Engineering Undergraduate Theses

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Open Access
Additive Manufaturing Trial for Secondary Spacecraft Structures
(2022-12-07) Abells, Ryan; Audette, Lucas; Sysoev, Rostislav; Tkach, Martin; Labossiere, Paul; Labossiere, Paul
The team completed a project for Magellan Aerospace to redesign traditionally manufactured satellite components for fabrication with additive manufacturing (AM) technology. This involved analyzing the feasibility of using AM instead of traditional manufacturing methods. Magellan Aerospace is interested in exploring the benefits of AM technology for component production, assembly, cost, and structural optimization. Compared to traditional manufacturing, AM can rapidly produce highly optimized parts. In this project, an antenna mount bracket was redesigned, and the entire design process was documented for Magellan Aerospace. Autodesk Fusion 360 is a solid modeling software that pairs powerful simulation capabilities with cloud computing to aid in developing an optimized design. The team used Fusion 360’s generative design (GD), a type of simulation that can produce structures from a set of inputs including loads, geometries, and certain design objectives. The team also experimented with running topology optimization (TopOp) studies iteratively to produce a design from a large initial geometry, but design with TopOp was found to be inferior to GD. TopOp was instead used to further optimize GD results. Research into AM technologies found direct metal laser sintering (DMLS) to be the most suitable manufacturing method, given its availability, precision, and ability to produce strong parts. Electron beam melting (EBM) and binder jetting (BJG) were also considered but were rejected due to limitations on compatible materials and dimensional accuracy, respectively. Magellan Aerospace specified that the material used for AM should have similar mechanical and thermal properties to Al-6061 (aluminum), requiring the team to focus on aluminum powders. AlSi10Mg was unsuitable for this project due to heat treatment requirements and difficulty with chemical processing. Specifically, AlSi10Mg requires quenching during heat treatment, which could shatter the geometry of the optimized part. Additionally, the presence of silicon makes chemical processing of these components difficult. A headdCP1 has similar strength and cost to AlSi10Mg, is heat treated via precipitation hardening, and can easily be chemically processed. Therefore, Aheadd CP1 is well-suited for the redesigned bracket. Another post-processing consideration is dimensional accuracy, for which a drawing was created to communicate required tolerances. TopOp studies were run on the GD bracket post-generation to trim remaining unnecessary weight, resulting in a final design roughly 60% lighter than the original bracket. Static load, buckling, and vibration simulations were performed to analyze the bracket’s structural performance. Static and buckling simulations resulted in safety factors of 4.6 and 12.9, respectively. However, results of the vibration study showed that the part had a first mode of frequency of roughly 100 Hz, which did not meet the project specification for vibration performance. Efforts were made to edit the model and increase its natural frequency, but the team was unsuccessful due to software and time limitations. Magellan Aerospace requested a testing plan for verifying component performance. Porosity and the internal structure will be analyzed with CT scans. Structural integrity will be verified with proofload, shock, and vibration testing. Finally, internal and external calipers will be used to verify dimensional tolerances. The final deliverables for Magellan Aerospace are a process for redesigning components for AM, a 3D model of a redesigned antenna bracket, a testing procedure, and a cost analysis for the overall project. The total cost of design, manufacturing, and testing of the bracket is estimated to be $22,132.00 CAD. The team recommends that Magellan Aerospace pursues GD for AM to achieve optimized components according to design specifications.
Open Access
Adhesive Testing Chamber Design for Optimizing Acoustic Honeycomb Core Composite Panels
(2013-12-02) Berke, Andrew; Dueck, Lionel; Golin, Erin; Lobana, Jashanpreet; Luo, Yunhua (Mechanical and Manufacturing Engineering); Labossiere, Paul (Mechanical and Manufacturing Engineering)
Composite honeycomb core sandwich panel structures that require acoustic dampening properties have an adhesive layer reticulated during panel manufacturing. Depending on core and adhesive material types, application of different optimal parameter values for reticulation including air temperature, flow rate, and exposure time are required. The objective of this report is to address Cormer Aerospace’s need for a reticulation test cell to determine these values. The implementation of the presented design will aid in identifying optimal reticulation production parameters. Presented in this report is a standalone semi-automated reticulation test cell, which is comprised of three main modules. These modules include an oven chamber with drawer action, an air knife module, and a gantry module. The combined use of these modules allows application of reticulation parameters in a uniform, controlled, repeatable, semi-automated manner to address the client needs. Controls of adjustable processing parameters including temperature, airflow rate, and exposure time of the honeycomb-adhesive system allow the client to utilize the test cell in a research and development environment. To aid the client in procurement and assembly of the proposed design, a bill of materials, build drawings for installation instruction, and an itemized cost estimate are communicated, as well as analyses that ensure effective use. The proposed test cell costs $11,125.16 CAD to procure and meets client requests for a controllable test cell with variable temperature, airflow, and exposure settings that are applied uniformly.
