UNIVERSITY OF KENTUCKY
MECHANICAL ENGINEERING
MECHANICAL ENGINEERING
ME 411 / 412 CAPSTONE PROJECTS
Fall 2010 – Spring 2011
Fall 2010 Spring 2011
Summary of Projects A Pl
A.
Pleasure Marine Alternative Power M i Alt
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(Entrepreneur)
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J. Advanced Machine Technologies
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B. Toyota
K. AIAA – Design Build Fly Competition
C. Center for Applied Energy Research
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L. Weightless Wildcats
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D. Trane
M. Student Proposals (Entrepreneur)
E. AFRL Student Challenge
F.
G. LEDERGY Lighting Solutions H.
I. ASME Design Competition
A‐1 Pleasure Marine Alternative Power
Houseboat Project
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KY/UK has staked its claim to advances in the automotive/battery sector. I believe that another rich market with easier adaptation and entry to market opportunities for electric/solar power could be the pleasure marine business. Technical advances, applications and early design proof might even assist in longer term, larger market opportunities.
•
This project would address the mechanical propulsion and electrical power demands of a This
project would address the mechanical propulsion and electrical power demands of a “typical”
typical houseboat and ultimately result
houseboat and ultimately result in a in a
scalable electric boat design utilizing best in class components and systems and the most appropriate, state of the art processes.
Analyze existing standard houseboat designs and options and survey to define “typical” usage patterns, etc. to serve as design specs.
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Review power requirements, power cycle, weight to power ratios. vs. gas/diesel/fuel weight solar and auxiliary wind power options, etc. along with cost comparison/trade‐offs. Semester 1 ‐ Design review and analysis, development of a scalable design specification, initial review off components/systems.
Semester 1 Design review and analysis development of a scalable design specification initial review off components/systems
– Advances in technology, motors, transformers, energy storage systems, fuel cells, controls, solar, passive energy, etc. could be researched and best practices/products can be applied. •
Semester 2 ‐ Component selection, system design, potential prototype brass‐board build if funding available.
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Utilization of passive energy home designs (insulation/thermal bridges, etc.
Utilization
of passive energy home designs (insulation/thermal bridges etc —ref
ref. UK HBEER and solar home designs) UK HBEER and solar home designs)
should also be considered and applied as possible. If applicable specific targeted design challenges and constraints could be identified for future projects.
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One possible source for standard and option selections could be: http://www.sumerset.com/features.php
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Utilization of advanced materials might include: Flexible solar materials for awnings g
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http://www.powerfilmsolar.com/military‐products/solar‐field‐shelter.php
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Analysis of other industry developments as comparisons or foundation: Electric buses‐Proterra, TerraVolt, UQM Electric, etc.
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Contact: Gary Marshall 859‐559‐5720 (gary.marshall@eku.edu)
A‐2 Pleasure Marine Alternative Power
Powerboat Project
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KY/UK has staked its claim to advances in the automotive/battery sector. I believe that another rich market with easier adaptation and entry to market opportunities for electric/solar power could be the pleasure marine business. Technical advances, applications and early design proof might even assist in longer term, larger market opportunities.
•
Pleasure boats typically get about 4‐10 miles per gallon. This captive market typically pays at least a dollar/gallon premium for fuel at marinas. Web research shows very little advances in economy in this sector, since it is a highly discretionary/leisure market.
Some electric applications have been made, but most have been relegated to 5 mph. •
•
This project would address typical power and usage requirements for mechanical propulsion and electrical power demands of pleasure boats (i.e.18‐30 foot type boats‐150‐300 hp) and ultimately result in a scalable electric boat design utilizing best in class components and systems and the most appropriate, state of the art processes.
•
Semester 1 ‐ Design and usage review and analysis, development of a scalable design specifications, initial review off components/systems.
– Analyze existing standard designs and usage patterns to define a typical design specifications. – Review torque/power/efficiency requirements, power cycle, weight to power ratios. vs. gas/fuel weight, solar and auxiliary wind power options, etc. along with cost comparison/trade‐offs. – Advances in technology, motors, transformers, energy storage systems, fuel cells, controls, solar, auxiliary wind, etc. could
be researched and best practices/products applied. If applicable specific targeted design challenges and constraints could be identified for future projects.
