Integration of Funded Faculty Research, Capstone Experiences and Industry Requirements Aurenice M. Oliveira, Trever J. Hassell, and Wayne W. Weaver Michigan Technological University − oliveira@mtu.edu, tjhassel@mtu.edu, wwweaver@mtu.edu Abstract — This paper presents a senior design strategy integrating funded faculty research and industry requirements. Students participating in this type of senior design are directly involved with all the aspects of a complete system development cycle focusing on user needs and requirements. All the aspects of the project represents higher quality and larger scale than typical senior design projects, and in this way better resemble industry projects. The case study presented herein is a practical industrial project sponsored by a faculty member the construction of a research quality electric machine dynamometer and test-bed. Keywords—capstone; industry requirements; ABET; faculty research; test-bed. I. INTRODUCTION Capstone or senior design projects are challenging and important components in Engineering and Engineering Technology undergraduate education and usually teach students valuable skills in design, prototype construction, testing, teamwork, and project management related skills [1], [2], [3], [4], [5]. However, a high percentage of the capstone projects deliverables do not result in an operable system that follows industry standards and guidelines, or cover a complete product or system development lifecycle with focus on sponsor and user needs [4]. A complete engineering project lifecycle includes planning and analysis, build and test, implementation and maintenance phases, among others. Usually, capstone engineering and technology projects are product-oriented, focusing only on the build and test phases of development [4]. This approach serves as an additional element in the gap between engineering curriculum and what skill sets employers expect new engineering graduates to have. As pointed out in [6], employers have indicated that new engineering graduates have technical competences but several lack professional skills necessary to manage a real engineering project lifecycle, work with others collaboratively, write and present proposals, among others. In [2]-[3], based on a comprehensive national study, the authors list the 22 primary topics covered in engineering and technology capstone projects. The topics range from written/oral communication to CAD design and layout, but it doesn’t include any topic related to user needs or user testing. As a consequence, the focus is on the product end of the system development lifecycle neglecting the user-centered analysis, design, test, and implementation phases of the development lifecycle [4]. 978-1-4673-5261-1/13/$31.00 ©2013 IEEE In this paper, the authors discuss a hands-on senior project consisting of collaboration among faculty, undergraduate and graduate students of the Electrical Engineering Technology (EET) program in the School of Technology and the Electrical and Computer Engineering (ECE) department in the College of Engineering at Michigan Technological University. The project gives the students the opportunity to be directly involved with all the aspects of a complete system development cycle focusing on user needs and requirements. In the EET program at the Michigan Technological University, students are required to complete a two-semester senior design project, which are typically industry-sponsored allowing students to work on real-world projects. More recently, however, some of the capstone projects were sponsored by faculty members instead of industry partners. This initiative serves to support some funded faculty research projects, and allows undergraduate students participating in the project to interact with graduate students, faculty members of the college of engineering and school of technology, and customers. Design, construction, system integration, software, and testing all involved other researchers instead of just the capstone team, which in turn, created new project management challenges such as team work, communication, documentation, scheduling, among others; resembling a larger scale project in industry. The case study presented here is a practical industrial project sponsored by a faculty member the construction of a research quality electric machine dynamometer and test-bed. The project followed practical industry project standards and all the aspects of the project presents higher quality and larger scale than typical senior design projects, and in this way better resemble projects in industry. The test-bed will be used for externally funded research projects in several areas such as electric drives systems, electric propulsion systems, power electronics, and ac microgrids, among others. The test-bed was designed and built with the forethought to enable a wide variety of electric machine configurations and applications, as it provides a platform for testing of innumerous projects. In addition, the test-bed will be used for undergraduate and graduate education. This project allows students participation in the