Open Access
Adjustable anti-scatter grid system for mammography tomosynthesis final report
(2012-06-11) Crawford, Graeme; Dueck, Nathan; Kirkbride-Taylor, Brian; Bull, Jordan; ElMekkawy, Tarek (Mechanical and Manufacturing Engineering); Labossiere, Paul (Mechanical and Manufacturing Engineering)
Thirteen Engineering Co. (TEC) was tasked with developing a concept for an anti-scatter grid system that is compatible with mammography tomosynthesis machines, for CancerCare Manitoba (CCM). In the initial phases of the project, 16 concepts were generated. This was then narrowed down to the four most promising designs, from which two concepts were chosen to be developed further. The two designs chosen are the adjustable septa, and the multiple grid changer designs. In the adjustable septa concept the x-ray absorbing septa are redesigned so that they can be rotated. These septa can then be moved to the desirable angle for each image along the tomosynthesis sweep. The second concept is the multiple grid changer. In this design multiple anti-scatter grids with differing set septa angles are used. These grids are stored in a grid rack and then individually moved into the imaging position, as needed for the sweep. After an image is taken the anti-scatter grid is retracted and the next grid is then placed for imaging. To save space the grids are rotated halfway through an imaging sweep and then reused. In this report these two designs are developed further and their performance is compared against a previously selected set of criteria. It was found that the adjustable septa design had superior performance in the sweep angle, number of images per sweep, reliability and sweep completion time categories. The grid changer was better in the minimizing radiation dosage exposure category and both designs had a similar source to image distance. Due to the proprietary nature of tomosynthesis mammography machines, it was not possible to obtain dimensions for an existing device, because of this it was not possible to evaluate the designs based on device size. When both designs were compared to the project objectives, the adjustable septa design's performance exceeded the performance of the multiple grid changer design in many of the design criteria. TEC recommends the CCM should further develop the adjustable septa design. Further development in the areas of computer x-ray modelling and production of prototypes to properly establish the adjustable septa design's x-ray absorption properties, reliability, and manufacturing costs.
Open Access
AdjustableFiberglass Transformer Pad Mold
(2019-12-04) Couture, Nick; Drabchuk, Nick; Dyck, Andrea; Fedorchuk, Connor; Labossiere, Paul (Mechanical and Manufacturing Engineering)
This design report provides an overview of the design process used by the U of M Team to develop a 2-dimensionl adjustable mold for Structural Composite Technologies’(SCT)custom transformer pad (T-Pad) production process. The purpose of designing the adjustable mold was to reduce the high production costs and long lead times for the current custom T-Pads. Additionally, the adjustable mold was intended to improve the surface quality of the custom T-Pads. Deliverables for the project include a SolidWorks model of the final design, engineering drawings, operation instructions, formal quotes, a Bill of Materials (BOM), and a design report detailing how the mold meets the project metrics. The adjustable mold needed to meet several target metrics that were composed by SCT and the U of M team at the onset of the project. Key metrics included the mold size which needed to range from 5’ x 5’ up to a size of 10’ x 8’ and have a height of 36”. Height adjustability was an optional component of the design scope. Additionally, the mold needed to be discretely adjusted in increments of at minimum 6” in both directions. The other key metrics were assembly time and mold maintenance which needed to be limited to two hours for two people and 15 minutes per mold cycle respectively. The mold required a maximum weight of less than 3750 lbm such that it could be transported by forklift intact if required and a maximum individual component weight of 100 lbm to meet the requirement of two workers being able to assemble the mold. Finally, after a detailed economic analysis based on previous custom T-Pad sales volume, it was determined the capital cost of the mold needed to remain under CAD$ 25,000 but would be competitively advantageous if it remained under CAD$ 10,000. A female mold design was preferred over a male mold design to improve the surface finish of the finished T-Pads. Based on these core metrics the U of M team developed a preliminary list of 62 component-based concepts. These components were then combined into preliminary list of 15 complete concepts. These 15 concepts...
