Design Projects Documentation



Design Projects Documentation

|Title of the project: |Radio Controlled Cargo Aircraft |

|Project description: |Design and build an RC cargo Aircraft capable of lifting the payload for SAE |

| |sponsored competition. The design will be scored in three categories: design |

| |presentation, and accuracy of the predicted payload. The objective is to familiarize|

| |the design process from concept, to detail design and report presentation, to final |

| |hands-on manufacturing as “real time“design engineering. |

|Team members: |Daryl Johnson, Jeff Leeper |

|Sponsor Industry: |SAE |

|Project year: |1989 |

|Title of the project: |Pier Block Machine Redesign Progress Report |

|Project description: |Redesign a concrete form shaping machine owned by the Concrete Shop of Vancouver, |

| |Washington. The existing machine had been overused thus exposed safety hazards. It |

| |was also difficult to operate. The goal of the redesign is to improve the operation |

| |control, reduce the safety hazards, and increase reliability and durability of the |

| |machine. |

|Team members: |Mike Dockter, Tom Lonergan, Colin Wright |

|Sponsor Industry: |The Concrete Shop of Vancouver, Washington |

|Project year: |1990 |

|Title of the project: |Tank Farm |

|Project description: |Design a new tank farm for Imperial Paint for its paint storage facilities. The |

| |objective is to comply with the new environmental protection regulations governing |

| |all bulk storage facilities that would take effect in December 1998. The task also |

| |intends to maximize the efficiency of allocation of petroleum based material in the |

| |current storage. |

|Team members: |Sam Louie, Mike McConnel, Tony Yan |

|Sponsor Industry: |Imperial Paint |

|Project year: |1990 |

|Title of the project: |Redesigning The Tensioning System For An I.D. Silicon Wafering Saw |

|Project description: |Redesign a wafer I.D. saw to improve the slicing process in terms of throughput and |

| |wafer quality for Wacker Siltronic, Inc. The target is to develop a system that |

| |enables rapid blade changeover (5 to 10 minutes) while improving the wafer quality as|

| |less than 30 microns of run-out at 3 standard deviations. The project includes two |

| |separate phases, 1) a remote tensioning system, and 2) a device easy and efficient |

| |for mounting the pre-tensioned blade to the saw. |

|Team members: |Paul K. Durant, Chris Burkle, Brent Running |

|Sponsor Industry: |Wacker Siltronic Inc |

|Project year: |1995 |

|Title of the project: |Metal Building Assembly Fixture |

|Project description: |Redesign the current building assembly fixture to improve its performance and |

| |increase its usability. The fixture design will include 12 – 16 ft wide buildings, |

| |allow different framing member spacing between building sizes, and allow installation|

| |of doors and windows anywhere around the building perimeters. The redesigned fixture|

| |will be able to work on the same site where the job is. The fixture size will be |

| |adjusted to 8 ft long and 4 ft wide for transportation. |

|Team members: |Russel Reigel, Steve Rothe, Ali Kashi |

|Sponsor Industry: |Reigel Buildings, Inc |

|Project year: |1994 |

|Title of the project: |Design of a Ground Ambulance Gurney |

|Project description: |Design a Ground Ambulance Gurney (a medical emergency wheeled cot or stretcher) for |

| |Life Port to stay in competition on the gurney market. The design model NE-31 must |

| |meet the following constraints: |

| |18” (height) x 76” (length) x 22” (width). |

| |Able to carry 500lb patient with maximum deflection of 1”. |

| |The four wheel casters must be free to allow the gurney to maneuver around corners. |

| |Compatible with the existing attachment systems used in ambulances. |

|Team members: |Richard Berney, David Graham, Mike Rusch |

|Sponsor Industry: |Life Port, Inc |

|Project year: |1990 |

|Title of the project: |A Method to Rebuild Delaminated Color Printer Heads |

|Project description: |Designing a procedure to rebuild the delaminated color printer heads so that the |

| |returned defective heads can be reused. The rebuilt heads not only need to be |

| |functional, but also need to meet the following goals: |

| |The built head will have a service life of 7 years. |

| |The head rebuilding must use the existing equipment at Tektronix as much as possible.|

| |The process must complete by June 9, 1989. |

| |Four phases are developed for the rebuilding process: |

| |Disassembly and sorting. |

| |Surface preparation. |

| |Adhesive selection. |

| |Reassembly. |

|Team members: |Mark Erickson, Eric Muhvy |

|Sponsor Industry: |Tektronix |

|Project year: |1989 |

|Title of the project: |Unwind Stand for James River Corp |

|Project description: |Design an unwind stand for James River Corporation. The design focuses on areas of |

| |self loading, brake, and tension controls. The targets are to increase productivity,|

| |eliminate paper breakage, ensure the edge alignment, ensure self loading, and |

| |properly position the bulk rolls. Utilizing the latest technology in paper tension |

| |control and brake devices, the design also includes a scissor lift mechanism mounted |

| |in the floor, and a hydraulic actuator integrated with a photo-electronic senor for |

