Department of Technology

2003-04 Senior Design Conference

2003-04 Annual Senior Design Conference for Electrical & Information Engineering Technology and Manufacturing Technology Majors 

Thursday, April, 29, 2004, Ind Tech Center ITC 3 
Time:  1:30 pm – 5:00 pm 
Department of Industrial Technology, College of Natural Sciences
University of Northern Iowa

You are cordially invited to attend and review the following 2003-04 Senior Research & Design Projects. Your attendance and feedback are very important for us. This is the first time, we are having a joint senior design project seminar bringing both Electrical & Information Engineering Technology, Manufacturing Technology, and Construction management students together very successfully in collaborated projects. Your attendance will also honor our senior design students who worked very hard in this academic year.

Refreshments will be served.

OST PROCESS REDESIGN

Presenters: Joshua A. Evans, Stephanie L. Sickels, & Katherine M. Waterman 
Faculty Advisor:  Dr. R. O’Meara
Sponsor/Industry Supervisor: Carl Vass, Safety & Env. Manager,  Federal Mogul, Burlington, IA.
Time: 1:35 – 1:50 pm
This project is for the champion spark plugs Co. in Burlington, IA.  The team studied the OST testing station current practices and redesign the testing procedure to eliminate the excessive strain on operators due to the need to flip the plastic trays into metal holders for testing the spark plugs for defects prior to shipping.  The team suggested some solutions as (1) operator manual changes, (2) a pneumatic involvement.  A design for a machine to perform the flipping process is also studied to avoid the possibility of related wrist and arm injuries.

UNI ELECTRIC CAR “Panthers EV”

Presenters: Floy, Kristopher M.
Schlickman, Timothy L. Vo, Dao M.
Faculty Advisor:  Dr. S. Giese
Sponsor/Industry Supervisor: 
Time: 1:55 - 2:10 pm 
The team is involved in the designing of an electric car “Electrathon Car” for UNI.  Areas to be covered during the study of this project are: the drive system, body design, framing and other critical aspects of the car design.  Final selection of the components of the car is investigated.  A final parts list is  developed including final interior/exterior designs, and functioning of the power train is also defined.

JOHN DEERE NON-ENGINE TEST CELL SPECIFIC FAILURE NOTIFICATION & SAFETY SHUTDOWN

Presenters: Paul Rael, John Burton 
Faculty Advisor: Dr. R. Pecen. 
Sponsor/Industry Supervisor: Jon Anderson, Steve Hart, Dennis Miller, PEC, Deere & Company.
Time: 2:15 – 2:30 pm

This project includes upgrading  and improving current test cell monitoring, problem recognition, and test cell efficiency in JD PEC.  A PLC based system is implemented to monitor multiple test variables and shut down the test in the event of a failure.  Our solution is to configure a Micrologix 1200 PLC to monitor various inputs from temperature and pressure, to shaft breakages, and output this information to an operator interface and shut down the test, indicating to the technician which sensor caused the test cell stoppage.  A PLC based system was deemed far more flexible and adaptable than other solutions investigated.  The cost was also found out to be competitively priced with other solutions with far more performance capability.  The final product for JD PEC is ready and tested successfully.

IND TECH  DEPT CENTENNIAL BRASS MEDALLION

Presenters: Robby L. Cromer, Kristopher J. Kuker, and Brett A. Shaffer 
Faculty Advisor:  Dr. S. Giese
Sponsor/Industry Supervisor: 
Time: 2:35 - 2:50 pm
This project involves the design aspects, the preparation of molds, material selection, tooling, and casting a medallion to commemorate the centennial celebration of the Dept of Industrial Technology.  The design phase includes use of appropriate software to produce different possible designs the medallion.  Each of these designs are studied for its merits, ease of production, and compliance with use of UNI logos,  materials selection study to choose the best material to produce and how to secure it for the production phase.  Selection of casting method, mold preparation, scheduling with the Ind Tech  MCC personnel, final preparations for production and casting, and finishing operations are finalized.  The team has produced 250 medallions.

INTERFACING WEATHER STATION DATA TO A “LIVE” WEBSITE BY LabView™  FOR IOWA ENERGY CENTER - ANKENY:

Presenters: Jason Djuren, Jerry Bjerke Faculty Advisor: Dr. R. Pecen.
Sponsor/Industry Supervisor: Curtis J. Klaassen, & Xiaohui (Joe) Zhou, IEC, Energy Resource Station, Ankeny, Iowa.
Time: 2:55 - 3:10 pm
A wealth of data can be measured from the outdoor environment. This project examines and impellents one method of obtaining this data and displaying it on a web server. Weather data was obtained from 14 sensors and streamed into two LabView™ Field Point data acquisition modules. Thorough the use of LabView™, we were able to log the data and display it on a web server in a user-friendly format. 