research of possible solutions and the selection of the one that best meets the sponsor criteria and user needs, then they design, construct, and present a finished product. In addition to the application of knowledge learned in previous courses, students develop technical and soft skills such as: how to research and comply with current Occupational Safety and Health Administration (OSHA) standards for test-beds, learn how to use AutoCAD for test-bed layout and electrical schematics, practice industrial type circuit construction, components selection and acquisition, learn and use industrial communication protocols as well as team and time management. The students also further develop critical thinking and accountability. The assessment methodologies for this senior design course uses indirect and direct measurements to assess the applicable ABET a-k criteria [7]. The assessment results indicate improvements in the student comprehension of key concepts, and increased students’ confidence to start their careers in the industry. II. RESEARCH PROJECT BACKGROUND The goal of the capstone project that we present here as a case study was to design and construct a dynamometer testbed with the capability to test electric machines of moderate sizes. Dynamometer systems are used for testing and verification procedures in several applications including automotive, industrial, and manufacturing. Dynamometers have the capability to simulate a wide range of loads a system may experience, precise controllability, and unit testing prior to the unit under test reaching the customer. Additional motivation for having a dynamometer test-bed comes from the increasing penetration of electric propulsion in modern automobile [8] and Michigan Technological University growth in hybrid vehicle education and research [9], [10]. Electric Vehicles (EV) and Hybrid Electric Vehicles (HEV) both use electric machines for either full or partial traction of the vehicle. A dynamometer test-bed was developed with the purpose of research into various electric propulsion drives systems, including the flexibility to accommodate various types of machines. Such a test-bed would be a great asset to have in our power electronics research lab. In addition to the EV or HEV applications, a dynamometer test-bed could also be used to model a load in a small ac Microgrid. This load could mimic the load cycle of hydraulic pump systems or a heating, ventilation, and air condition (HVAC) system of a small building. A. Design Requirements The faculty sponsoring this project had specific industry type requirements that had to be followed by the team, including: 1. Testcell safety system following OSHA standards – also, devices must have adequate guarding to protect users from injury, use of cable tray to protect cables, safety relays; 2. Efficient use of space – cell must be as compact as possible to fit in the available room; 3. Wired communication with laptop for configuration; 4. Variable frequency drive (VFD) must communicate via Modbus RTU receiving its commands from the testcell PC; 5. 6. 7. 8. 9. 10. 11. 12. 13. VFD step-up transformer, since VFD operates at a higher input and output voltage than the testcell infrastructure voltage supply. High accuracy torque/speed monitoring; Testcell infrastructure controls must be PLC-based and independent of the VFD and inverter controls; PC-based controls: user interface controller station with National Instruments LabVIEW GUI, dSPACE embedded controllers, Allen-Bradley Micrologix communication adaptor, and operator pushbuttons station; Inverter with opto-isolated (fiber-optic) gate drive and fault signal output for electrical isolation and noise immunity; Signal isolation to isolate any control signal input signal to the one that will be connected into the dSPACE embedded controller; Electro-magnetic interference (EMI) isolation; Easy operation; User manual. III. TESTCELL DESIGN AND CONSTRUCTION The electric machine test-bed is a collection of various commercially available and custom made components. It is designed to enable a wide variety of electric machine configurations and applications, as it provides a platform for testing of innumerous projects. The current configuration of the test-bed features two identical 20 HP ABB induction machines in a back-to-back testing configuration. The “dynamometer” is controlled via an ABB (full 4-quadrant) variable frequency drive. The “prime mover” machine is driven from a custom IGBT inverter controlled via a dSPACE embedded controller. Both shaft torque and speed can be measured via a compact digital torque meter. The power wiring of the test-bed is controlled by a Motor Controller and Safety System Enclosure (MCSSE). The MCSSE includes a standalone programmable logic controller (PLC) system controlling the power flow throughout the system. The testbed machine mounting tables, shown in Fig. 2, were built in modular fashion to accommodate various electrical machine types and sizes. Fig. 1. One Line Test-bed Circuit characterization. All the students participated in Phases I and II. At the start of the