| |lateral adjustment. |

|Team members: |Peter Arola, Kevin O’Connell, Man Wah Poon, Arthur Miller |

|Sponsor Industry: |James River Corporation. |

|Project year: |1987 |

|Title of the project: |Warn Vacuum Locking Hub Group |

|Project description: |Design and prototype a remotely-actuated mechanisms which can engage and disengage |

| |the clutch ring with the inner drive gear for Warn Industries, Inc. The design |

| |objectives focus on the mechanism itself as follows, |

| |The remote actuation will be accomplished by way of vacuum or pressure delivered |

| |through the spindle. |

| |The design must allow the clutch ring to move to the locked and unlocked positions |

| |repetitively and reliably. |

| |It must survive the exposed location of a front wheel hub in a four-wheel drive |

| |vehicle. |

| |The mechanism must fit into approximately the same internal cavity of the hub as |

| |found on Warn’s current design. |

|Team members: |Brian Baker, Mike MacGregor, Ken Millard, Daniel Morrow |

|Sponsor Industry: |Warn Industries, Inc. |

|Project year: |1995 |

|Title of the project: |The Densification of Energy Wood Material for Economical Transpiration to Distant |

| |Energy Markets |

|Project description: |The objective of the design is to propose and evaluate a method to densify (bale) |

| |waste wood materials for convenient and economical long range transportation to |

| |distant energy markets. The design focuses on two areas of processes, the method of |

| |densifying waste wood and means of transportation for shipping waste wood. |

|Team members: |Richard Allen, Steve Ringous, Roger Doolin, Ali Khashab |

|Sponsor Industry: |USDA Forest Service Pacific Northwest Research Station. |

|Project year: |1995 |

|Title of the project: |Tillamook Cheese Project |

|Project description: |The objective is to design an automated cheese trimming system to replace manual |

| |operation that causes injuries due to repetitive motion. Eliminating manual |

| |operation in this trimming process reduces the medical cost due to the injuries. |

| |Along with the savings from medical costs and recycling the excessive cheese from |

| |oversized cheese block, this project would ultimately bring $80,000-$10,000/yr |

| |savings to Tillamook Cheese Corporation. The automated cheese trimming system would|

| |be integrated into the existing conveyor system at Tillamook Cheese Corporation. |

|Team members: |Jim Jackson, Fred Frey, Jerry Stole, Terry Daugherty |

|Sponsor Industry: |Tillamook Cheese Corporation. |

|Project year: |1992 |

|Title of the project: |Bonnelville Navigation Lock |

|Project description: |The design proposes a new navigation lock gate actuating mechanism. The existing |

| |navigation lock that has not been replaced in the last twenty years has a long |

| |downtime in the event of mechanical failure. The long downtime could be up to 3 |

| |weeks that disrupts the traffic on the entire Columbia River. The components of the|

| |existing lock were custom made that takes longer time and expensive to replace. The |

| |new navigation lock would be less expensive in maintenance and shorter downtime that |

| |would ease the bottleneck condition developed on the Columbia River. |

|Team members: |Jim Jackson, Fred Frey, Jerry Stole, Terry Daugherty |

|Sponsor Industry: |US Army Corps of Engineers, Mechanical Design Section, Portland Oregon. |

|Project year: |1986 |

|Title of the project: |Design of Condensate Return System |

|Project description: |This is a preliminary design and economic evaluation of a steam condensate recovery |

| |system that will serve Ballast Water Treatment Plant for Portland Ship Repair Yard. |

| |One of the Ship Yard services is the separation and treatment of a mixture of water |

| |and crude oil, known as ballast water. The separation process utilizes steam from a |

| |nearby boiler house to heat and separate the mixture. After repeated cycles, the oil|

| |will be skimmed and the water will reach its purity level accepted to return to |

| |sewage or the Willamette River. Before this project, none of the condensate |

| |generated in the whole process was recovered. The water and its remaining heat all |

| |lost along with the chemicals in the water to prevent the corrosion in the boiler. |

| |The design objective is to capture the maximum amount of steam condensate possible |

| |and return it to the boilers at the highest temperate possible with free maintenance |

| |and reasonable cost. |

|Team members: |Scott Hewitt, Bill McKay, Dan Watson |

|Sponsor Industry: |Portland Ship Repair Yard, Port of Portland, Swan Island |

|Project year: |1990 |

|Title of the project: |Pneumatic Switch |

|Project description: |Redesign a pneumatic switch, an HVAC valve used in a cab of a truck for Sprague |

| |Aristo-Aire to meet their customer needs. Driven by the cost (under $8.00), the |

| |redesign report discussed two alternatives, use of the spool valve operated by a cam,|

| |and an adaptor allowing the current product to fit an Eaton style rocker arm switch, |

| |and picked latter as its final decision. The report gathered information of existing|

| |valve mechanisms, and did analysis including valve body, cam piston, bulking, |

| |pressure vessels, heat transfer, and rocker plunger. The report presents |

| |discussions of quality, decision matrix, and drawings |

|Team members: |Michael Pepelaskov, Danny Yuwono, Scott Hartell, Tom Lee |

|Sponsor Industry: |Sprague Aristo-Aire |

|Project year: |Dec., 1995 |

|Title of the project: |Freightliner Twin Steer |

|Project description: |The Twin Steer system is used in heavy duty truck to increase the load carrying |