Open Access
AE2100 kitting cart design
(2012-06-11) Guerreiro, Patrick; Ramnath, Sundeep; Saggi, Mandeep; Grewal, Manpreet; Singh, Meera (Mechanical and Manufacturing Engineering); Labossiere, Paul (Mechanical and Manufacturing Engineering)
StandardAero’s AE2100 engine servicing facility is facing some issues in dealing with the handling of engine components. Engines are requiring greater levels of dismantling and the current carts used to store, track and transport engine components (kitting carts) are becoming inadequate. The current carts do not safely handle all of the components that are being dismantled. In order to provide adequate accommodation for the additional components, temporary carts have been procured. The temporary carts provide additional space to store engine components but, because they are general use carts, they do not handle the components in an efficient manner. Thus, the amount of shop floor space required to kit an engine is far too great. This report discusses the design details for a new CCM kitting cart. The new CCM kitting cart design reduces the overall shop space required to kit an AE2100 CCM to 24.75” by 48”. Additionally, the cart can accommodate a CCM in both an assembled or dismantled configuration, further decreasing the floor space required. The wood material provides for easy in-house manufacturing of the cart. Specific accommodations have been made regarding the placement of all CCM components; that is, everything has its specific place. Relatively heavy components, such as the assembled CCM, are placed on a shelf located at approximately waist height reducing the strain on the technicians using the cart. Boxes for miscellaneous components are placed on special trays to make searching for parts easier. Casters provide for ease of mobility of the cart. The total cost of the new CCM kitting cart is CDN $824.52 and is expected to decrease as technicians become more efficient in manufacturing the cart. The modifications recommended to the PTM cart will reduce the floor space required for the cart by moving the casters under the cart. Furthermore, the addition of another shelf will allow for better accommodation of power turbine blade trays. Team 2 believes that the design details discussed in this report adequately address the issues with the current kitting cart system.
Open Access
Aerial Lift Platform Design for Engine Testing Service
(2013-12-02) Biggs, Jessica; Borisov, Genadi; Halpin, Jared; Verwey, Cameron; Atamanchuk, Kathryn (Mechanical and Manufacturing Engineering); Labossiere, Paul (Mechanical and Manufacturing Engineering)
The ALPS (Aerial Lift Platform Specialists) were tasked with designing an aerial lift platform for the GLACIER facility in Thompson, Manitoba. This project consisted of three major phases: project definition, concept design, and final design. The first major project phase required identifying the problem statement and project objectives, and outlining the target specifications. We identified the constraints and limitations associated with designing an aerial lift platform (ALP) for use at the GLACIER facility, and outlined a project schedule. The second project phase was concept focused, and involved a great deal of research. We investigated all aspects of the required design, and identified current market solutions for the specific areas of design associated with our concepts, such as platform design, lifting mechanisms, and steering geometries. Employing the use of concept screening and scoring matrices, our team filtered a preliminary list of 62 concepts, spanning the eight functional categories of design, down to 23 suitable designs. Moving into the final project phase, we began final concept design, focusing on each of the eight functional design categories individually, and combining these optimized groups into one coherent final design. The GLACIER facility is in need of an ALP capable of meeting their size requirements. In order to meet facility requirements, a suitable lift must have a working surface area large enough to allow for access to all components of the engine while performing maintenance, troubleshooting, and sensor connection. The approximate size required for such a lift is 20’x20’. These restrictions result in increased costs associated with engine testing, longer turn-?time, and reduced efficiency. The aerial lift platform we developed resembles that of a traditional scissor lift platform. Four wheels situated at the corners of the base platform consist of 28-16-22 MH20 solid rubber tires mounted on custom 22” diameter steel rims, with one set of wheels pivoting freely to give provision for steering of the platform. Wheels spindles re mounted high to allow for larger diameter wheels, while the base frame is built low to the ground in order to minimize the retracted height of the platform. Four sets of scissors are mounted […]
Open Access
AGI Westfield 35' Flight Forming
(2021-12-08) Rempel Boschman, Michael; Liu, Wenbin; Tehlan, Bhumit; Thind, Resham; Labossiere, Paul; Labossiere, Paul
AGI Westfield currently produces 25' flights, which is the critical component of an auger that helps farmers to transfer grain into grain bins. The flight is the helicoid section of the grain auger. AGI Westfield would like to produce 35' flights. Due to limited space in the facility, team 9 must find a solution to produce the 35' flights in the same footprint of the 25' flight production facility. The final solution features the design of new standoffs that secure the tube on the red helicoid forming table, which changes the current design from producing the helicoid then sliding the tube into the helicoid to forming the helicoid directly around the tube in one step. This reduces the total required length of the manufacturing footprint and allows AGI Westfield to produce 35' flights without expanding the areas. In order to accomplish forming the helicoid around the tube, the tube preparation station goes in tandem to the red helicoid forming machine to allow the tubes to be dropped off into the red helicoid forming machine. To ensure that the tubes can still slide into the helicoids once the helicoids are formed, the tube preparation station is longitudinally aligned with the welding station. Other features of the design include the various types of coupler inserts on the welder to accommodate various diameter flights. The new material flow map was demonstrated in detail on how parts are transported and stored during the new proposed production streams. Furthermore, the failure mode and effect analysis was completed to help clients prevent any risks that could undermine project goals. Most risks were identified from the red helicoid forming phase. Changing the layout of the facility and forming the helicoid around the tube allows the cycle time per foot to decrease from 45.88 seconds/foot to 38.84 seconds/foot. The cost estimation of parts designed for integrating the new solution was determined as $3,586.80 USD. The final design provides automation recommendations, such as a hydraulic system to push flights, which will reduce the potential strain on the workers that could cause safety hazards.
