Senior Design Topics AY 2016 2017

(1) EV Wheelchair Mod: a high performance EV module for wheelchairs

Faculty advisor: Drs. Y. Ertekin, I. Husanu

Project Goal: To develop a portable and easily attached apparatus which can be installed and
removed easily from a standard wheel chair as used today by active and independent
paraplegics. The battery pack needs to be lightweight and provide the necessary voltage,
current and capacity for the selected motor. Design team need to study and understand the
customer needs. Ideally the system should provide for a 10 hour excursion, with intermittent
usage, ultimately traversing >5 miles of rough terrain. A modular and adaptable drive system
needs to be created. The current concept is to have the drive system attach to the back of a
"standard" off-road wheelchair. The current concept is to have two drive motors attached to the
wheel chair with two output wheels that use friction to engage with the wheelchair wheels. The
user should be able to adjust the tension of the drive wheels against the wheelchair wheels.
Need students to spec and identify suitable drive motors to create enough torque to drive the
larger wheelchair wheels and push the wheelchair up a 30% grade over rough terrain. Project
target cost must not exceed $2,000.

(2)

Endoscopic Carpal Tunnel Release (ECTR)

Faculty advisor: Drs. Y. Ertekin, I. Husanu

General Scope of Project:
ET students will gain information from current Endoscopic Carpal Tunnel Release concepts,
Hand and Wrist Arthroscopy, competition, and market influence that determine the feasibility of
this project. Once a design is determined within the given time constraints all testing and
verification/validation needs should be met along with surgeon correspondence and approval.

Goal of Project:
With the guidance of a mechanical device, a knife blade needs to be deployed as the transverse
carpal ligament is sectioned. This device will be disposable and be able to connect to standard
arthroscopy equipment that is designed. It will snap onto the arthroscope at the light cord post.
It will incorporate a handle so that the force vector applied by the surgeon is axial along the line
of the arthroscope and the procedure. This device will be self-contained eliminating interface
problems.
A constraint list for the device includes the following:
a)
b)
c)
d)
e)
f)
g)
h)

the device should minimize obstruction of the surgeon's vision;

it must be made of nontoxic materials;
it must be made of materials that do not corrode;
it must be sterilizable or throw away;
its target cost must not exceed $5,000 (surgical tool & standard arthroscopy equipment);
it must not have sharp edges;
it must not pinch or gouge the patient; and
it must be unbreakable during normal surgical procedures.

(3)

Thermal & Kinematic Modeling of CNC Machines

for Fast calibration and Software Based Accuracy
Improvement

Faculty advisors: Drs. Y. Ertekin, I Husanu

There are three main sources of errors in machine tools that determine machine tool accuracy:
(1) errors due to geometric inaccuracies, (2) thermally induced errors, and (3) load induced
errors. It is well established that among the above machine tool error sources, geometric and
thermally induced errors may exceed 50% of the total machining error. It is, therefore,
imperative to identify and minimize this effect by compensatory measures.
Equally important in machining is the confidence in the measuring instruments from which part
quality characteristics are ascertained. Part dimensional accuracy check has been largely based
on post-process inspection such as a coordinate measuring machine (CMM). CMMs are widely
used in the manufacturing industry for precision inspection and quality control, and recognized
as reliable and flexible gauges suitable for assessing the acceptability of machined parts. The
downside of this technique is that non-conforming parts can be produced between inspections.
To remedy the problem, a machine mounted touch probe has started gaining popularity, which
has the similar working principles of CMM. The probe enables the measurement of machined
parts while they are still fixed on the machine. By providing part size or gauged information
directly into a CNC controller, a closed-loop process control can be realized in the form of