| |capacity. Freightliner’s Twin Steer system poses problems when navigating uneven |

| |byways and rugged terrain. Using QFD (Quality Function Deployment) techniques, the |

| |project focuses on the front suspension used universally on various models of |

| |Freightliner trucks that will distribute the loading evenly over both the front |

| |axles. The proposal for the new suspension offers improved steering geometry over |

| |the current design and free of interference of the tire and the steering linkage. |

| |The intent is to solve the problem of 1) possible overloading on one axle; 2) |

| |interference of the right tire with the steering linkage. The final design uses a |

| |mix of exiting Freightliner components and new parts manufactured in house from |

| |standard Freightliner materials. The redesign has achieved equalization, and has |

| |been recommended to be a standard option for Freightliner heavy duty truck. |

|Team members: |Doug Johnson, Eric Kominek, Chris Phimister, Dilan Silva |

|Sponsor Industry: |Freightliner Corporation. |

|Project year: |unknown |

|Title of the project: |Refrigeration Update Design |

|Project description: |The project presents the design and analysis of a retrofit kit for semi-trailer |

| |refrigeration unit to replace earlier style of Thermo King model SNWD units and |

| |subsequent reinstallation into the glider kit to produce a unit which is a comparable|

| |in design and performance to late model Thermo King SB style units. The |

| |accomplishment also includes the update that is less than half of the cost of a new |

| |refrigeration unit. The design features include a flush mount evaporator section, |

| |improved evaporator fan design, and the conversion from CFC based refrigerant to an |

| |EPA approved HFC based alternative. The project consists four major tasks, 1) frame |

| |design and analysis; 2) evaporator fan selection and analysis; 3) alternative |

| |refrigerant selection and analysis; and 4) construction of the prototype Glider kit. |

| |The project also covers cost analysis of building the prototype and recommended |

| |testing procedure for determining the refrigeration performance of the prototype |

| |under actual operation condition. |

|Team members: |Andrew Gorman, Dodd Juenemann, Scott Basom |

|Sponsor Industry: |Thermo King Corporation |

|Project year: |June, 1994 |

|Title of the project: |Final Report Prototype Air Burst Screen Cleaning System |

|Project description: |The objective of the project is to develop a functional prototype of an air burst |

| |system to remove debris from two selected dewatering screens, as means of studying an|

| |effective replacement to the mechanical systems at the new JBS (Juvenile Bypass |

| |System) at Bonneville Dam. The project is to meet the request from the National |

| |Marine Fisheries Service (NMFS) to improve the survival rate of the young salmon |

| |during downstream migration. |

|Team members: |Dwayne M. Weston, Jeff Howard, James N. Rawlinson |

|Sponsor Industry: |U.S. Army Coprs of Engineers, Portland District |

|Project year: |June 1997 |

|Title of the project: |Large Building Monitoring |

|Project description: |The project is about the development of an energy monitoring procedure for large |

| |commercial buildings. The project presents a method that substantiates and pinpoints|

| |the savings attained in monitoring the various energy loads from the retrofits. The |

| |project derived the answers about the reason of monitoring a particular load, the |

| |measurement precision, recording frequency, the duration of the monitored load, the |

| |method of gathering ambient weather information, power quality analysis versus |

| |monitoring accuracy, monitoring procedure versus multiple-load testing, data |

| |acquisition system being stationary versus portable, and compatibility between |

| |procedure and the retrofit system. |

|Team members: |Dryan D. Babcock, Kevin C. Fish |

|Sponsor Industry: |Microgrid Inc. |

|Project year: |June 1993 |

|Title of the project: |IDC Fab Chiller Project |

|Project description: |The project analyzes the alternative sources of energy for facility cooling. These |

| |alternative energy sources are the use of natural gas and absorption driven chillers |

| |instead of electricity driven to cool the incoming air or remove the water vapor. |

| |The project focuses on reducing electrical energy costs for a chiller plant by using |

| |heat recovering from gas-engine-driven (GED) chillers to power absorption chillers. |

| |The design requirements are 10000 ton maximum required cooling load, payback period |

| |of 1 ½ to 2 years, inside dry bulb temperature of 70 (F, inside relative humidity of |

| |42-45%, and use off-the-shelf components. Additional requirements are space |

| |constraints, use of heat recovery, chilled water temperature, system reliability, |

| |maintenance downtime, system life, system cost, and fab location and ambient |

| |conditions (Austin, Texas). |

|Team members: |David Bueffel, Doug Crombie, Tony Hunt, Danny Wilhelmi |

|Sponsor Industry: |Industrial Design Corporation (IDC) |

|Project year: |June 1997 |

|Title of the project: |Human Powered Hydrofoil Design Report |

|Project description: |The project investigates the propeller and foil theories, and presents programs to |

| |predict a ten foot diameter air propeller and a wing tapering from a 2” to a 4 “ |

| |chord length. The project studied ergonomics and evaluated the data from the riders |

| |who were tested for their horsepower output (0.9 to 1 horsepower output is expected |

| |for an athlete pedaling at 100 rpm. The project presents a drive train system design|