Open Access
Aircraft Skin Handling Device for Magellan Aerospace
(2017-12-06) Sandhu, Harjasdeep; Stephanson, Mitchell; Furlan, Jesse; Iwhewhe, Matthew; Labossiere, Paul (Mechanical and Manufacturing Engineering)
Magellan Aerospace required a material handling device for composite aircraft skins to reduce the amount of damage that occurred during manual handling and operation by the operators. The damage that occurs on the composite skin delays the production of the horizontal tail assembly and creates large overhead cost for the company. The material handling device, as required by the clients and operators, had to transport the composite skin in the near vertical position and allow for rotation to the horizontal position for various work processes. The device also needed to support a change in the skin as the skin becomes trimmed in one of the work processes. In addition, the skin needs to be height adjustable for ergonomic purposes. Further requirements from the client were safety, economical to manufacture, sturdy, rugged and easy to maintain. The objective of this report was to design the most efficient material handling device that will meet all of the clients’ requirements. This objective was achieved by establishing customer needs, developing various design concepts and optimizing the highest scored concept. The device consists of a base frame that sits on four caster wheels. The frame has two vertical members. Attached to the members is a vertical adjustment mechanism and a rotational adjustment mechanism. An upper frame is connected to the rotational mechanism and has welded clamps. The clamps are used to mount the aircraft skin to the device. The base frame is made from aluminum 6061-T6 tubing with an overall dimension of 60x108x50 inches. A truss design minimized the effect of bending in the members. Under maximum loading, the frame has a minimum yield stress factor of safety of 2. The height adjustment mechanism consists of a square tubing sleeve that sits outside of the vertical member of the frame, free to slide up and down. Pin holes are placed through the frame to lock the sleeve at a height range of 34 inches to 39 inches from the ground using a ½ inch pin. An extension spring is connected to the sleeve and the frame to support the skin during vertical adjustments. The rotational...
Open Access
Ambutech Joiner Operation Design
(2016-12-07) Hammad, Ahmed; McKay, Connor; McQuarrie, Curtis; Schappert, Anna; Labossiere, Paul (Mechanical and Manufacturing Engineering)
Ambutechis a division of Melet Plastics Inc. which manufactures mobility canes. Ambutech provides their customerswitha custom product made ofaluminum, fiberglass, or graphite.Aluminum and graphitecanes make up 93.8% of total sales. The projectfocusedon the joining processforassembling graphite and aluminum canes. The team analyzed Ambutech’s manufacturing process using the 8-step method. Both aluminum and graphite lines are standalone and run in tandem. The takt timefor the cane assembly processis 281 [s/cane] for both the aluminum and graphite assembly lines. Currently the only stages of the manufacturingunder the takt time are the aluminum press and final assemblystageof both canes. The goal of the project was toreduce operator time needed at the joiner process so thattheoperatorcan spend more time at the tape roller, which is the current bottleneckin the assembly line.With anunderstanding of the process, concept generation, and concept selection completed, the detailed designcould begin. The team separated the machine into three sections: shaft delivery, ferrule delivery, and the joiner. Fatigue analysis was completed on parts which experienced high loadsandlarge cycle counts to extend the life of the machine.The final concepts were: vibratory hoppers for theferrule deliverysystem, three shaft hoppers with a capacity of 50 shafts are used fortheshaft deliverysystem,anda shaft rotator with replaceable inserts and an electric linear actuator is used for the joining operation.Consideration was madeto reduce the payback period, maintenance costs, and costs associated with machine downtime. The machine was designed to be identical between the two manufacturing lines, with only the applied force needing to be changed between the aluminum and graphite lines.One machine will cost $ 44 564.28CAD, which includes all materials, components, and labor to assemble the machine, which is within budget.