automatic tool offsets to correct deviations or prevent defects in machined features. This is
particularly important for a modern, computer controlled production environment, where very
little human intervention is expected during the machining cycle. This is especially true with
workpieces that are very difficult to handle. The accuracy of the probe, however, is affected by
the machine tools positional accuracy and positioning system. Since the same machine which
produces the parts is used for inspection, there is an inherent problem in the accuracy of probe
inspection. Therefore, in order for the probe data to be used as a feedback control, the
capability of probe needs to be analyzed and the factors affecting the probe data need to be
ascertained for a better control.
Students will conduct experiments to develop Thermal & Kinematic Modeling of CNC Machines
using Renishaw Ballbar and Laser systems (Available in Mechanical Lab). These models will
be used for Part Accuracy Improvement via Software Error Correction. Students will develop On
Machine Probing & Quality Control processing system for Haas CNC Machining center. By
providing part size or gauged information directly into a CNC controller, a closed-loop process
control can be realized in the form of automatic tool offsets to correct deviations or prevent
defects in machined features. Part quality improvements will be verified using manual CMM.
Students will also develop machine calibration artifacts for fast machine calibration and quality
improvement. A profilometer will be used to measure surface finish of the machined
component.

(4)
Design & Development of Desktop Rapid
Prototyping Machine for the Study of MET615
Faculty advisor: Dr. Y. Ertekin, Dr. M. Mauk
This project will result in a finished, new, well-designed 3-axes rapid prototyping machine that
will then be made available for the lab use of students of ET615 Rapid Prototyping, MET407
Manufacturing Processes & MET316 CNC courses. Operate with variety of metal powders. The
machine should be able to deposit metal powders in layers to build a solid prototype object.
From well-documented and comprehensive plans and construction manual, through electronics,
motor drive and chassis kit combinations, to fully-assembled systems, there should be a
solution to fit novice skill-level. A constraint list for the machine includes the following:

USB control and networkable, drive bipolar stepper motors of servomotors

Comprehensive operation manual
A "Desktop" size form factor with 6"x6"x6 (3D, X-Y-Z) workspace
Needs software to read STL (StereoLithography) CAD models and generate tool
paths for layered manufacturing
Provide several project entry points: plans; kits; completed product
Be built from both purchased or recycled (scavenged) materials and components
Be budget-sensitive and cost-effective. its cost must not exceed $5000.
Operate with variety of metal powders. Machine should be able to deposit metallic

powder materials in layers and fusion weld metal powders to build a solid prototype
object.
Configurable to accommodate small part tolerances (<.005)

(5)

Integrated wind and Solar Powered Outdoor Area

Lighting, Wirelessly Monitored

Faculty Advisors: Drs. I. Husanu, M. Mauk

Over the last decade, public works projects have shown a greater interest in utilizing green
power for their small load applications than in years passed. This has included the addition of
solar panels to area lights and blinking warning lights. Wind power has seen increased usage in
large scale power production with the construction of wind farms composed of large horizontal
axis wind turbines. Vertical axis turbines have seen limited development for small scale
applications. Each source of power, wind and solar, has its own benefits and limitations. Solar
power is dependable and predictable. Wind power, rising cubically with wind speed, is capable
of high outputs at unpredictable times. Solar power operates on a cycle following the daylight
hours, while a wind turbine is capable of producing power at any hour.
The goal of the project is to establish an autonomous (off-grid) power system capable of
supporting the required power of the light and to study the performance of the systems
components. The monitoring of this system must be wirelessly performed and decoupling of the
Savonius and Darrieus turbines must be accomplished. This project will focus on the integration
of the various components into a functioning unit and the resulting preliminary performance of
the system as a whole, while the best control and storage units will be designed and studied
during the project.
DoE sponsorship will be made available and will be discussed with advisors upon chosen
optimal solution.

(6)

Development and Automation of Thermography

and Imaging for Solar Cells

Faculty advisors: Drs. Michael G Mauk and Richard Y Chiou

Thermal cameras image the infrared radiation emitted by all objects. The thermal image is rich
in information about the object, particularly with regard to materials properties, defects and other
anomalies. The recent advent of low-cost, high-performance IR cameras opens up new
applications for thermal imaging in research, manufacturing (process control and quality