•
Semester 2 ‐ Component selection, system design, potential prototype brass‐board build if funding available.
•
One encouraging design is www.edison‐marine.com that can pull a skier and cruise at 30 mph, although it also incorporates a high‐end wooden hull.
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Utilization of advanced materials might include: Flexible solar materials for awnings http://www.powerfilmsolar.com/military‐products/solar‐field‐shelter.php
•
One typical industry standard boat for design modeling might be the 1997 Mariah Z209 Talari, 21 foot, 2850 lbs., 5.7L Mercruiser
One
typical industry standard boat for design modeling might be the 1997 Mariah Z209 Talari 21 foot 2850 lbs 5 7L Mercruiser stern drive, stern drive
210 HP, 40 gal. gas tank, 4mpg.
•
Contact: Gary Marshall 859‐559‐5720 (gary.marshall@eku.edu)
B‐1 Toyota
Eliminate Electrophoretically Deposited (ED) Drips
Eliminate Electrophoretically Deposited (ED) Drips
Background:
Surface appearance and durability are critical factors for customer appeal in the manufacturing of automobile car bodies. To
assure the highest quality welded car bodies are processed through a series of coating processes in which anticorrosion joint
assure the highest quality, welded car bodies are processed through a series of coating processes in which anticorrosion, joint sealing and colored coatings are applied. Each of these coatings has a particular purpose for the finished vehicle body but the
processes of application can produce undesirable effects if not carefully controlled.
One of the critical anticorrosion processes is the application of an electrophoretically deposited (ED) coating. In Paint Department’s ED area drips form on the exterior body when water containing paint solids remain on the body prior to the body
Department’s ED area, drips form on the exterior body when water containing paint solids remain on the body prior to the body
entering the ED oven. These drips create defects at various locations of the body (mainly vertical surfaces) that require repair. The defects are in locations of the body that are difficult for production Team Members (TMs) to make a good repair. The repairs also generate dirt on the body which is difficult to remove and has adverse effects as the body moves through the remainder of the
Paint shop. The drips occur on approximately 35‐40% of the bodies and are not model specific (impact both Camry and Avalon). The drips also force ED TMs to deviate from normal standardized work when performing the repair operations.
The drips also force ED TMs to deviate from normal standardized work when performing the repair operations.
Project Scope and Expectations:
TMMK Paint is aware of investigation that has shown favorable results in reducing ED drips by heating the ultra‐filtered (UF) rinse above the current process temperature. Participants from the UK Senior design team would be asked to confirm this theory works in elimination of ED drips, determine the appropriate temperature control range to effectively eliminate the drips, investigate and l
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design the best method to automatically control the process temperature within that desired range, and run trials to prove the result is repeatable. TMMK will provide hands on engineering support throughout the project and budget (as needed).
Contact: Rich Alloo (rich.alloo@tema.toyota.com) Phone 859‐257‐6262 x256, RMB 210D
C‐1 Center for Applied Energy Research
Photobioreactor Support System
Photobioreactor Support System
The University of Kentucky’s Center for Applied Energy Research was challenged by the state of KY to demonstrate the feasibility
of using algae to sequester coal fired power plant flue gas. Algae are the fastest growing known photosynthetic organisms and uses sunlight and carbon dioxide to create energy for itself. Carbon dioxide represents only .03% of atmospheric air but can be up to 20% of coal power plant flue gas. The system that we grow our algae in is a photobioreactor.
The project will consist of designing a frame to support the photobioreactor. Ideally, finite element analysis will be conducted to estimate and account for stress due to the weight of the reactor, wind loading, thermal loading, and design optimization. The goal for the fall will be to have a proposed design for the frame, a basic model of the system, and finite element results. Work in the spring will focus around generating engineering drawings with geometric design and tolerancing, prototype construction, and an evaluation of potential improvements. Material cost, availability, and ease of construction are important aspects of this design. Contact: Michael Wilson (mwilson@caer.uky.edu) (859)257‐0319
D‐1 TRANE
Door Screen Redesign
Door Screen Redesign
Trane air handling units include door screens covering door openings for plenum fans to prevent inadvertent contact with a rotating fan wheel. Access to the fan components for inspection or maintenance requires removal of the door screen by removing multiple fasteners. Reinstalling the door screen requires replacement of these multiple fasteners. See photos below for design details.