 UNI SOLAR ELECTRIC BOAT “E-BOAT”

Presenters: Dan Frisch, Matt Brustkern, Eric Schumacher; Jamie Ruth, Jack Steuben, Phil Tentinger.
Faculty Advisors: Dr. R. Pecen, Dr. M. Fahmy 
Sponsor/Industry Supervisor: Iowa Energy Center, CNS SOAR, Kay’s Mfg, Janesville, Reuter’s Welding & Repair, Jessup.
Time: 3:15 - 3:30 pm 
Students  from the EIET and Manufacturing Technology majors have been working together for the past two semesters to optimize the electrical, electronics, and mechanical design of UNI eBoat.  This year’s team has researched and eliminated the downfalls that have plagued teams in the two previous competitions. The same vessel that has be used in previous years has undergone a dramatic transformation for this year that has made it much lighter, faster and sleeker with vastly improved reliability. New solar arrays custom made by team, new electrical motors, and computer aided speed controller are some of the new developments.  This project will continue to initiate new design ideas in the field of clean boat technologies in Iowa waterways, ultimately affecting the community in a very positive way.

DELTA TARGET MACHINE
Presenters: James W. Bean, Mitchell J. McQuillen, and Brian J. Zimmer 
Faculty Advisor:  Dr. S. Giese
Sponsor/Industry Supervisor: Ind Tech Dept
Time: 3:35 – 3:50 pm 
The project deals with the Delta archery target-stuffing machine.  The two main areas of concern are: 
(1) The material used to fill the target bag: The current material used consists of long strips of an insulation material.  Due to the fact that the material is bailed prior to usage, it must be shaken apart before it can be stuffed into the target bags, and (2) The manual stuffing of these bags that is currently being utilized. 
The team studied the possibility of designing an automatic machine for the stuffing process of the target bag.  Different ways are discussed after a through search of the literature.  A manual machine with simple principles is designed to assist in the stuffing of the target bags.

STARR WIND POWER PROJECT AT HICKORY HILLS PARK

Presenters: John Mackamul, Rusty Elson, Billie Johnson,  Tony Kanne.
Faculty Advisor: Dr. R. Pecen, Dr. M. Fahmy.
Sponsor/Industry Supervisor: UNI Foundation through a private donor, Black Hawk County Conservation Board, Iowa Laser Inc. 
Time:  3:55 - 4:10 pm
This project includes wind data monitoring, design and construction of a new wind turbine to be used in a new hydro-wind hybrid system.  The main objective of this project is to develop a functional hybrid system that generates zero-emission electricity utilizing hydro and wind renewable resources in Hickory Hills Park.

STARR HYDRO POWER PROJECT AT HICKORY HILLS PARK

Presenters: Dennis Craun, Brian Mayfield Easie Toingar, Tony Kanne, Rusty Elson. 
Faculty Advisor: Dr. R. Pecen, Dr. M. Fahmy.
Sponsor/Industry Supervisor: UNI Foundation through a private donor, Black Hawk County Conservation Board, American Pattern. 
Time: 4:10 - 4:25 pm
This project includes design and development of a hydro turbine to generate zero emission electricity  used in a new Hydro-Wind Hybrid system in Hickory Hills Park. Project includes all necessary steps of generating green electricity and supplying it to the cabins in Hickory Hills Park. 

Autonomously Guided Vehicle (AGV)

Presenters: Cory Heisterkamp, & Matt Starr. 
Faculty Advisor: Dr. R. Pecen, Dr. F. Chalkiadakis. 
Sponsor/Industry Supervisor: CNS SOAR Grants. 
Time:  4:30 - 4:45 pm
The goal of this project is to examine the feasibility of developing a vehicle capable of self-guidance and speed control. With a limited budget and resource constraints, the AGV accomplishes obstacle-detection, line-tracking and auto-steering concepts. Ultimately, such concepts may find their way into automobiles of tomorrow with the hopes of making travel safer for drivers and their passengers.

AXTELL HARLEY CYLINDER DESIGN IMPROVEMENT

Presenters: Nicholas P. Jones, Sheldon E. Klein, and Rodney S. Niemer
Faculty Advisor:  Dr. Y. Lerner 
Sponsor/Industry Supervisor: Chaz Cooney, Axtell. 
Time:   4:45 – 5:00 pm
This project deals with the study of machining practices of a machine shop that specializes in Big Bore Harley Davidson motorcycle engines.  The team studied  and evaluated current machining practices, efficiency of tooling, identify major problem areas, availability of proper fixturing and jigs, and equipment deterioration.  Areas of study  also included efficiency of drilling and tapping operations, space utilization, and shop layout.  Achievements are much easier processes, less cost demanding, more output, more fool proof, and less operator error outcomes.

MANY THANKS TO ALL OF OUR INDIVIDUAL, GOVERNMENT,   AND CORPORATE SPONSORS, INDUSTRIAL ADVISORS, AND DEPARTMENT FACULTY & STAFF MEMBERS!

For more information: Please call Dr. Pecen at (319) 273 2598 or just e-mail him at Pecen @uni.edu