project at the beginning of fall semester in September of 2011, some previous work was already done to: acquire donations for the electrical machines and VFD, testcell electrical machine table was designed and constructed, mounting hardware attached to the wall, various components for use in the testcell purchased. The various components are comprised of DC power supply, several inverters, and electrical power meter with accessories. Fig. 2. Testcell – start of the project Table I. Project Major Tasks Phase I: II: III: Task Cell Architecture Design Testcell Safety Research MCSSE Design MCSSE Parts Selection and Procurement MCSSE Construction Isolation Transformer Cabling and Connectors Embedded Controller/PC Station Initial Micrologix Program Expanded Micrologix Program w/ added f Testcell Power/Control Wiring ABB VFD Drive Configuration ABB VFD LabVIEW Program Motor Coupling/Torque Sensor Specifications Testcell User Manual Signal Isolation and Interface Board Signal Gain Tuning Electric Machine Parameter Estimation System Performance Characterization The capstone projects in the Electrical Engineering Technology (EET) Program at the Michigan Technological University are comprised of two academic semesters. However, this particular project, since also involved a graduate student, was completed in three phases: Phase I, during the fall semester of 2011, Phase II, during the spring of 2012, and Phase III, during the summer of 2012. In Table I we highlight the project major tasks in each phase. The graduate student participated on the team both as a technical advisor and as a project engineer. With this dual role he contributed both to the completion on the EET senior design project and a successful commissioning of the testcell system. The fact that not all students were involved in the last phase of the project didn’t impose any problem for the overall students’ experiences. Phases I and II consisted of all the construction, system integration, and documentation for the test cell. Phase III was for additional parameter estimation and performance Fig. 3. Testcell infrastructure: subpanel During Phase I of the project, the team researched and designed an architecture approach, ordered, and constructed the Motor Controller and Safety System Enclosure (MCSSE). The first task completed was the design of the test power architecture shown in Fig. 1. The testcell at the start of the project is shown in Fig. 2, and the infrastructure enclosure MCSSE and subpanel is shown in Fig. 3. The completion of these tasks included knowledge of the operation of the individual components and specific placement of the contactors to control electrical energy flow. The team researched and selected the components to be used in the MCSSE, which included the Allen-Bradley Micrologix controller, contactors, fuses/fuseholders, safety relay, terminal blocks, enclosure fan, DIN rail mounts, DC power supply, and wire way. The team also was responsible for the enclosure layout scheme and placement of the components on the back panel. The wiring schematic used to construct the MCSSE and testcell cabling was developed and guided the team with good practices in assembling the sub-plate and enclosure. Along with the enclosure and subpanel, the team ordered the materials necessary for the complete testcell power cable routing. Several other components were also researched and ordered, including the isolation transformer, operation station computer, dSPACE embedded controller, PLC, safety relays, and high voltage shielded power cables and connectors. During Phase II of the project (spring 2012), the team continued to research and order several components needed to complete the testcell. This would include the motor flexible coupling, torque sensor, motor coupling guard, embedded controller, and control signal isolation modules. The conduit used for the ESPB enclosures/operations was bent, and the wiring of the high voltage and communication cables was completed. The team also installed the analog control signal wiring between the work bench and controller station. Also during phase II the team programmed the initial Micrologix program that allowed running the testcell system. The graduate student worked very closely with the EET team member who was responsible for the VFD communication LabVIEW program. They specifically set up the drive with the appropriate parameters to allow communication between controller station and VFD. The team also completed the power and signal routing, and complete the safety items necessary for operation of the dynamometer. Table II summarize the main objectives and deliverable of the EET students. “Enabled”, “Powered”, “ON” and “Fault”. These states dictate what, if any, combination of contactors and indicating lights are on. During the summer semester of 2012, Phase III of the project, the final items were completed to have a fully functional system. These final items included control signal gain tuning, electrical machine parameter estimation, baseline system data collection, and testcell performance testing. The completed testcell system is