Trane would like a student team to review the door screen design and propose design alternatives that would make it faster and easier for fan access and replacing the screen after access. The design must still be secure enough to prevent unintentional
contact with the fan moving parts.
Trane will provide an engineer to work with and mentor the students. We can meet weekly at Trane and/or via conference calls as
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agreed to by the design team. We will provide current design drawings and design specifications as required. We will provide assistance in building design samples for evaluation and testing, including material and fabrication of parts.
Contact: Jim Wendschlag (jwendschlag@trane.com) (859)259‐2506
D‐3 TRANE
Ganged Door Handle for Inward Opening Doors
Ganged Door Handle for Inward Opening Doors
Trane air handling units include both outward and inward opening doors. Outward opening doors are used on sections under negative pressure and inward opening doors are used on sections under positive pressure. The outward opening doors include an option for ganged door handles, where a single handle will open multiple door catches. See photo below. The single handle doors are especially important when the upper handles are not reachable without standing on a ladder.
We would like a student team to develop a design for a single handle inward opening door. See photo below for inward opening
door with multiple handles. As much as possible we should use components common to the outward swinging door design.
Trane will provide an engineer to work with and mentor the students. We can meet weekly at Trane and/or via conference calls as
agreed to by the design team. We will provide current design drawings and design specifications as required. We will provide
agreed to by the design team. We will provide current design drawings and design specifications as required. We will provide assistance in building design samples for evaluation and testing, including material and fabrication of parts.
Contact: Jim Wendschlag (jwendschlag@trane.com) (859)259‐2506
D‐6 TRANE
Disconnect Switch Handles
Disconnect Switch Handles
Trane air handling units include disconnect switch handles. These handles have a mechanical latch that interacts with the door to keep the door latched closed when the disconnect switch is in the on position. The design we have today does not consistently latch correctly and is very sensitive to placement and adjustment. We would like a student team to improve the latching mechanism. See photo below for the current mechanism of the disconnect handle.
Trane will provide an engineer to work with and mentor the students. We can meet weekly at Trane and/or via conference calls
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agreed to by the design team. We will provide current design drawings and design specifications as required. We will provide assistance in building design samples for evaluation and testing, including material and fabrication of parts.
Contact: Jim Wendschlag (jwendschlag@trane.com) (859)259‐2506
E‐3 AFRL Student Challenge
Flapping Wing Micro Air Vehicle Actuator
Program Description
The Air Force Research Laboratory (AFRL) is facing
challenges in growing and maintaining strategic skill sets
in its workforce, particularly in the key disciplines of:
Aerospace, Materials, Mechanical, Electrical, Computer,
Software Development, and Engineering Mechanics. The
AFRL Senior Capstone Project has been established to
address these challenges by having senior engineering
students
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Represent specific technical challenges to AFRL, and 2)
Meet the universities' engineering departmental
requirements for a senior "capstone project". The
purpose of the program is to provide students with the
opportunity to work on projects with the Air Force
Research Laboratory, learning more about AFRL technical
needs in the process, and to connect AFRL personnel and
students for potential future opportunities in
employment and research.
Sponsor: Air Force Research Laboratory Air Vehicles Directorate, WPAFB, OH Dr. Donald B. Paul 937.255.7329 Donald.Paul@wpafb.af.mil
Dr. Gregory H. Parker 937.255.7750
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Gregory.Parker@wpafb.af.mil
G‐1 LEDERGY Lighting Solutions
LED Light Tower
Project Description
LEDERGY Lighting Solutions is looking to design a portable “green” light tower based on the following criteria:
• Lighting system to be powered by solar power with the energy stored in long‐life, 7 yr. battery(s)
• Light tower capable of 12 hour continuous operation with a full battery charge
• Light tower to utilize a small diesel engine to recharge the battery – not to operate the light tower
• Light output equivalent to current 4000W light towers • Mast capable of omni‐directional telescoping (to 30’) with a 4‐panel LED light bank
• Tower will utilize the most advanced, most powerful LEDs available.