| |that supplies the power to propeller from the rider using standard bicycle |

| |components. Using FEA, the project presents the design of the hull and tubular |

| |structures to support the foils and propeller. |

|Team members: |Craig Ulrich, Robert Ray, James Oliver, Gerald Knrdonowy, Linda Jackson, Paul |

| |Giuffrida |

|Sponsor Industry: |The International Human Powered Vehicle Association, Inc |

|Project year: |June 1992 |

|Title of the project: |1996 SAE Mini Baja Final Report |

|Project description: |The project is of an SAE sponsored annual Mini Baja competition. The ultimate goal |

| |of the project is to design and build a prototype of an off road vehicle. The intent|

| |of the prototype was the acquisition of suspension and drive train loading data, as |

| |well as information leading to the improvement of the overall design. The maximum |

| |vehicle size is 60” wide x 96” long, 8hp, and 4 cycles Briggs and Stratton engine. |

| |The competition is intended to simulate an industrial engineering situation in the |

| |form of prototype development, and is limited to a maximum production cost of $2500 |

| |per vehicle in a 4000 vehicle run. In addition to the technical specifications, SAE |

| |sets strict safety regulations. Vehicles conforming to safety and technical |

| |regulations are subjectively judged by practicing engineers based on marketability, |

| |design innovation, aesthetics, and cost effectiveness. The cars then compete in |

| |dynamic events intended to evaluate their performance characteristics. Dynamic |

| |events consist of a maneuverability slalom course, a hill climb, a drag race, and a |

| |four hour endurance event. |

|Team members: |Chris Aspmo, Dave Hort, Bill Hayhurst |

|Sponsor Industry: |Society of Automotive Engineers |

|Project year: |June 1996 |

|Title of the project: |Water Heater Design Project: Out for the Long Run |

|Project description: |The project researches the causes of the tank failure of residential water heaters |

| |and presents a new design of hot water heater with longer life (35 years versus 5-12 |

| |years of conventional water heater lives). The result of the project is a design |

| |that employs an anodic protection system and a sediment removal system to protect the|

| |tank from failure and thus increase tank life to at least 35 years. Schematics of |

| |the design were created such that a prototype can be constructed. The prototype can |

| |then be used to test the concepts generated. |

|Team members: |Jake Abraham, Peter Villanueva, Samarith Loeung |

|Sponsor Industry: |American Water Heater Group |

|Project year: |Unknown |

|Title of the project: |Condensate Recovery System |

|Project description: |The project was to evaluate the economic feasibility of recovering lost energy and |

| |/or water from the Tall Oil area steam condensate. The team concluded that the Tall |

| |Oil area under utilized the heat value from condensate produced. The condensate |

| |collection tank was under sized and only returned a portion of the available |

| |condensate for boiler water preheat. The project proposed Liqui-Mover |

| |collection/pumping system that would have a larger capacity and return more |

| |condensate. A new plate and frame heat exchanger is presented to replace with the |

| |shell and tube heat exchanger thus the heat transfer would be more effective from |

| |returned condensate to the boiler feed water. The new heat exchanger combined with |

| |the Tall Oil return system would cost Hercules $27,600 and save $40,000, that yields |

| |103% return on cost (ROC). |

|Team members: |Art Utter, Fred Imayoshi, Randy Mathieu, Susan Grant |

|Sponsor Industry: |Hercules, Inc |

|Project year: |June, 1995 |

|Title of the project: |UHMW-PE Parts Welding |

|Project description: |The project involves the development and design of an improved process for joining |

| |ultra-high molecular weight polyethylene (UHMW-PE) hubs to sprockets. To spin-welded|

| |the hubs to the sprockets, Solidur used a lathe to spin the hub against the |

| |stationary sprocket, generating enough heat from friction to weld the parts. The |

| |complexity of the lathe requires skilled labor intensity from the machinists. The |

| |molten plastic being thrown from the parts also became safety concerns. The project |

| |recommends an improved form of spin-welding through the use of automation that would |

| |reduce the skill level required to run the lathe, and free the lathe for other uses. |

| |Based on the economic analysis of costs, the team determined the configuration of the|

| |spin-welding fixture from the two alternatives, a dual-spindle welder that could weld|

| |two hubs at once, and conversion of an out-of-tolerance milling machine, and decided |

| |to use the conversion of an out-of-tolerance milling machine. |

|Team members: |Brian Bonn, John Calderbank, Larry Coon, Rich Rampone |

|Sponsor Industry: |Solidur Pacific Co. |

|Project year: |June, 1993 |

|Title of the project: |Tri-County Metropolitan Transportation |

|Project description: |The project was to develop an alternative wheelchair restraint system for the |

| |physically challenged riders of the Tri-County Metropolitan Transportation District |

| |of Oregon (Tri-Met) that reduces the company’s liability for injuries sustained by |

| |the restrained passengers and the drivers that must insure the safety of the regarded|

| |passengers. Tri-Met had been able to accommodate the wheelchairs before the change |

| |of modern wheelchair styles such as varied sizes of tires between front and rear, and|

| |3 tires instead of 2. Tri-Met previous restraint system could not work as intended. |