shown in Fig. 4 and Fig. 5. The test-bed is primarily comprised of off the shelf commercial products. The components are integrated together to form a functional electric machine dynamometer test-bed. The oneline system is classified into two distinct portions; the “prime mover” and dynamometer. In Fig. 5, the top branch of the circuit, prime mover, consists of the A (DC power supply) and B (DC-AC Inverter). The lower branch of the one-line diagram is classified as the dynamometer and consists of E (isolation transformer), F (variable frequency drive), and the second induction machine, Motor 2. The current test-bed configuration includes two 20 HP ABB induction machines in a back-to-back testing configuration. The dynamometer is controlled by a four quadrant ABB Variable Frequency Drive (VFD). In addition, a DC power supply and a couple of voltage source inverters (VSI) were available for use in this project. All of these components served as the essential components in the testcell system; however system integration including some form of safety system was needed to safely control the behavior of the testcell. The testcell architecture was designed for two machines “back to back” testing. A one-line schematic is shown in Fig. 1. The two identical induction machines are mechanically coupled together via flexible motor couplings and torque sensor. There is only one source of electrical energy for the motors, a 208 Vac 50 Amp 3 phase receptacle, which is supplied from a power panel in the test-bed room. This source would supply two “loads”; the magna DC power supply/inverter and an ABB frequency drive. The Magma DC power supply powers the APS inverter, which in-turns supplies power the “Prime Mover” electrical machine, M1. Because the frequency drive operates at a different voltage than the main source power a transformer is needed. The frequency drive would then supply the “Absorber” electrical machine, M2. The high level control scheme of the testcell safety system puts the system in one of five states; “Ready”, Fig. 4. MSSCE Panel Layout Fig. 5. Test Cell System and Component Integration Overview TABLE II. TEAM OBJECTIVES AND DELIVERABLES Phase I – Fall 2011 Project proposal OSHA Report Components: Researched, selected, ordered AutoCAD Functional System Report/Presentation IV. Phase II – Spring 2012 Incorporate PLC control start/shut down procedure Fault detection Sensor Integration of Communication (ModBus) integration User documentation Final Report/Presentation BENEFITS The team members received numerous benefits from involvement with this type of capstone project that they would not get in a traditional senior design project. The first major benefit was working on a real collaborative multi-disciplinary project among faculty, undergraduate and graduate students of the EET program in the School of Technology and the ECE department in the College of Engineering. Another very important benefit team members received is determining real system design requirements. Although not unique to this senior design project, but very important, is that students obtain skills in both technical report writing and oral presentation. Each semester the team was required to write progress reports and to give presentations. These reports consisted of many aspects of the team’s progress as well as procedures the team followed regarding safety. What is different in the reports and presentations from the traditional class room report and presentation setting, is the audience. The audience consisted of professionals from industry as well as faculty members and fellow students. The team was given feedback from these individuals and was expected to change or explain any issue that was presented. This demonstrated to the students the level of expectation for formal report writing and presentation skills, and gave them prior experience to the expectation level they will encounter in industry. Students were also exposed to industry tool such as CAD design and layout, dSPACE embedded controller, National Instruments LabVIEW VFD control, PLC programming, Allen-Bradley Micrologix Program, communication (ModBus) integration, sensor integration, fault detection, OSHA safety standards. Graduates will be able to use the technical knowledge from the use of the development tools they were exposed to during all phases of the project as well as some experience to complex system level problem solving. Potential industry employers and faculty sponsors also benefit from this collaboration. Potential employers will benefit from hiring graduates exposed to project following industry type requirements. The faculty sponsoring this project will use the test-bed as a research platform for externally funded research projects in several areas such as electric drives systems, electric vehicle propulsion systems, power electronics, ac MicroGrid, among others. The test-bed was designed and built with the forethought to enable a wide variety of electric machine configurations and applications, as it provides a platform for testing of innumerous projects. In addition, the test-bed will