

• Electronic management system 

• 2D/3D Modeling management 

system 

• Floor Layout Assessment 

• Work flow plans plans 

ISO 9001 

250 

200 

150 

100 

50 

0 

1200 

1000 

800 

600 

400 

200 

0 

Annual Product on (Units 

n Thousands) 

Cu ent P oposed 

Cu ent 

Necktab Production 

(Units Per Day) 

Quality Management System (QMS) Pyramid 

Allows a blind laborer to side-seam a necktab 

Previous 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 

JUKI Fixture 

Northeastern Association 

of the Blind at Albany 

New Press for Tyvek Line & Electrical 

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. 

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

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. 

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.


LabVIEW Controls 

Camera 

Engineering Students On The Ball 

Ball Balance System 

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

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. 

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. 

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. 

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 

Base plate dimensions 20” x 20” 

Plate dimensions: 13.875” x 11” 

Camera Arm Height: 26.5” 

Close-up view of actuation system 

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) 

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

Underside view of the Ball Balance Apparatus. 


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. 

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. 

[1] 

[2] 


Above: Student reviewing the posters at the 10th anniversary celebration. 

Below 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. 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 Study 

Alex Camhi (MGTE), Eric Chapin (MECL), Linda Donoghue (MECL) , Jesse Kenyon (MECL), Zachary Loya (MECL), 

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

KNUST & RPI 

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. 

Gas Generation Gas Collection and Delivery Gas Analysis 

•Gas Production (dry wood): 330-340 L/kg 

•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 

Full System 


•Fully functioning testing device 

•O&M Manual 

•Test Plan 

Next steps: 

•Testing and Data Acquisition 

•Field testing in Ghana 

•Rotameter Range: 0-4 L/min Air 

•Orifice Size: 0.089” 

•Sustained Flame Height (H2): 0.7” @ 1.5L/min 

• Flame Shield: Protection from wind 

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

Visitors from KNUST listening to Professor 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 illustrate mathematical 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 Arcs 

Team: 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 

Arcs software designs to 

physical models. 


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. 

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 

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)

Wild Animal Detection and Repellant Systems 

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) 

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. 

Detecting 

Unit 

Farm Area 

Semester Objectives: 

Infrared Detection System 

o Detect animals up to 100m away 

o Program for user interaction and 

visualization of predators in the area 

o Cost less than $200.oo USD 

Detection System Block Diagram 



o Detect an object up to 22.6m away 

o Program for user interaction 

o Cost less than $100.00 USD 

System Visualization 

Detection 

Threshold 

Repellant 

Beacons 

Ultrasonic Repellant System 

o Output noise level of 120dB at 50m 

o Adjustable output frequency band 

o Power consumption of less than 500W 

o Cost less than $300.00 USD per unit 

Repellant System Block Diagram 


o Output noise level of 100dB at 10m 

(calculated) 

o Adjustable output frequency band 

o Power consumption of 13W for system 

o Cost approximately $100.00 USD per unit 

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. 

Technical Results: 

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. 


A test bed was created to 

characterize detector and emitter 

performance. 


A Chebyshev Chebyshe high pass filter and op 

amp power amplifier were successfully 

developed and implemented. 

θ 

IR detector 

& Circuitry 

Measuring Tape 

(Length varied by tester) 

Transmitting IR LED 

& Circuitry 

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

Max Ra ge o T an m ss on 

0 

0 

0 

0 

0 

0 

0 

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

One ra sm t ng IR LED 

Two Tr nsm t ng IR LEDs 

Th ee Tra sm t ng IR LEDs 

0 

10 15 20 25 0 35 40 45 50 55 60 

Rece ver O f et in Deg ees 

Ultrasonic Filter Frequency 

Response 

Future System Design 

Long 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 Stein 

Business Development Manager 

Guest Lecturer 

Mark Anderson 

Project Engineer 

Charles “Casey” Goodwin 


Aren Paster 


Scott Miller 


Rich Alben, Ph.D. 

Clinical Associate Professor 

Valerie Masterson 

Administrative Specialist 

Jeff Morris 

Technical Manager, CAD/CAM/ 

CAE 

Scott Yerbury 

Electromechanical Technician 

Sam Chiappone 

Manager, SoE Fabrication and 

Prototyping Facilities 

Sam Chiappone 

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

AFFILIATED FACULTY 

Biomedical Engineering (BME) 

Eric Ledet, Ph.D. 

Assistant Professor 

Electrical, Computer & 

Systems Engineering (ECSE) 

Lester Gerhardt , Ph.D. 

Professor 

Biplab Sikdar, Ph.D. 


Partha Dutta, Ph.D. 

Professor 

Ken Connor, Ph.D. 

Professor 

Industrial & Systems (ISE) 

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. 


Michael K. Jensen, Ph.D. 

Professor 

Deborah A. Kaminski, 

Ph.D. 

Professor 

Matthew A. Oehlschaeger, 

Ph.D. 


Materials Science 

Engineering (MSE) 

Daniel Lewis, Ph.D. 


Rahmi Ozisik, Ph.D. 


John LaGraff, Ph.D. 

Adjunct Professor 



About The Design Lab 

Our Mission 

The O.T. Swanson Multidisciplinary Design Laboratory (The Design Lab) mission, 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 led to Rensselaer’s recognition by Business Week magazine as one of the top 60 design 

schools in the world! 

Providing Real World Experiences for Students 

Over 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 Curriculum 

We 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 Institute 

The 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 Reality 

The 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 Better 

Every 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 Entrepreneurship 

Every 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 & Design 

We 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 Vision 

Our 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

ev. 02152011 

Rensselaer Polytechnic Insitiute 

School of Engineering 

O.T. Swanson Multidisciplinary Design Laboratory 

110 8th Street 

JEC 3232 

Troy, N.Y. 12180-3590 USA 

http://DesignLab.rpi.edu 

518.276.6746

About The Design Lab - Rensselaer Polytechnic Institute

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