2016
AME CAPSTONE PROJECTS
AME Capstone Projects 2016 Categories CATEGORY: PROTOTYPE DESIGN P1
High Speed Glycol Vaporizer
1
Student Team: Kody Jones, Jordan Maun, Jensen Stenberg, Jordan Winslow Advisor: Dr. Dalton Sponsor: Cameron
P2
MEMS Subsea Autonomous Robot
2
Student Team: Bao Ngo, Nick Julch, Ryan Jacob, Viet Tran, Moises Bernal Advisor: Dr. Stalford Sponsor: Schlumberger
P3
Car Cover Design
3
Student Team: Team Members: August Murdock, Austin Hicks, Jon Britton, Taewoong Kim Advisor: Dr. Siddique Sponsor: Dr. Bassel Hassoun
P4
Single Person Cab Environment for an Asphalt Paver
4
Student Team: Brian Allen, Brandon Tolbert, Othman Bawareth Advisor: Dr. Mistree Sponsor: Volvo Construction Equipment
P5
Optimization of an Impeller
5
Student Team: Christie Alexander, Sean Davison, Sam Delagi, Alli Haselwood, Patrick Helms Advisor: Dr. Stalford Sponsor: GE Oil and Gas
CATEGORY: STUDIES S1
Fluid Flow Loop Design
6
Student Team: Colton Hill, Joey Ducker, Abdul Alsoiad, Lawrence Dahunsi Advisor: Dr. Dalton Sponsor: Weir Oil and Gas
S2
Tinker Energy Assessment Team
7
Student Team: Konnor Lohman, Tanner Nees, Vu Tran, Michele Musgrove Advisor: Dr. Stalford Sponsor: Tinker Air Force Base
S3
Tinker HVAC Retrofit for Building 4057
8
Student Team: Matthew Gilliam, Chris Dameron, Kate Wanezek, Ryland Oliver Advisor: Dr. Stalford Sponsor: Tinker Air Force Base
S4
Creating Rumble Strips in Fresh Asphalt Student Team: Hussain Al Marhoon, Remington Butler, Joshua Ellenburg, Uytran Le Advisor: Dr. Mistree Sponsor: Volvo Construction Equipment
9
2016
AME CAPSTONE PROJECTS
S5
Mechanical Seal Test Stand
10
Student Team: Christina Chavez, Wenyuan Luo, Alex Stockyard, Briek Pauwels Advisor: Dr. Siddique Sponsor: GE Oil and Gas
CATEGORY: TESTING T1
Design of a Test Setup for Multiple Butterfly Valves
11
Student Team: Michael Howell, Tyler Spencer, Colin Sullivan, Garrett Svane Advisor: Dr. Stalford Sponsor: Cameron
T2
High RPM Rotary Seal Test
12
Student Team: Jeremy Adams, Michael Allen, Keelan Prewett, Brandon Warner Advisor: Dr. Siddique Sponsor: Schlumberger
T3
Experimental Setup to Evaluate Life of Dynamic Polymer Seals in Fluids with Particulates
13
Student Team: Karl Geerts, Jordan Miller, Marli Sussmann Advisor: Dr. Siddique Sponsor: Schlumberger
T4
Experimental Setup Lubricants & Metal-Metal Galling
14
Student Team: Adam Brobson, Caleb Berryman, Nathan Herrera, Abbas Al-Sawaf Advisor: Dr. Siddique Sponsor: Schlumberger
T5
Cable Permeability Setup
15
Student Team: Kyle Wager, Ahmad Dashti, Khiem Nguyen, Davis Boatright Advisor: Dr. Siddique Sponsor: Schlumberger
T6
Design and Development of Low Velocity Impact Tester
16
Student Team: Daniel Edlin, Brian Flinn, Andrew Lucas Advisor: Dr. Siddique Sponsor: Dr. Liu
CATEGORY: INTERDISCIPLINARY I1
Automated Guided Vehicles to Improve Plant Efficiency & Safety
17
Student Team: Brax Casey, Paul Curtis, Corey Elder, Victoria Morrison Advisor: Dr. Mistree Sponsor: Hitachi
I2
Tinker Air Force Base Alternative Process for Part Cooling Student Team: Ben Berka, Stephen Gonzalez, Crislyn McWethy, Megan Snelling Advisor: Dr. Dalton, Dr. Raman Sponsor: Tinker Air Force Base
18
2016
AME CAPSTONE PROJECTS
I3
Error Free Part Identification
19
Student Team: Caleb Davis, McKenzie Middle, Sylvia Tran, Matthew Von Gonten Advisor: Dr. Siddique, Dr. Allen Sponsor: Tinker Air Force Base
I4
ESP Warehouse Productivity
20
Student Team: Abdullah Albukhidhr, Aziz Taylakh, David Graft, Elyssa Mooney Advisor: Dr. Mistree Sponsor: GE Oil and Gas
I5
Cable Preparation Cell in ESP Control Plant
21
Student Team: Jackie Chen, Christopher Flix, Kitty Winstel, Jerry Varughese Advisor: Dr. Mistree, Dr. Raman Sponsor: GE Oil and Gas
I6
Technical, Political, and Recovery Factor Challenges in Shale Development
22
Student Team: Dana Saeed, Wiley Abbott, Brandon McCabe Advisor: Dr. Siddique, Dr. Mistree, Dr. Pournik Sponsor: Baker Hughes
CATEGORY: VEHICLE DESIGN V1