be used for undergraduate and graduate education; the test-bed is currently being used for two specific laboratory classes: Introduction to Power Electronics and Introduction to Motor Drives. V. ABET CAPSTONE REQUIRMENT AND ASSESSMENT Capstone senior design experiences are both a graduation requirement for engineering and technology majors and a requirement for ABET accreditation of these programs. The capstone or senior design experience is typically the last bridge for students between their undergraduate engineering curriculum and the engineering profession. The ABET-ETAC Criteria−5 [7] states “The Integration of Content Baccalaureate degree programs must provide a capstone or integrating experience that develops student competencies in applying both technical and non-technical skills in solving problems.” The integration of capstone experience and externally funded faculty research projects is an effective way to actively engage students in challenging engineering design problems. In addition, the senior capstone experiences are a primary source of documentation of the achievement of the ABET Criteria 3 – Program Outcomes [11]. Criteria 3 requires that engineering technology programs must demonstrate outcomes (a-k), and includes: (a) an ability to select and apply the knowledge, techniques, skills, and modern tools of the discipline to broadly-defined engineering technology activities; (d) an ability to design systems, components, or processes for broadly-defined engineering technology problems appropriate to program educational objectives; (e) an ability to function effectively as a member or leader on a technical team; (g) an ability to communicate effectively. The project example that we discussed in this paper successfully satisfies all these requirements, as previously discussed in this paper. Project participants have the opportunity to determine real system design requirements, work with graduate students and faculty members, to obtain both professional report writing and presentation skills, and to be exposed to industry leading development tools and hardware. Moreover, a broad range of educational and professional benefits results for students participating in projects that integrates capstone experience and externally funded faculty research, which focuses on a real world problem. The assessment methodologies for this senior design course used indirect and direct measurements to assess the applicable ABET a-k criteria. The success indicators were based in direct and indirect quantitative measures such as written reports, oral presentations, student surveys (midterm and end of semester ), and instructor/students meetings. The assessment results indicated improvements in the student comprehension of key concepts, and increase in students’ confidence to start their career in the industry. In Table III, we summarize the key skills acquired and applied by the students based on the EET curriculum and specifically project related. In Table IV (on page 6), we show the summary of student achievement of the student learning outcomes (SLO) for this capstone and quality of instruction as required by ABET for the capstone group of fall 2011/spring 2012. The results show the correlations between the project objectives and capstone requirements. All the SLO had acceptable results with exception of SLO 2 (organize research and data for synthesis), which is attributed to the lack of experience of the undergraduate students in working on research level projects. We intend to emphasize this objective during the next capstone cycle. The direct measurements included technical reports and technical presentations open to faculty, students, and Industrial Advisory Board members. The technical reports and the presentations have standardized scoring rubrics (which will be presented during the FIE meeting presentation). The students also developed a user documentation manual for the test-bed. The capstone team technical presentation scored slightly higher among three industry sponsored capstone projects presented at the same time. The overall quality of the project received positive comments for all the members. The test-bed has been used for classes and serving as project demonstration for visitors from industry, prospective students, among others. TABLE III. CURRICULUM AND PROJECT RELATED SKILLS EET Curriculum Wire Specifications Electrical Machine Operation VI. Project Related General Safety Practices for testbeds AutoCAD ModBus Component Selection Process Industrial Type Circuit Construction PLC Hardware and wiring FINAL REMARKS The integration of funded faculty research and industry requirements in a capstone project can provide distinctive benefits to undergraduate students, graduate students, and faculty involved in the project. All the aspects of the project consisted of higher quality and larger scale than typical senior design projects, and in this way better resembled projects in industry and better prepared students to enter the workforce. In particular, students participating in this type of project developed useful project skills, and