Design to incorporate required elements for tower stability
• Design to incorporate required elements for tower stability
LED Light Tower Benefits
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Reduction in operational expenses by 97% Uses 95% less fuel Virtually eliminates monthly maintenance
Virtually eliminates monthly maintenance Lights will have a 15+ year life (50,000 hours) Quieter operation Solid state lights better survive transport Photovoltaics (PV) superior Cooler operation
No safety training required
Can redirect light panels during operation
Can breakdown for transport immediately after use Requires less space to operate much smaller and lighter
Requires less space to operate, much smaller and lighter
Battery operation eliminates dangerous diesel fumes Contact: Jeff Lorch (jefflorch@windstream.net) (859)421‐1975
I‐1 ASME DESIGN COMPETITION
H2Go: THE UNTAPPED ENERGY SOURCE
THE UNTAPPED ENERGY SOURCE
• The ASME Student Design Competition provides a platform for ASME Student Members to present their solutions to a range of
design problems‐– from everyday household tasks to groundbreaking space exploration. Each team is required to design,
construct and operate a prototype meeting the requirements of an annually determined problem statement.
statement
• The Student Design Competition showcases the extraordinary talents of mechanical engineering students while encouraging
them to develop innovative ideas towards an improved quality of life for all. Each year, several teams of up to four students
compete at Student Professional Development Conferences in districts worldwide. Winners then proceed to finals at the ASME
International Mechanical Engineering Congress and Exposition (IMECE). Cash prizes and awards are presented to winners at
both district and final competitions.
competitions
• Green energy is being used more each day. Wind turbines, wave turbines, hydroelectric dams, geothermal heating/cooling,
biofuels and solar panels are all being constantly improved to be more efficient and environmentally friendly. Roughly 7% of the
world’s energy is currently generated from these sources [http://www.eia.doe.gov/fuelrenewable.html]. However, there is a
green source of energy that has not yet been fully tapped ‐ rain. The potential energy of 1 inch of rainfall on the average
single‐story
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captured in motion. Devices to convert and store this energy could be created and an untapped and readily available energy
source utilized. In addition, the water itself could be stored for a variety of everyday uses.
• Your challenge is to design a scaled, proof of concept prototype for rain energy conversion. Your prototype device will propel a
model car as far as possible in a straight line by converting the potential energy of one liter of water at one meter height. All
water must be contained within the device and a penalty will be assessed for any water spilled.
• http://www.asme.org/Events/Contests/DesignContest/Student_Design_Competition.cfm
J‐1 ADVANCED MACHINE TECHNOLOGIES
Experimental Testing Procedure for Nano2Go Tooling
Experimental Testing Procedure for Nano2Go Tooling
Background:
Advanced Machine Technologies, LLC (Amtech) has developed a proprietary set of tooling for
positioning workpieces for micro and nano‐manufacturing. This set of tooling has the tradename
“Nano2Go” tooling and consists simply of a pallet (top) that mates with a base (bottom).
Project Scope and Expectations:
It is desired to design and implement an experimental testing procedure and set‐up that measures the
positioning repeatability and accuracy of the various pallets as they are interchanged between several
different bases. The process should be automated such that the pallets and bases can be interchanged
a very large number of cycles (>100,000) without human intervention and the data stored on a
computer The testing apparatus would be housed in a class 10,000
computer.
10 000 cleanroom with moderate levels of
temperature and humidity control. Measured quantities would be positioning accuracy and
repeatability of each pallet with each base and of the entire group of pallets and bases, and humidity
and temperature for each position measurement. In the fall semester, the system will be designed and
analyzed. In the spring semester, the design will be finalized and implemented subject to funding.
Contact: Chris Morgan (cmorgan@amtech.us.com) Phone 502‐243‐0263 (Work) 859‐489‐9612 (Cell) Company Website: www.amtech.us.com
K‐1 2011 AIAA Design Build Fly Competition
2009
2010
Learning to fly and securing funding are two key
efforts in Fall 2010. Funding will need to be secured
as part of the project effort; previous budget info and
a funding strategy are available as a starting point.