| |The project provides the development of a universal wheelchair restraint system to be|

| |installed on the buses to replace the outdated system for all styles of wheelchairs |

| |to meet ADA (American with Disabilities Act) and FTA (Federal Transit Administration)|

| |requirements. |

|Team members: |Brad Grabo, Loren Morris, Kellie Reid, Eric Tubbin |

|Sponsor Industry: |Tri-Met. |

|Project year: |January, 1996 |

|Title of the project: |Step-Chair Project |

|Project description: |Initiated by the chair of Electrical Engineering Department of PSU, Dr. Scghaumann, |

| |the project was a joint development between both the electrical and mechanical |

| |engineering senior students. The objective was to build an electro-mechanical device|

| |that would attach to a wheelchair, regardless of configuration, providing a means of |

| |traversing a step or a curb. The project presents the design focusing on the |

| |constraints of weight, size, automation, safety, efficiency of power use, ease of |

| |retrofittability, and climb time. The final deliverable includes a proof-of-concept |

| |prototype and a written report containing a recommendation, conceptual CAD drawings, |

| |and FEM analysis. |

|Team members: |Joe Brackin Dale Campbell, Tim Culligan, Bob Essex, Erik Halverson, Dave Henkemeyer, |

| |Jesse Inkpen, Larry Montoya, Craig Sarkinen, Mike Willardson, Ken Wolf |

|Sponsor Industry: |Electrical and Mechanical Engineering Dep’t of PSU. |

|Project year: |June, 1996 |

|Title of the project: |Facility Plan |

|Project description: |The project was to redesign an existing factory layout at Sequent Computer Systems, |

| |Inc. Focused on the subset of the overall factory layout and closely followed |

| |established methodology used in facilities planning at Sequent, the project reaches |

| |viable solutions for two large problems related to Production Floor Layout and Job |

| |Shop Layout. The solution meets the customer requirements for the new manufacturing |

| |system production and product logistics. |

|Team members: |Christian Vega, John Peterkort, James Chen, Vinesh Lal |

|Sponsor Industry: |Sequent Computer Systems, Inc. |

|Project year: |June, 1993 |

|Title of the project: |Curb-Climbing Wheelchair Redesign |

|Project description: |The project is the continuation of a senior electrical-mechanical joint project that |

| |began in 1996. The design was never operational though the substantial progress was |

| |made in the basic concept of the chair. Based on the previous design, the project |

| |was to redesign and build a prototype curb-climbing wheelchair that is safe and |

| |functional to both ascends and descends curbs automatically. The project spotted the|

| |problems from the previous design thus, setup new requirements and constraints, and |

| |proposed solutions so that the new prototype would be operational. |

|Team members: |Robert Deline, Clint Hutzenbilier, H. Mac Kuokka, Kent Nielson, Valentine Powers |

|Sponsor Industry: |Electrical and Mechanical Engineering Dep’t of PSU. |

|Project year: |June, 1997 |

|Title of the project: |Curb-Climbing Wheelchair Redesign |

|Project description: |The project targeted the existing problems of Single Roll Tissue (SRT) O-thane Belt |

| |Transport System that introduces product defects and resulting downstream machinery |

| |malfunction issues in the tissue processing. The project was to design a new SRT |

| |Transport System that eliminates snagging of SRT tails while meeting the needs of the|

| |existing system. Using QFD (quality function deployment) techniques, the project |

| |achieved a Retracting Table Top Chain SRT Transport System Design leading to reducing|

| |associated costs thus increasing productivity. |

|Team members: |Jeanne Lewis, Kellie Reid |

|Sponsor Industry: |James River Corporation. |

|Project year: |June, 1997 |

|Title of the project: |Design Project – James River Corp. (JRC) Wauna Mill |

|Project description: |The project utilizes the design methodology so called “Five Diamond Methodology”, |

| |developed by Migliore and Goulding of Portland State University, a design development|

| |process from initial conception to final implementation. The report details the |

| |methodology as it was used to solve problem associated with the work order requested |

| |at James River Corporation. The work order selected was a request for a closed loop |

| |liquid/liquid heat exchanger to cool the air compressor. Under the constraints of no|

| |change to the compressor and compressor operation, less than $100,000 budget, and |

| |keeping the water process chemistry acceptable, the project provides alternative |

| |approaches that are more cost effective than the corrosion inhibitors previously used|

| |at JRC to dealing with the corrosion problem of the air compressor leading to |

| |premature failure. |

|Team members: |Bob DeWitt, Geoff Ford, Martin Mance, Allen Zandonatti. |

|Sponsor Industry: |Wauna Paper Mill, James River Corporation. |

|Project year: |June, 1995 |

|Title of the project: |Freightliner Hood Tilt Assist Project |

|Project description: |The project was to redesign the hood tilt assist mechanism for more ergonomic reasons|

| |for Freightliner’s commercial trucks. Requiring less effort to open and close, the |

| |new proposed design offered a new hood tilt assist concept as an improvement upon |

| |Freightliner’s existing design. The final design for the hood locking mechanism |

| |utilized a linkage that mounts to the side of the radiator and also behind the front |