Open Access
Analysis and Recommendation of Core Annealing Furnace Designs
(2013-12-02) Rabadia, Ketan; Gamble, Adam; Streuber, Gregg; Haruna, Issa; Bassim, M.N. (Mechanical and Manufacturing Engineering); Labossiere, Paul (Mechanical and Manufacturing Engineering)
The batch-process electric bell annealing furnace currently used by Carte International Inc. is outdated and is believed to be operating at below acceptable efficiency. The authors of this report have been contracted to assess the condition of the current furnace and recommend a course of action including the recommendation of a new replacement furnace. A Failure Modes and Effects Analysis (FMEA) identified seven key failure risks in the current system. These failure modes are identified as: core oxidation, foreign contamination, failure to achieve soak temperature or time, overheating of cores, non-uniform temperature distributions, thermal shock, and general safety. Further work was performed to collate available data on the construction, history, maintenance, and operation of the existing furnace to assist future analysis by the Client. Finally, an experimental analysis was planned and arranged for the Client to test for the presence of non-uniformity in operating temperature distributions within the current furnace. Due to long lead-times on equipment acquisition this experiment could not be performed in time for this report; however, it will be carried out by the Authors in the coming weeks. In parallel, theoretical work was undertaken to establish a cohesive set of client needs and metrics which were used to adjudicate various proposed replacement systems. Five quotes were obtained from various suppliers consisting of variations on two key furnace designs: a new (replacement) bell furnace, or a switch to a single-piece workflow rolling hearth furnace. Each was compared against the generated client needs. The final analysis indicated that based on currently available data a switch to single-piece workflow is not cost effective due to the large capital cost and space requirements of rolling hearth furnaces. Replacing the existing furnace with an updated, high efficiency bell furnace is recommended. Current operations and growth projections are directly on the boundary between batch-optimal and single-piece-optimal conditions. Should production or growth projections be revised upwards, single-piece workflow systems would become preferable. As such, a full description of a recommended rolling hearth design is also included as an alternate proposal that can be pursued should further data become available that countermands the above conclusions.
Open Access
Analysis of air conditioning compressor mount to reduce noise, vibration and harshness
(2012-06-11) Fullante, Jasen; Fair, Matt; Newton, Dave; Strahl, Justin; Symonds, Malcolm (Design Engineering); Labossiere, Paul (Mechanical and Manufacturing Engineering)
The purpose of this report is to design a solution originating in New Flyer Industries‟ Xcelsior bus line. The issue is excessive vibration and noise generated in the engine compartment caused by the air conditioning compressor. Additionally, belt whip between the air conditioning compressor and the engine crankshaft pulley is to be reduced. This report will also examine future considerations for design solutions including methods of electronic damping, an alternative air conditioning compressor, and air conditioning hoses. It is determined that a ROSTA ISOCOL U 50 vibration mounting plate is recommended to reduce noise and vibration caused by the operating compressor. A torsional damping pulley is suggested to be installed in place of the crankshaft pulley in order to reduce belt whip during operation. For future considerations, a modular damping unit integrated with a screw compressor and Galaxy 4890 hoses is recommended.
Open Access
Analysis of Pediatric Upper Extremity Wrist Hand Orthoses
(2020-12-09) Abrahams, Blair; Alcantara, Jerrod; Moyer, Stephen; Sawchyn, Tyler; O'Brien, Sean; Labossiere, Paul; O'Brien, Sean
This report outlines and details the design of a Wrist Hand Orthosis (WHO) for treating hand spasticity for the Rehabilitation Centre for Children. The purpose of this project is to improve upon the long lead times and poor comfort of the current WHO's used. The final design is arrived at through generating a number of concepts, and selection based on performance criteria. This design uses a Low Temperature Thermoplastic template, custom fit to patients based on measurements taken by an Orthotist. Features include ethylene-vinyl acetate (EVA) or polyethylene (PE) foam lining for comfort, and Velcro straps for fastening to the patient. Design refinement is described through a prototyping phase undertaken by the RCC. The final design weighs between 62-86 grams, is 25% to 40% more breathable than the currently used devices, costs $49.71 to produce, and a batch of six devices can be produced in 1.3 hours. Recommendations to improve this design include further material testing, refinement of template designs, manufacturing improvements, and optimization for further breathability.
Open Access
Ankle-Foot Orthosis (AFO) Design
(2016-12-07) Hempel, Franzeska; Javed, Zafar; McKenzie, Chanelle; Wu, Misilyna; Labossiere, Paul (Mechanical and Manufacturing Engineering)
The team was assigned to work with Anderson Orthopedics (AO), a private company specializing in the ability to provide patients with a customized ankle-foot orthosis (AFO). The main objective of the project was to optimize the posterior strut geometry of the AFO for individuals suffering from dorsiflexor and plantarflexor weaknesses, and be able to 3D print the brace in order to receive patient feedback.After identifying the needs and constraints of the project, the team was able to begin concept development for the AFO and brainstormed 17 preliminary concepts, which were narrowed down to four concepts using qualitative screening analyses. The top four designs chosen were: the Basic (#1), Wishbone (#5), Posterior Lattice (#10), and Layered Strut (#11) concepts. Finally, a preliminary qualitative FEA scoring analyses was performed in order to choose the final concept design to further optimize based on the performances under the constrained settings of the gait cycle, on a modifying software SolidWorks®. As a result, the Basic concept was selected.In order to optimize the design of the Basic concept, the team considered three main variables: material selection, inclination angle, and material thickness. The final model chosen to 3D print was made out of PC-ISO and an inclination angle of 90°, which we name the Basic(PC-ISO, 90°). Using this model, further optimization and customization of the brace was performed, which resulted inthe final model: BIA.The BIA was 3D printed using PC-ISO at an inclination angle of 90°, sole thickness of 3 mm, and varying posterior strut thickness from 4-7 mm,which resulted ina spring-back force of approximately 168 N, and an estimated increase in energy return of 38%. The total cost of manufacturing the BIA at North Forge was roughly $264.The last phase of the project consisted of3D printing the Basic (PC-ISO, 90°) model and presenting our final model, BIA, to the client and patient for feedback. After receiving feedback from both the client and patient, recommendations for any future development in the projectwere made.