Equipment and in‐depth background information are
available from p
previous UK DBF teams to build on for
this year’s effort.
Faculty contact: Dr. Suzanne Weaver Smith
Contest Website: http://www.aiaadbf.org/
In 2009 and 2010, the University of Kentucky participated
in the AIAA Design Build Fly competitions. ME 411/412
capstone design students, along with underclassmen,
formed the team of undergraduates that designed, built,
tested, redesigned, rebuilt, flight tested, reported,
redesigned,
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successfully
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competed. UK’s team has achieved success in the design
and build phases, but to date we have not flown enough
pre‐competition flight tests to place among the top teams.
In order to be successful in the DBF competition, all three
aspects ‐ design, construction and flight testing – must be
mastered.
The objective of this design project is to design, build and
fly a remote‐controlled aircraft to successfully meet all of
the requirements of the AIAA DBF 2011 competition (see
www.aiaadbf.org).
This project will require 10‐12
capstone students in 3
3‐4
4 teams with responsibilities for
designing, building and testing the aerodynamics,
structures, propulsion, power, control, landing and other
systems necessary to pass technical inspection and to
complete all of the missions defined for the 2011
competition. Learning to fly and learning aircraft design
without a course offering will be significant challenges,
although advice is available from DBF alums who are
current UK grad students.
Securing funding to support material purchases and travel
expenses is another aspect of the project. Several avenues
are available for funding.
L‐1 Weightless Wildcats
Microgravity Flight Experiment
Support Straps
(16x)
The University of Kentucky Weightless Wildcats have conducted experiments as part of NASA’s Reduced Gravity Student Flight Opportunities Program (Microgravity University) since it’s inception in 1997. To date, ten teams of UK engineering students have successfully conceived, proposed, designed and conducted their own experiments two other
designed and conducted their own experiments; two other teams have designed and conducted experiments as part of the NASA Systems Engineering microgravity initiative.
The objective of this design project is to conceive, propose, design and conduct a microgravity flight experiment for the 2011 campaign of the NASA Microgravity University
2011 campaign of the NASA Microgravity University. Students will work with a NASA contact to develop a project plan for the 2010‐2011 year. Examples of proposed experiments from the last few years include:
Depending on the experiment option, this project will be in collaboration with NASA/UK partners or with industry partners. Developing a successful proposal to the NASA Microgravity program and securing funding are two major efforts in Fall 2010. There is no guarantee of being selected by NASA for a microgravity experience or that prior years sponsors will provide funding for this project. Prior proposals are available to serve as examples for planning the project; strategies and contacts for securing funding are also available as a
contacts for securing funding are also available as a starting point.
Faculty contact: Dr. Christine Trinkle
1)Ultralightweight elements of future spacecraft 1)Ult
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communication systems are constructed as thin curved films whose deployment has been studied at UK. This option is to develop an experiment for videometric measurement of thin‐
film aperture deployment.
2)Cubesats (e.g., KySat) make use of available subsystems developed by companies specializing in small satellites Foster‐
developed by companies specializing in small satellites. Foster
Miller (prior UK Weightless Wildcats partner) is interested in working with UK students to develop and conduct experiments validating their concepts for expandable space structures.
3)Long‐term human spaceflight requires medical treatments that can be performed in zero‐gravity environments. Even simple medical injections can be hazardous if air bubbles are not removed from a syringe prior to injection. The 2009‐2010 Weightless Wildcats team worked with NASA to develop and test bubble removal methods in zero‐G environments.
M‐1 Student Proposal
Electronic Spool Assisted Turbocharger
Background:
The turbocharger has been used by the automotive industry as a means to improve power output for decades. Naturally the turbo
has been adopted by the racing world for the same reasons applied to a larger scale. One of the major drawbacks to the
turbocharger is what is known as “turbo lag”. Turbo lag is a term that refers to the time between a driver accelerating to a point that
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large contribution to turbo lag is the fact that the turbocharger has to “spool” or accelerate to its operational rotational velocity.
This is achieved by a turbine blade inserted into the exhaust system which in turn drives the compressor on the intake side.