| |grill location. The design main advantage is its automation, meaning the driver |

| |needs only to open the hood in the conventional manner, and the locking mechanism |

| |automatically engages. The final design met Freightliner’s requirements of reducing |

| |the opening and closing forces to 35 and 40 pounts. |

|Team members: |Jaswant Sandhu, Ken Tran, Todd Wurster. |

|Sponsor Industry: |Freightliner Corporation. |

|Project year: |June, 1996 |

|Title of the project: |Evaluation and Redesign of a Bone Mill |

|Project description: |The project was about an evaluation and redesign of the bone mill for Acumed, Inc. |

| |Using functional decomposition techniques, the team performed an in-depth analysis on|

| |the previous design. Based on the knowledge and information gained during the |

| |preliminary assessment, the redesign generated the concept and prototype. Through a |

| |method of one-to-one comparison and using the criteria developed during the initial |

| |research, the team evaluated the redesign concepts and presented the most successful |

| |options of the redesign to Acumed so that Acumed could make the final decision on |

| |which prototype to pursue. The project presented a refined final prototype, a |

| |stainless steel, vertical cast body with integrated receiver bowl and inverting |

| |capability including drawings for manufacturing. The report also introduced new |

| |manufacturing processes including recommendations for fabrication and finishing |

| |processes into the design. |

|Team members: |Connie Drake, Shawn Gibbs, G. Vicky Jerome, Bruce Kell. |

|Sponsor Industry: |Acumed, Inc. |

|Project year: |June, 1994 |

|Title of the project: |Vehicle Diagnostics |

|Project description: |The project presents a study of the feasibility of monitoring the battery system of a|

| |Freightliner truck, and intends to measure the capacity of the battery by utilizing |

| |the data collected by Data Link of the truck. The goal is to predict when the |

| |battery is near the end of its life to start the truck. The Data Link of the truck |

| |previously gathered information about the trucks performance such as oil pressure, |

| |oil temperature, coolant temperature, ambient air temperature, and etc at 1-10 |

| |seconds. The project presents a test with the installation of additional analog |

| |sensors that measures the battery voltage, the current of the starter, and the |

| |battery temperature much faster. From the test data, a measurement of the capacity |

| |of the battery is calculated. From the calculated value, the characteristics of the |

| |start cycle, an estimation of the state of the battery is made. The information |

| |along with the start test is compared with the reference data from the start cycles |

| |performed on a new battery charged to specified percentages of its rate capacity. |

| |From the data, trends that indicate low battery capacity are identified. |

|Team members: |Jeff Lusardi, Wenyu Lin |

|Sponsor Industry: |Diameter-Benz Research and Technology Center, North America, Inc |

|Project year: |January, 1998 |

|Title of the project: |Proposal for Automated Molten Metal Delivery at Consolidated Metco |

|Project description: |Due to the request by Oregon Plant of Consolidated Metco, Inc for automation of a |

| |molten metal transportation and distribution system to reduce the cost and improve |

| |the die cast system, the project proposed a design of a semi-automatic system capable|

| |of delivering aluminum to an operator designated holding furnace without further |

| |human intervention. The project utilized concurrent engineering methods to research,|

| |evaluate, select, and design the system. |

|Team members: |Alan Hatfield, Tim long, Behnam Karandish, Qui Luu, Chris Stone |

|Sponsor Industry: |The Clackamas, Oregon Plant of Consolidated Metco, Inc |

|Project year: |June, 1998 |

|Title of the project: |Columbia Machine Palletizer |

|Project description: |The project proposed a replacement of the previous hydraulic system in Columbia |

| |Machine palletizer model FL200 with an alternate that performs as well as or better |

| |than the previous system, while eliminating environmental concerns, reducing noise, |

| |and maintaining consistent and reliable operation in a variety of climates. The |

| |project follows the design constraints such as non-hydraulic, same or better speed |

| |and control, environmentally safe, safe and smooth and quieter operation, reliable 24|

| |hours / day operation, option of redesign the structure, and fall within budget. |

|Team members: |Antonio Edgar, Andrew McGuire, Robert Grossnickle, Jeff Wey |

|Sponsor Industry: |Columbia Machine, Inc. |

|Project year: |Jan, 1998 |

|Title of the project: |Warn Clutch System |

|Project description: |Requested by Warn Industries for their clutch system used in their 8-kip and 12-kip |

| |winches, the project presented a new design utilized a pull and twist motion to |

| |disengage the winch, and utilized a spring to allow the rotated lever to snap back to|

| |engage the winch. The new design offered the feature that when the motor is running,|

| |the operator cannot snap the lever into the engaged position. The project report |

| |identified and solved the problems of the previous clutch lever. The new design |

| |conforms Warn Industries constraints and the standards of SAE. |

|Team members: |James E. Smith, Bardia Razzaghi, Bill Sterling, Dan Seale |

|Sponsor Industry: |Warn Industries, Inc |

|Project year: |Jan, 1992 |

|Title of the project: |Strapbinder J-Series Hose Clamp Semi-automatic Hand Tool |

|Project description: |Requested by A.J. Gerrad LlC Company, the project was to design a hand held (less |