Open Access
Articulating Jig for Railside Bungalow Roofs
(2017-12-06) Wang, Aoyu; Burnham, Evan; Logan, Kyle; Duynisveld, Stephen; DeGagne, W.C.D (Mechanical and Manufacturing Engineering)
The sponsor of this project is Modern Manufacturing Limited (MML). MML builds aluminum bungalows that house railway controls and components. The current process that MML uses to assemble and install the roof assemblies of these bungalows has shown to be inefficient and not as ergonomically friendly as they desire. Our team set out to design a new system for assembling and installing these roof assemblies that will not only be easier for the assemblers, but will also improve the safety and comfort. The previous process has the roof assemblies being assembled on stationary stands, requiring the assembler to move around the assembly to gain access to welding points. The previous process also required three to four additional assemblers to assist with the installation of the roof on top of the bungalow assembly, which was done using an existing bridge crane. Our improved design includes a new assembly jig for the roof to facilitate fabrication. This jig has the ability to locate and hold the components required for the roof assembly, and allows for the assemblers to rotate the entire assembly for access where required. Also included in our design is a new jib crane that uses a horizontal trolley to move the entire jig assembly towards and away from the bungalow assembly. The horizontal trolley uses a vertical hoist that is attached to the roof jig to move it vertically and into position for installation on the bungalow. Also attached to the horizontal trolley is a vertical stabilization beam. This vertical stabilization beam uses a vertical trolley to attach the horizontal trolley to the jig assembly. This way when the jig assembly is being moved in the vertical direction it will not sway or rotate, as it would if it were only being lifted by the hoist. The final design uses a W18 X 50I-beam on the main jib crane to which our horizontal trolley is attached. The horizontal trolley uses a W8 X 21 I-beam, as its vertical stabilization beam, and a 6,600lbcapacity hoist to lift the roof jig and roof assembly. The final jig design uses metal “ribs”...
Open Access
An Assistive Smart Mirror for Daily Living
(2023-04-13) Modrcin, Dora; Yin, Hester; Reimer, Sydni; Du, Yuyao; Jacobson, Natasha
Individuals with mild cognitive impairment (MCI) experience challenges completing hygienic tasks independently due to short-term memory loss and difficulties sequencing tasks together. A caregiver can help by providing reminders and cueing. However, dependency on a caretaker decreases independence which may impact self-confidence. This smart bathroom mirror, shown in Figure 1, may help individuals with MCI to complete hygienic tasks, supporting independent living. The focus tasks are brushing teeth, flossing teeth, washing face, washing hands, applying deodorant, and brushing hair. The smart mirror reminds the users of their daily hygiene tasks and will proceed with step-by-step cueing when the user activates a task using the keypad. The smart mirror incorporates a custom-built hardwood frame containing a panel of smart mirror glass and a Dell 27" 2722 monitor. A PIR motion sensor, a 9-button keypad, and a Raspberry Pi 3 B+ connect to the monitor. The material of the back panel is Medium Density Fibreboard (MDF) which is secured using screws, allowing access to the internal electronics when needed. Brackets with screws fasten the smart mirror to the wall. The languages used to program the smart mirror are HTML, CSS, and JavaScript. There were eight tests; of particular interest are the internal heat and humidity tests that ensure the smart mirror's internal temperature remains below 40 °C and relative humidity (RH) does not exceed 30%. The design team also tested the functionality of the smart mirror to confirm that smart mirror technology could effectively cue hygiene tasks. The main recommendation is for testing to occur with individuals who live with MCI to conclude the effectiveness of a smart mirror in increasing the independence of this population. In addition, recommendations to improve the physical build and software are made.