Problem:
A sudden spike in engine power, as is provided once a turbo spools, greatly upsets the dynamics of the vehicle and if a driver does
not understand or account for turbo lag costly mistakes can be made. This is especially true in high performance and racing
applications. Therefore one of the focuses of manufacturers and racing teams has been to reduce the spool time of their
turbochargers with the end goal of instantaneous power boost.
Proposal:
The basic concept of the Electronic Spool Assisted Turbo (ESAT) is to apply a computer controlled motor to activate the intake
portion of a turbocharger until the exhaust driven turbine portion is able to power the system independently of the motor. Given a
properly sized motor and control system this should eliminate a vast majority of turbo lag leading to the ultimate goal of instant
power from the turbocharger.
Design Concerns:
This p
project
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– Effects of creating vacuum in the exhaust system
– Engagement/disengagement of motor from turbo
– Properly sizing motor
– Electrical load on system
– Mounting of motor
– Shaft
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– Bearing selection
Contact: Bill Kirk (William.Kirk@uky.edu) (859)321‐5982
M‐2 Student Proposal
Gravity Conveyor Speed Governor
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Background:
I am a Mechanical Engineer by training and thought of this idea 15 years ago at a production facility using a gravity conveyor system
with a mechanical drag linkage system driven by an electric motor. It was complex, needed constant adjustment, maintenance, and
did not consistently slow the product properly. Since it utilized a mechanical “drag” arm that moved up to contact and slow the
product, it occasionally would cause product to bounce off the conveyor. We investigated if there was a better product on the
market but could not locate one. I recently saw the “Palletflo” system that uses an elastomer to perform the same basic function.
This made me wonder again if my idea might have commercial application. The concept is to utilze pneumatic or hydraulic pressure
to control the speed of a gravity conveyor roller thus preventing a “run‐away” condition of the product on the gravity conveyor.
Basic Design
Basic
Design
Enclose a simple vane (vane pump) to create pneumatic or hydraulic flow through an orifice. The orifice can be a fixed size or
adjusted using a needle valve to set the desired speed at the point of application. As product encounters the roller with the speed
governor on it the product will begin turning the vane. As the vane RMP increases the fluid flow will increase and increase the drag
as the flow is restricted through the orifice. A slow movement will be slowed very little (or none at all) while a faster movement will
increase the drag as the increased flow becomes restricted by the orifice.
orifice Depending on the application the system can be either
pneumatic based or hydraulic based.
Possible Configuration Options
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Speed Governor built into the conveyor roller itself for new installations
Speed Governor attached to the end of the conveyor roller from outside the frame for new installations
Speed Governor unit attached through some type of linkage (v‐belt, cleated belt, chain, elastic band, etc…) to multiple conveyor rollers
Speed Governor built into a conveyor skate wheel to replace standard conveyor skate wheels
Speed Governor unit with a rubber roller to mount under an existing gravity conveyor roller as a retrofit for existing conveyor systems
The rubber roller would contact the existing conveyor roller and control its speed
Project Sponsor: Claud Day (cfday@yahoo.com) (270) 929‐2129
Student Contact: Dexter Day (dexterday@uky.edu) (270) 315‐5157
M‐5 Student Proposal
Prosthetic Joint
Introduction: The survival rate for a soldier wounded in either Operation Iraqi Freedom or Operation Enduring Freedom is 90.5%. Previously, the
conflict with the highest survival rate was Vietnam, with 76% of wounded soldiers returning home. The increase in survivability
means that
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soldiers are returning with are limb related, these soldiers are returning with a loss in quality of life. Those in the Armed Services
experience a more active lifestyle than the average civilian citizen and loss of a lower limb can drastically change the ability of the
returning Veteran to enjoy activities that pre‐deployment would have been part of their daily routine.
Proposal: To date there is no well designed prosthetic ankle that allows for lower limb movement comparable to the natural gate of a human being. This team will design and test the feasibility of a prosthetic joint that would allow for the joint user's intended limb motion using electrically motivated fluid shifts. Design Considerations:
• Safety • Durability • Flexibility/Stiffness • Size • Reliability
Project Sponsors: Dr. Parker & Dr. Pienkowski
Student Contact: Becky Schneider (rjschn2@email.uky.edu) (502) 330‐2749