| |than 18 lbs) semi-automatic tool to install any J-series pre-formed hose clamps. |

| |Traditionally, the hose clamp installation tools were either manual versions or semi |

| |automatic bench mounted units. This portable tool would reduce the cost therefore |

| |reduce the price and gain the market. Powered by the compressed air (80 psi) and |

| |with less than 30 seconds, this installation tool tensions the clamp and reports the |

| |clamping force being applied to the hose, and then holds the tension force until the |

| |clamp is sealed and the excess banding material is cutoff. |

|Team members: |Michael V. Fenton, Dean C. Marleau |

|Sponsor Industry: |A. J. Gerrard LLC Company |

|Project year: |June, 1996 |

|Title of the project: |Weld improvement Project |

|Project description: |The paper dealt with the time required in the weld area when change their products at|

| |Custom Hoists department of Warn Industries. The project focused on the setup |

| |process and new fixturing that would allow faster change from product to product. |

| |The team analyzed and determined the problems, and provided solutions that would |

| |reduce the required time to change products for welding. |

|Team members: |Scott Lambing, Jon R. Stroud, Cory Williams |

|Sponsor Industry: |Warn Custom Hoists, Warn Industries, Inc |

|Project year: |January, 1995 |

|Title of the project: |Drum Weld Fixture |

|Project description: |The paper presented a welding fixture that deals with welds between flanges and |

| |tubing on the winch drum at Custom Hoists department of Warn Industries. The |

| |existing fixtures did not work well and took too much time to setup. The project |

| |presented modifications on the existing fixtures to solve the problems the existing |

| |fixtures have. As a redesign, the modifications focused on the fixture holding the |

| |spool flanges firmly against the headstock and tailstock while allowing the flanges |

| |of the spool to rotate, and expanding outward against the flanges when activated. |

|Team members: |Scott Lambing, Jon R. Stroud, Cory Williams |

|Sponsor Industry: |Warn Custom Hoists, Warn Industries, Inc |

|Project year: |June, 1995 |

|Title of the project: |Palletizer Push Bar Design Proposal |

|Project description: |This proposal outlines a strategy for increasing the speed of a palletizer HL90 |

| |manufactured by Columbia Machine. With minimal additional cost, the goal of the |

| |project is to increase the processing speed by eliminating a product backup at the |

| |pusher section of the palletizer. |

|Team members: |Marvin Joanis, Arnold Top, Ralf Busby, Scott Witt |

|Sponsor Industry: |Columbia Machine, Inc. |

|Project year: |January, 1994 |

|Title of the project: |Human Powered Vehicle |

|Project description: |The project was to design and build a high performance vehicle to compete in the 1996|

| |ASME sponsored human-powered vehicle competition. The PSU human-powered vehicle is a|

| |semi-recumbent bicycle fully enclosed in a carbon fiber/Kevlar faring. Continued |

| |from the last year’s competition, this project focused on the fairing and additional |

| |seat design offered the improvements that allow a greater degree of reliability and |

| |rider comfort. |

|Team members: |Basem Abdallah, Shawn Murphy, Jason Wilson |

|Sponsor Industry: |ASME |

|Project year: |June, 1996 |

|Title of the project: |Veterinary Hospital Animal Cage Heater |

|Project description: |This report presents the design of a simple device that provides uniform heat to all |

| |parts of the animal, allows for bodily fluid drainage, easy to clean, and operates |

| |quietly without hazardous to animals during and after the animal surgery. The device|

| |does not interfere with the cage door motion and veterinarian’s view of the animal |

| |inside the cage. The design utilized a combination of existing devices which added |

| |to its flexibility. The device consists of a lightweight plastic slab that fits |

| |inside of a medium sized animal cage and two fans that attached to the slab allowing |

| |heated air to flow under the animal and out of the cage. |

|Team members: |Martia Jenkins, Hung Dang, Patrick Sandow, Jamie White |

|Sponsor Industry: |East Mill Plain Animal Hospital |

|Project year: |June, 1995 |

|Title of the project: |Electrical Resistance Space Heater |

|Project description: |The design presented a quiet, compact, smoothly warm, and inexpensive space heater |

| |that would compensate heat due to the heat loss varied from ventilation performance, |

| |and satisfy 10% occupants who always feel cold on their feet in the heating climate |

| |of the building. Cadet Manufacturing made heaters but not satisfactory to the 10% |

| |unsatisfied building occupants. The design offered features of the heater capable of|

| |floor, wall, or desk knee-hole mounting, one hour running and automatically shutoff, |

| |hand, or toe, or knee activation with push button, maximum 500W power, and noise |

| |level is below 40 dBA. |

|Team members: |Wayde Hager, David L. Hall, Steve Waitman |

|Sponsor Industry: |Cadet Manufacturing, Vancouver, Washington |

|Project year: |June, 1992 |

|Title of the project: |Precision Chain Grinder |

|Project description: |This project concerns the design of a precision saw chain grinder to be used in the |

| |test laboratory of Oregon Cutting Systems Division (O.C.S.D). The task of the |

| |project was to design a fully adjustable, partially automated, precision saw chain |