Sooner Racing
23
Student Team: Blake Harms, John Downey, Ross Moseley Advisor: Dr. Siddique Sponsor: OU Gallogly College of Engineering
V2
Sooner Powered Vehicle
24
Student Team: James Ross, Cody Lawler, Michael Dillon, James Nguyen Advisor: Dr. Dalton Sponsor: OU Gallogly College of Engineering
V3
Sooner Off-Road: Semi-Trailing Arm Suspension
25
Student Team: Gatlin Arnold, Stephen Walta, Tim Willis Advisor: Dr. Dalton Sponsor: OU Gallogly College of Engineering
V4
Design of Green-Energy Tricycle
26
Student Team: Tyler Spencer, Mckenna Beard, Addison Berryman, Austin Burrus Advisor: Dr. Siddique, Dr. Chang Sponsor: OU Gallogly College of Engineering
CATEGORY: AEROSPACE ENGINEERING AE1
AIAA DBF Crimson Skies
27
Aaron Allred, Alex Spens, Chris Sherlock, Dalton Gregory, Nathan Justus, Seth Fackler Advisor: Dr. Hays Sponsor: OU Gallogly College of Engineering
AE2
Unmanned Aerial System (UAS) Dynamometer Daniel Carlton, Alec Watson, Hannah Hunt, TonÄ?i Maleta Advisor: Dr. Hays Sponsor: The University of Oklahoma
28
2016
AME CAPSTONE PROJECTS
AE3
Lockheed Martin Supersonic Jet Trainer
29
Karl Geerts, Keith Logan, Sam Parrill, Travis Phifer, Luis Rodriguez, Charles Thuo, Kayla Witthus Advisor: Dr. Striz Sponsor: Lockheed Martin
AE4
Bergey Aerospace High Altitude Research Plane (HARP)
30
Ryan Fitzgerald, Chelsea Williams, Constantine Nyalenda Advisor: Dr. Hays Sponsor: Bergey Aerospace
AE5
Northrop Grumman Reusable Spaceplane
31
Brandon Siok, Nick PequeÉo, Sean Ly, Jacob Bass Advisor: Dr. Striz Sponsor: Northrop Grumman
AE6
Composites Processes and Weather Rocket Design
32
Justin Jackson, Alex McKinstry, Karl Verschuren, Dustin Rann, Jon Stone, Mitch Longergan Advisor: Dr. Hays Sponsor: The University of Oklahoma
AE7
IAS Weather UAS
33
Julian Goelz, Jesse Nozari, Jason Bertels, Vladimir Velasco Advisor: Dr. Striz Sponsor: Innovative AeroSolutions LLC
INDUSTRY SPONSORS
34
2016
P1
AME Capstone Projects
High Speed Glycol Vaporizer
Cameron wants to develop a high-speed glycol vaporizer to use at their upstream facilities. The vaporizer will efficiently introduce a MEG (monoethylene glycol), water, gas, heat transfer fluid, and salt mixture to a tank. The heat transfer fluid will be used to vaporize the water and MEG. The MEG will then be separated the MEG from the water to reuse it. In order to accomplish this, direct contact heat exchange must be utilized. One of the most important aspects of the introduction of the MEG/water mixture into the heat transfer fluid is the nozzle. The nozzle can dictate velocity, flow profile, the point of evaporation, and the mixing efficiency. A nozzle design and tank configuration have been completed in order to determine the most efficient way to introduce the MEG/water mixture to reuse the maximum amount of MEG possible. An Excel calculator has been developed utilizing the different concentrations, the flowrate, and the geometry in order to determine the time it takes to vaporize the MEG.
PAGE | 1
2016
P2
AME Capstone Projects
MEMS Subsea Autonomous Robot
The goal of the project is to create an autonomous system that is able to lower a tubing sub assembly into the casing sub assembly of a subsea well. The tubing sub will be lowered in such a way that a fiber optic cable attached to the tubing can be plugged into an input on the casing sub. Hall Effect sensors (HES) and Rare Earth magnets (REM) are used for sensing capabilities for this system. An actuator and stepper motor are used for translational and radial movement. In order to understand how to properly use these components together, a series of tests were conducted. The tests investigated the relationship between HES and REM in various environmental conditions. The tests also involved understanding how the various motors worked in the system. With these tests, a realistic prototype was built that met design specifications and the goal of the project.