assurance), and reliability. The Drexel Engineering Technology program recently acquired a
new state-of-the-art IR camera (FLIR Model 360), plus new CCD cameras for near-infrared,
visible, and fluorescence imaging. The main objective of this project is to develop techniques
and equipment to apply these imaging methods to solar cells. Solar cells are interesting and
relevant subjects of study due to the diversity of phenomena (reflection, scattering,
photoluminescence, electroluminescence, localized heating, thermoelectric effects, etc) that
can be explored and assessed with imaging techniques, and the importance of solar cells for
renewable energy and as a commercial product. It will be informative to compare various
techniques (optical, thermal, and other technologies) to corroborate and assess alternative
approaches. We have a large inventory of different types of solar cells and solar cells in various
stages of manufacture that can be used for this project. One theme of this project is automation
(robotics) of imaging so that these methods can applied in manufacturing processes, e.g., on
conveyer belts. For more details and demonstrations, contact the advisors listed above.

(7)

Imaging for Solar Cell Characterization and

Diagnostics

Faculty Advisor: Michael Mauk

Co-Advisor: Dr. Richard Chiou
This project is part of a National Science Foundation grant to develop various imaging
techniques to evaluate solar cell materials, solar cells, and modules (on the factory floor and
installed in the field). It will use thermal imaging cameras, infrared and visible CCDs,
fluorescent cameras, laser light scattering and other techniques to characterize the materials
properties, surface roughness, and optical characteristics of solar cells as well as the reliability
of solar cell modules. One thrust is to benchmark various characterization techniques and to
develop simple desktop or portable (handheld) CCD-camera based methods that provide
substantially the same information for in-line process control, quality assurance, and educational
purposes. This project will provide the students with considerable hands-on experience in
increasingly important topics including semiconductor materials, solar cells, infrared imaging,
machine vision, and image processing.

(8)

Automatic Laser Coupling into a NanoparticleCapturing Optofluidic Chip

Faculty Advisor: Michael G Mauk

Co-Advisor: Dr. Robert Hart, President and Chief Technical Officer, Optofluidics, Inc.
Sponsor: Optofluidics, Inc. (University City Science Center, 3600 Market Street)
http://www.opfluid.com/
Optofluidics, Inc. is a new company (2011) with the goal of developing microfluidic and
biophotonic technologies for single molecule analysis and point of care medical diagnostics.
Located in Philadelphia, their development partners include the National Science Foundation,
the Defense Advanced Research Projects Agency, and BioAdvance.
Topic: Optofluidics currently sells a flow cell that has a built-in tiny waveguide (or optical fiber)
used in an advanced nanoparticle measurement system. In order to operate properly, a laser
needs to precisely coupled into a waveguide or fiber (see below). Their current method is
tedious. They are interested in the Senior Design team designing and prototyping a system that

automatically aligns a laser into the waveguide. This would entail, for example, designing and
machining custom fixtures, putting them on XYZ piezo stages, and using feedback from an
optical detector to align the laser aligned to the waveguide.

And the final product:

(9)

Combined Algae Bioreactor/Solar Cell Array for

Biofuels and Photovoltaic Electricity

Faculty Advisor: Michael Mauk

Co-Sponsor: University of Pennsylvania School of Engineering
Co-Advisor: Dr. Jay Zemel, University of Pennsylvania and Dr. Richard Chiou
This project is to build a small prototype system that cultures algae for production of biofuels,
combined with solar cells to produce electricity. The algae are biomass that can be converted
to various liquid fuels as a substitute for petroleum-based fuels. The system is a desktop-sized
plastic-based (acrylic) fluid system in which suspensions of algae circulate and grow. Some of
the solar energy is used to power solar cells which provide pumping power and surplus
electrical power. Some preliminary working prototype components are available as a starting
point. The rationale for this project is that algae respond to red and blue parts of the solar
spectrum, and silicon solar cells respond best to the green part of the solar spectrum. Thus,

better utilization of solar energy is possible. Also, the flickering light exposure due to circulation
flow seems to make algae grow faster than in static ponds.
As an idea of the scope of this project, some related prototypes are shown.