| |grinder that would be able to meet the requirements such as sharpening a standard 20 |

| |in loop of saw chain in 20 min. or less, sustaining cutter to cutter repeatability of|

| |+/- 2 degrees of accuracy for all three angles of concern, allowing fabrication of |

| |the design at the O.C.S.D to use existing components, and keeping the total cost of |

| |the design below $15,000. |

|Team members: |Tim Vonderohe, Kelly Jackman, Taylan Caglar, Vince Tejeda |

|Sponsor Industry: |Oregon Cutting Systems Division (O.C.S.D) |

|Project year: |June, 1991 |

|Title of the project: |Mining Vehicle Tilt Table Design |

|Project description: |The project was to design a 15x 40 ft tilt table that tips in one plane along 40 ft |

| |edge using a two-way hydraulic cylinder and journal bearings. Using structured |

| |design methodology, the team evaluated the concepts, and selected the concept. The |

| |team completed a detailed analysis of the hinge and pin connections and has provided |

| |detailed drawings for the components. Using FEA and maximum deflection technique, |

| |the project presented the platform design, calculated the required section |

| |properties, and determined the configuration of the structural members. |

|Team members: |Robert W. Cowling, Casey Dotson, Minh Nguyen, Hai Vu |

|Sponsor Industry: |Atlas Copco Wagner |

|Project year: |June, 1996 |

|Title of the project: |Design of A Telephone Answering Machine |

|Project description: |The project was to design a telephone answering machine for those individuals who are|

| |intimidated by electronic devices. The project was requested for the senior people, |

| |in age from 50 to 75, who are not yet familiar with using answering machine. The |

| |project examined the design of a telephone answering machine from lust to dust. The |

| |fact that many people dislike missing phone calls was a major factor in the project |

| |selection. Therefore, a design methodology was formulated to attack the problem. |

| |The project included problem recognition and definition, defining customer |

| |restraints, gathering and analysis of information, generating alternative solutions, |

| |and evaluating and implementing solutions. The end result is a design that is |

| |compact and user friendly. |

|Team members: |Kellie Reid |

|Sponsor Industry: |Unknown |

|Project year: |March, 1996 |

|Title of the project: |Prime Mover, Human Powered Vehicle |

|Project description: |The report is a one man project in addition to Portland State University’s 1996 HPV |

| |entry. The author designed and built his own fairing using his connections with the |

| |experts in composites and laying up fiberglass and carbon cloth. Continued from |

| |1995’s work that provided the frame design and prototype, the project focused on the |

| |fairing design report, prototype, and the testing that was required. |

|Team members: |Trent Warwick |

|Sponsor Industry: |ASME |

|Project year: |June, 1996 |

|Title of the project: |Prime Mover, Human Powered Vehicle |

|Project description: |The report is a one man project in addition to Portland State University’s 1996 HPV |

| |entry. The author designed and built his own fairing using his connections with the |

| |experts in composites and laying up fiberglass and carbon cloth. Continued from |

| |1995’s work that provided the frame design and prototype, the project focused on the |

| |fairing design report, prototype, and the testing that was required. |

|Team members: |Trent Warwick |

|Sponsor Industry: |ASME |

|Project year: |June, 1996 |

|Title of the project: |Design Submittal for Energy Resource Center for HVAC Laboratory |

|Project description: |The project proposed to build a HVAC laboratory that is not available in Portland |

| |area for educational and research purpose by students, professionals, and others who |

| |with an interest in HVAC. Used a cause and effect and affinity diagrams, the project|

| |conducted a survey of the potential customers, and compiled their needs. Using |

| |Quality Function Development (QFD) procedure, the project ranked the needs of the |

| |potential customers, and developed measurable engineering goals for the design. |

| |Using Paul’s decision matrix, the project developed concepts based on the needs of |

| |the potential customers. The final design incorporated a Variable Air Volume (VAV) |

| |Air Handler Unit (AHU) supplying a test chamber and an additional HVAC zone equipped |

| |with false heating and cooling loads. An extensive and comprehensive array of |

| |instrumentation and controls is included for analysis of psychometric relationships |

| |and energy usage. |

|Team members: |Roger Sorrentino, Dennis Conser, Dennis Vega |

|Sponsor Industry: |The Energy Resource Center (ERC) |

|Project year: |June, 1996 |

|Title of the project: |Log Boss Group |

|Project description: |The Project report describes the conceptual development of an active-sensor bandmill |

| |strain system. The system has two objectives: first, to reduce the response time of |

| |the strain system, and second, to maintain a dynamically controlled strain on the |

| |bandsaw blade during operation. The project includes study of the straining process|

| |development and evaluation of possible strain configurations, ANSYS analysis of |

| |response time, and recommendation of a strain system with integration into a |

| |commercial bandmill. The project predicted future work that would entail the |

| |building of a bandmill prototype using an active-sensor straining system, testing and|

| |performance evaluation, further modification if necessary, and finally, production of|

| |a commercial bandmill. |

|Team members: |Tim Golik, James Knope, Dan Smith, Allen Williams |

|Sponsor Industry: |Log Boss, Inc |

|Project year: |June, 1998 |

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