Open Access
Automated Fixture for Leak Detection Scanning
(2016-12-07) Watson, Chris; Khangura, Parminder; Bozynski, Alex; Han, Jiaqi; Labossiere, Paul (Mechanical and Manufacturing Engineering)
Price Industries designs and manufactures components for heating, ventilation and air conditioning systems. One series of products they manufacture is the Price LFDC / LFDCSS Series Laminar Flow Diffusers with replaceable high-efficiency filters. The laminar flow diffusers provide filtered air to environments where air quality is important, such as hospitals and clean rooms. The diffusers are manufactured from sheet metal, and each diffuser has various seams and joints that are tack welded and caulked. To ensure that the diffusers function as intended, each unit must undergo an aerosol challenge test to detect any leaks. The aerosol challenge test involves pressurizing the diffuser with air infused with oil particles and using a photometer to detect if the oil-infused air is escaping through any of the seams or joints. The current process involves a worker with a handheld device manually passing the device’s nozzle over the seams. The objective of our project was to design a fixture that can automatically scan each seam and joint as well as alerting the worker to a detected leak, with minimal human interaction. We were also tasked with designing the documentation system for documenting the location of leaks detected that can be tied into the barcode scanning system. After considering the constraints, limitations, customer needs and target specifications, we generated a variety of concepts. We analyze the concepts with decision matrices and determined the best concept for each component of the design. After determining the best concepts, we began the final design process. We designed a test fixture which meets all the requirements determined. Our test fixture is comprised of a manually adjustable frame, four leadscrews with guide rails, and four nozzle carriages that run along the lead screws. The adjustable frame allows the test fixture to accommodate multiple diffuser sizes. Leadscrews run along each side of the test fixture and are driven by mounted stepper motors. The leadscrews and guide rails are used to move the nozzle carriages along each side of the diffuser to scan the seams. The nozzle carriages are comprised of a simple C shaped frame where the nozzles, valves, and a...
Open Access
Automated Packaging Machine Modifications
(2015-12-07) Safniuk, Josh; Kinch, Anthony; Wang, Yunan; Liu, Shuai; Balakrishnan, Subramaniam (Mechanical and Manufacturing Engineering)
Melet Plastics utilizes an automated packaging machine to attach header cards to its injection molded egg holder product. However, the financial advantages of using automation have not manifested at Melet due to the high failure rate of the machine. This report was created by JAYS Mechanical Consulting to identify the machine failure modes, provide recommendations for modifications to reduce the occurrence of these failures, and provide detailed designs of these modifications. A failure modes and effects analysis (FMEA) conducted by JAYS Mechanical Consulting identified four failure modes associated with the machine. These four modes are: stapler misfire, misshapen staples, incorrect positioning of the staple, and incorrect positioning of the header card. The positioning failure modes have low variability and frequency. JAYS Mechanical recommends systematic set-up procedures to prevent positioning errors incurred during set-up, and modifications to the header card and card dispenser to prevent operator error during card reloading. The stapler misfire and misshapen staple failure modes were found to be a result of the stapler used in the machine. The main mechanisms of failure were interference of the egg holder handle on the stapling process and previous back plate modifications that prevent proper stapling. JAYS Mechanical Consulting is recommending two modification designs to deal with the stapling failure modes. The first design addresses these failure modes by applying modifications to the stapler currently used in the machine. Immobilization of the staple back plate and material removal from the bottom arm of the stapler are the key features of the first design. Immobilizing the back plate in its intended position ensures proper stapling and the material removal allows clearance for the handle preventing any interference with the stapling process. The estimated cost of this first design is $195.72, well below the allowable budget of $5000, and the design is quick to implement. The second design JAYS Mechanical Consulting recommends implements the Senior A16/L pneumatic stapler from Margreiter-Technik. The designed modifications are all based on making the stapling machine compatible with the Senior A16/L stapler. This stapler has the clearance necessary to prevent interference from the egg holder handle and […]
Open Access
Automated Pizza Pop Rack Mover
(2020-12-09) Altasin, Janus; Jackson, Jadon; Olson, Steven; Tien, Kelvin; O'Brien, Sean; Labossiere, Paul; O'Brien, Sean
The General Mills Pizza Pop facility located in Winnipeg, Manitoba, is the sole producer of Pizza Pops throughout all of Canada. With such high demand, it is critical to ensure all manufacturing processes are analyzed and optimized in search of improvement. However, when it comes to the manufacturing capabilities of manual labour, limitations such as strain injuries and harsh temperature arise. Therefore, to increase both human safety and manufacturing throughput, automation can be implemented. The scope of this design is contained from where the Pizza Pops begin getting placed on trays to where the Pizza Pops get taken to the packaging line. This process is very manual and requires the support of 5 operators. For one process, where an operator moves racks within a freezer, the work environment is challenging as the temperature is regulated at around -12° F. General Mills is looking to reduce these manual tasks through automation while only requiring 1 operator. This report performs a detailed analysis on implementing a fully automated system for tray loading, rack transportation, and Pizza Pop freezing. For the tray loading category, a dual head elevator is used to load two trays into a single rack at a time. The dual head was required to meet the current throughput of 17 trays per minute and can load up to 18.5 trays per minute. The racks are automatically indexed for the tray loader to keep supplying racks when they become full. For rack transportation, an AGV will driven under the racks, engage with a connection bar and then transport the rack to the desired location. An embedded magnetic strip path will be placed through out the area to provide a path for the AGV's to follow. It was found that a total of 3 AGV's continuously operating are needed to meet the required throughput time. However, more AGV's can be added in the future if an increase in throughput exceeds the capability of 3 AGV's. Lastly, upon further analysis of the freezer, it was determined that AGV's alone inside the freezer would be insufficient. Therefore, an indexing rail system was developed to operate inside the freezer, capable of moving racks quickly and efficiently. Racks are loaded into each rail via an AGV and engage with the rail latching mechanism. This latch is powered by an electric pulley system and is responsible for bringing the racks up to the front of the freezer. There are a total of 9 indexing lanes, each with an 8 rack capacity, allowing a max of 72 racks in the freezer. A cost breakdown has been provided to detail how much each individual system will cost, including operational and preventative maintenance costs. For the overall system to be installed, it is estimated to cost approximately $996,000 CAD. In summary, this automated system has been proven feasible within the General Mills facility. The design meets and exceeds throughput, reduces required employees from 5 to 1, and increases employee health and safety.