had the opportunity to be directly involved with all the aspects of a complete system development cycle focusing on user needs and requirements, in addition to follow practical industrial project standards. For the cases that we investigated there is no significant difference in the students’ perceptions whether their capstone project is sponsored by faculty or industry as long as the project gives the students the opportunity to develop a broad range of skills. However, students’ participating in these types of faculty sponsored projects have the potential for more employment opportunities due to the projects similarities with industry projects. Most of the industry sponsored projects in our program have a relatively small budget as compared to our case study, which can limit the complexity of the industry sponsored projects. REFERENCES [1] M. P. Brackin and J. D. Gilbson, "Capstone Design Projects with Industry: Emphasizing Teaming and Management Tools," in ASEE Annual Meeting, 2005. [2] S. Howe and J. Wilbarger, "2005 National Survey of Engineering Capstone Design Courses," in ASEE Annual Meeting, 2006. [3] S. Howe and J. Wilbarger, "Current Practices in Engineering Capstone Education: Further Results from a 2005 Nationwide Survey," in IEEE/ASEE Frontiers in Education, 2006, pp. T1E5-T1E10. [4] C. S. Helps, B., "Atypical Senior Capstone Projects: The process is the produce," in ASEE Annual Meeting, 2009, pp. AC 2009-1802. [5] R. E. Anderson, R. J. Anderson, G. Borriello, and B. Kolko, "Designing Technology for ResourceConstrained Environments: Three Approaches to a Multidisciplinary Capstone Sequence," in IEEE Frontiers in Education, 2012. [6] J. Selter, "Infusing Professional Skills Development into Co-Op Students," in ASEE Annual Meeting, 2012, pp. AC 2012-3287. [7] ABET. ABET Criteria for Accrediting Engineering Programs 2012-2013 (www.abet.org). [8] C. Chan, A. Boyscayrol, and K. Chen, "Powering Sustainable Mobility: Roadmaps of Electric, Hybrid, and Fuel Cell Vehicles," Procedings of the IEEE, vol. 97, pp. 603-607, 2009. [9] (2012). Hybrid Electric Vehicle Curriculum (HEV). Available: http://www.mtu.edu/hybrid/ [10] M. L. McIntyre and M. Young, "Plug-In Hybrid Conversion: As a Capstone Project and Research Test-bed," in IEEE International Electric Vehicle Conference, 2012, pp. 1-4. [11] P. King, "Capstone Design and ABET Program Outcomes in the US," in European Society for Engineering Education, Aalborg, Denmark, 2008. Table IV. Summary of Student Achievement of Course Objectives and Quality of Instruction Student Learning Outcome (SLO) Assessment Instrument for This SLO Standard Results 3a, degree 2 3b, degree 2 3f, degree 2 3a, degree 2 3b, degree 2 3c, degree 2 3d, degree 2 3g, degree 3 3k, degree 3 Weekly meetings, project development phases; 70% of students will score 70% or better. 70% of students will score 70% or better. 80% of students scored 70% or better 67% of students scored 70% or better 3e, degree 3 3g, degree 3 3k, degree 3 3e, degree 3 3g, degree 3 3h, degree 3 3i, degree 3 Weekly meetings; University Expo Capstone Conference, Final oral presentation. 70% of students will score 70% or better 70% of students will score 70% or better 70% of students will score 70% or better 87% of students scored 70% or better 80% of students scored 70% or better 100% of students scored 70% or better Project development phases, and scheduled deliverables. 70% of students will score 70% or better 87% of students scored 70% or better Project design, construction, testing following OSHA requirements. 70% of students will score 70% or better 94% of students scored 70% or better Project design, construction, testing, and scheduled deliverables in line with sponsor requirements and approved by sponsor. 70% of students will score 70% or better 100% of students scored 70% or better Project design and budget requirements approved by sponsor. 70% of students will score 70% or better 100% of students scored 70% or better Relates to Program Outcome(s) a 1. 2. Be able to research on applied electrical engineering technology. Organize research and data for synthesis. 3. Prepare written reports. 4. Prepare and present oral reports. 5. Work in teams. 6. Coordinate and work to meet scheduled deadlines and facilities, manage resources, etc. Learn general safety practices for test beds 3e, degree 3 3g, degree 3 3i, degree 3 3k, degree 3 3c, degree 3 3d, degree 3 3f, degree 3 3j, degree 3 Be able to make industrial type of circuit construction. 3a, degree 3 3b, degree 3 3c, degree 3 3f, degree 3 3c, degree 3 3d, degree 3 3k, degree 3 7. 8. 9. Learn how to make component selection and ordering. a. Weekly meetings, project phases Weekly memos, Bi-month reports, End of semester report, Final Report. Weekly meetings, project development phases, oral presentations, written reports/memos. In the second column, “Relates to Program Outcome(s)…”, the degrees are a way of prioritizing course outcomes. Degree 3 implies that the course places significant emphasis on that outcome, degree 2 implies moderate emphasis, degree 1 implies some but minimal emphasis.