(10)

Low Frequency Pulsed Electromagnetic Field

Device for Medical and Veterinary Applications

Faculty Advisors: Drs. Michael Mauk and Vladimir Genis

All living cells within the body possess potentials between the inner and outer membrane of the
cell, which, under normal healthy circumstances, are fixed. Different cells, such as muscle cells
and nerve cells, have different potentials of about -70 mV respectively. When cells are
damaged, these potentials across the membrane change. The application of pulsed magnetic
fields has, through research findings, been shown to help the body to restore normal potentials
at an accelerated rate, thus aiding the healing of most wounds and accelerating the natural
healing process.

Low frequency Pulsed Electromagnetic Field (PEMF) devices are widely used to relieve various
ailments in humans and animals, such as:

Bone growth stimulation and bone fracture healing

Treatment of painful and swollen joints associated with arthritis related problems

Wounds, scars, and soft connective tissue healing

Nerve regeneration

Numerous scientific papers have indicated that magnetic field stimulation has greatly decreased
the healing time of a variety of disorders. This reduces the cost associated with a long healing
process and speeds to full activity.
The parameters of the proposed hand-held low frequency pulsed electromagnetic field device:
Frequency of pulses 15, 30, and 60 Hz.
Magnetic field 5-30mT
The shape of the device can be similar to a hand-held massage device.

(11)

Wirelessly Powered Mouse Electrophysiology for

Cyber-enhanced Sleep Science

Faculty advisor: Dr. Lunal Khuon

Mice serve a key role in sleep science using animal models. Drexel University experts in image
processing, machine learning, and low power circuits are redefining the methods and
capabilities of sleep studies by bringing the strengths of cyber-physical systems (CPS) to sleep
science. The first phase of this CPS effort is to develop a prototype wireless head unit for a
mouse.
The project goal is to develop an electronic head unit for a mouse with the following capabilities:
1) wirelessly powered, 2) record electrophysiological signals such as EEG, EMG, and ECG (and
other physiological parameters such as temperature), 3) store the data for later retrieval or
wirelessly transmit data to an off-mouse receiver for data processing.
The challenges for the project are in meeting the size and mass constraints of an unobtrusive
unit that must fit comfortably on a mouse's head. The wireless head unit would enable the sleep
scientists to move away from the conventional tether system which currently has negative
impacts on the animal's behavior and limit studies to isolated, single mouse. A wireless,
untethered head unit would allow for freely behaving mouse and mice in groups, which better
represent the animals' natural environments. Additionally, an untethered system allows for better

visibility of the mouse and improve image processing-based physiological and behavioral
feature-extraction.
Student(s) must meet and consult with Dr. Khuon before receiving approval to select this
project.

(12)

Humane Feral Cat Trap (in coordination with West

Philadelphias Project MEOW*)

Faculty Advisor: Mr. Eric Carr

This project proposes to develop a safer, more automated humane live trap for catching feral
neighborhood colony cats for TNR (Trap / Neuter / Return) purposes. TNR is a safer, more
humane solution to cat colony population control than removal.
One disadvantage of current traps is that, while they do not directly harm the animal, they can
pose a threat if the traps are not carefully monitored. Trapped animals are stuck with only the
food and water available in the trap (if any), and could die of starvation, thirst, or exposure.
TNR volunteers are careful to only set traps they can monitor, so no cats are presently harmed.
However, this does make TNR a labor-intensive, time-consuming process, since a volunteer has
to make the rounds to check the traps every few hours.
A better alternative would be to have a remotely controllable and monitorable live trap, ideally
costing not more than twice the cost of a standard trap to produce, with the following features:

Trap sends email or text message when triggered, along with a picture of the trap;

Trap can be re-opened remotely if triggered inadvertently;

Trap re-opens to release the animal if trap message not confirmed within one hour, or if
the trap is not attended to within three hours, even if confirmed.
(This functionality is the most critical, and must work reliably.)

Trap should have sufficient battery capacity to run for at least a week;

Trap should be able to be disabled remotely or according to a schedule

(I.E. at night, to minimize the chance of catching a raccoon.)

Trap should always fail open (if batteries go low, etc.)

* I consulted with two major Project MEOW coordinators; they agree this would be very helpful.