Open Access
Automated Rain Detecting Drainpipe-Eavestrough
(2020-12-09) Cabral, Ryan; Johal, Manvir; Lucas, Cameron; Verana, Jeoffrey; Balakrishnan, Nishant; Topping, Aidan; Balakrishnan, Nishant
The Automated Downspout Device is an automated device that uses mechanical devices to rotate the downspout extension in and out of position. When it is raining, the downspout extension needs to be perpendicular to the exterior house wall and once the rain stops, the Automated Downspout Device rotates the downspout extension until it is parallel against the house wall. The Automated Downspout Device uses a Pelton wheel to generate the mechanical energy necessary to cause the rotation of the downspout extension. The rotation is aided by the using of PTFE sliding bearings and a spring is used to return the downspout extension back to its resting position parallel to the house wall. This report describes the full system operation of the Automated Downspout Device, as well as the operation of the major components. A maintenance and repair plan was established as well as the installation procedure. A description of the necessary manufacturing processes, including laser cutting, sheet metal bending and 3D printing is provided. Based off the Bill of Materials, a thorough cost analysis was performed that outlines the cost for outsourced components and materials.
Open Access
Automated Roll Carousel
(2022-12-07) Dallarte, JC; Jain, Roshan; Patel, Deval; Labossiere, Paul; Labossiere, Paul
The client requested engineering students at the University of Manitoba to create a design that automates material changeover during a manufacturing process. Currently, an operator must manually load and unload a roll of fiberglass fabric onto a static rack for processing. The automated design reduces the physical labor required by the operator, lowering safety risks involved with lifting 70 kg rolls of material. This design is called an automated roll carousel due to the structure and functionality of the design. The basic principles of the automated roll carousel involve rotation as a means of transportation of the rolls. An electric motor rotates a circular carousel via a geartrain and a chain. This carousel can hold eight rolls of material and can bring the material from an initial loading position to the correct feeding position for the material processing step. This carousel can then rotate to the next material as required by the operator. Three main factors of the automated roll carousel will be detailed. The structure included all static components and some non-drivetrain rotating components. The structure of the carousel will be detailed in this report, including all analytical and numerical analyses of all components under stress. The alignment and loading mechanism design will be outlined following the structure. The alignment included ways of constraining the roll to the mandrels while allowing for roll size adjustability via alignment cones. Loading the mandrels into the carousel was designed for simplicity and safety, maintaining low physical operator effort. The drivetrain and motor system were designed to be simple, safe, and efficient. The drivetrain has been designed to be compact and have enough power to rotate the entire carousel. As such a 2 HP electric motor was chosen, which was connected to a gearbox with a 1166 speed reduction ratio. This reduces the speed of the motor to 1.25 RPM, which is a safe speed for the carousel to operate at. The motor and gearbox are fully shielded, so there is no safety risk during operation. The gearbox includes a power-off brake that can render the carousel immobile at the press of a button. The operator can rotate the carousel forwards and backwards due to 3 phase power and open loop control. This design was quantified by its deliverables. A CAD model and drawing package were prepared for the client, which they can use to manufacture the carousel should they wish to proceed with the project. A bill of materials was also prepared, to quantify materials required to build the design. Quality engineering rigor was applied to the design, ensuring a quality design. Overall, the automated roll carousel properly meets the automation objective given by the client, reducing operator effort, and leading to a more efficient process.