Resources required: 2-3 EET students and 1-2 MET students.

(13)

Programmable-Color Dry Erase Pen

Faculty Advisors: Mr. Eric Carr and Dr. M. Mauk

Dry Erase boards have all but completely taken over from the older chalk-and-blackboard
technology. Dry Erase boards are easier to use and probably healthier to use than blackboards,
but some drawbacks remain.
Dry Erase pens are notorious for drying out. A technological solution to somehow mitigate this
(or at least warn the user that the pen has been left uncapped) would be useful. More useful
would be a single pen, easily refillable from a few primary color inks, which can draw on a dryerase board in arbitrary colors, performing the color mixing dynamically.
This project proposes to develop such a device. The deliverable prototype should be capable of
writing in dry-erase inks on a standard dry-erase board, in any arbitrary color specified by
RRGGBB (or, equivalently, CMYK or another appropriate colorspace.) Color depth should be
four bits per color (16 intensity levels) or more. The prototype should either be incapable of
drying out by design, or should automatically retract after a set period of inactivity, in order to
preserve the inks in a usable form.
The prototype pen should also be able to reproduce colors (with at least reasonable accuracy)
using a built-in color sensor. In this way.
Ergonomics of the final prototype should be acceptable, and the device should be capable of
being used for a typical university lecture (say, three hours of moderate use) without needing to
be recharged or refilled.
Resources needed: Suggested two EET students and two MET students.

(14)

Binaural Vision Replacement for the Visually

Impaired

Faculty Advisor: Mr. Eric Carr

This project proposes to investigate the use of computer vision and binaural audio to translate
the position of nearby large objects into components of an audio field created by a wearable
computer. Images from one or more digital cameras are analyzed by a computer and turned into
a 3D map of nearby objects (perhaps not distinguishing among them other than by distance and
location.) A 3D soundfield is then produced by imbuing the virtual objects with audio properties
(perhaps objects make a rushing sound when far, and increase in tonal clarity when near etc.)

Wearers of this system should be able to use the binaural (not just stereophonic) cues to locate
objects around them by sound alone.
Proof that the system works well could be demonstrated by, for instance, using it to navigate
around furniture in a darkened room.
As an alternative to the binaural approach (which should allow the use of standard
headphones), an array of speakers surrounding the users head may be investigated, in order to
recreate the 3D soundscape without resorting to binaural and psychoacoustic techniques. If
both approaches prove feasible, the most economical/practical one should be developed.
Resources required: 2-4 EET students and 0-1 MET students.

(15)

Smart DC Power Grid

Faculty Advisor: Mr. Eric Carr

This project proposes to develop a house- or car-scale Smart DC Power Grid, in which devices
collaborate in power sharing. Power (perhaps 12VDC) is shared among devices, similarly to
how power is routed in homes and cars. However, provision for a task-specific data channel,
perhaps I2C or similar, should be made. Devices would use the data channel to request power
from the bus as needed, or to contract with the bus to provide additional power.
The basic idea is to turn a car or houses power supply into a mini energy market, for the
purposes of increasing energy efficiency and providing useful strategies for energy consumption
reduction. Energy would be controlled on a demand basis, with the following categories of
devices envisioned:
1)
Power supply / controller. These use traditional power to ensure that demand is met, and
control the bus by brokering power requests. They should be able to source power, and ideally
recapture excess power as well.
2)
Demand devices. These simply consume power, but could potentially be programmed to
do so only when the cost for power advertised by the bus is low enough. (For example, a
computer which needed to complete a rendering job could do so at night, when cooling
requirements for the house are lower.)
3)
Power banks. These can store and release energy; the idea would be to have the device
earn money by accepting power when the cost is low, and providing power when the cost is
high.
4)
Emergency generators. These can provide power, but do so at a higher cost. (Note that
if the main power source fails, the expected response from the bus controller would be to
increase the price, prompting consumers to cut back on demand and producers to increase
production.

5)
Terminals. These monitor and optionally control the network, allowing inspection of each
devices production and/or consumption.
Suggested resources: 3-4 EET students; 0-1 MET students.