PAGE | 2
2016
P3
AME Capstone Projects
Car Cover Design
The objective of our Capstone project was to improve upon a design for a car cover created by our sponsor, Dr. Bassel Hassoun, and previously worked on by capstone groups in 2006 and 2010. The car cover is to be fully automated, and further more serve as temperature regulation during the hot summer and cold winter while shielding from weather hazards such as rain or hail. To this end we have analyzed the previous groups’ work and developed our own editions in an effort to overcome the shortcomings of previous designs. We have advanced a scissor arm design by shortening some of the bars lowering the overall weight, and implemented a fuller bar design for each linkage. Specific motors have been chosen from our Solidworks motion analysis, giving a viable means to power the product. The housing to hold the mechanism has been modeled and finished.
PAGE | 3
2016
P4
AME Capstone Projects
Single Person Cab Environment for an Asphalt Paver
Paver operators may experience extensive exposure to toxic fumes and the extremes of cold and heat in a paving work environment. Asphalt, a petroleum product used extensively in road paving, emits toxic fumes in its molten state. Further the temperature of asphalt during the paving process often exceeds 270째F. The acute effects of asphalt exposure include skin irritation, headache, heat stress, throat and eye irritation, and breathing problems. More serious health concerns such as lung and skin cancer have been associated with chronic exposure to asphalt fumes according to other studies. Enclosed cabs with positive pressure and air filtering systems can provide up to a 98% reduction in airborne residues. Further, an enclosed cab provides an environment where temperature can be controlled and reduce an operators exposure to the elements. A new enclosed cab environment that is adaptive to current operable pavers is proposed and reviewed in this study.
PAGE | 4
2016
P5
AME Capstone Projects
SRS / TRS Cover Design
GE Oil & Gas is currently using the TD1750 Pump, a design acquired through the purchase of Wood Group in 2011.GE has not performed their own analysis on the effect of balance holes in relation to stage efficiency. The design employs balance holes in an effort to reduce down-thrust while minimizing loss of generated lift. The team began by conducting thorough research of patents and publications concerning the effects of balance holes on impellers and other possible methods. Several balance hole modifications were created based on this research, and Computational Fluid Dynamics analysis was performed on the designs. The resulting data allowed the team to select the two most promising designs. These designs were manufactured and assembled into two seven stage pumps. The pumps were tested over the course of several days/hours in a test bench located in GE Oil & Gas OKC location.
PAGE | 5
2016
S1
AME Capstone Projects
Fluid Flow Loop Design
The objective of this project was to design a variable pressure flow loop that will assist Weir Mathena in conducting research related to flow characterization and erosion rates associated with oil field surface control valves. Throughout the process of drilling for oil, high pressure gas/mud deposits are sometimes released that rapidly erode valves and equipment. It is the intent that this flow loop be used to research materials that better resist erosion effects and increase the lifecycle of surface control valves. This modular based flow loop was designed to accommodate various valve sizes and is capable of using water or slurry mixtures as working fluid. The design includes one loop which utilizes a pressurized water tank for high pressure testing up to 15,000 psi and a second loop that uses a plunger pump for less extreme pressures. This design was modeled in SolidWorks and flow estimates were calculated by hand.
PAGE | 6
2016
S2
AME Capstone Projects
Tinker Energy Assessment Team
The team conducted energy assessments on 5 covered facilities at Tinker Air Force Base. The purpose of our energy analysis is not to obtain concrete energy results and solutions, but rather provide an estimation for energy consumption and to carve a path leading to the best energy-reducing solution. FormIT 360, Revit and Insight 360 were the 3 Autodesk softwares used to perform these audits. Building 414, 469, 4064, 6001 and 7017 were modeled in FormIT 360 and an energy analysis using Insight 360 was executed on each building. In addition, building 469 was modeled in Revit and an energy analysis was performed using Revit’s built-in energy simulation. For building 469, the energy results using the FormIT 360 and Revit models were compared. For the FormIT 360 models, the energy results for building 414, 469, 4064, 6001 and 7001 were reported as 956,000, 4,800,000, 940,000, 800,000 and 500,000 kWh/yr, respectively. For the Revit model of building 469, the energy results were 6,868,000 kWh/yr. Recommendations such as improvements in infiltration, lighting efficiencies and heating ventilation and air conditioning (HVAC) systems were considered in effort to reduce energy consumption by 10%. The team achieved energy reductions for building 414, 469, 4064, 6001 and 7017 in our analysis once implementing energy reducing agents by 24%, 38%, 24%, 15% and 9%, respectively, according to the Insight program. Our team concluded for all the buildings that the heating ventilation and air conditioning systems acquired the highest change in energy intensity.
PAGE | 7
2016
S3
AME Capstone Projects
Tinker HVAC Retrofit for Building 4057
Tinker Air Force Base is a major USAF facility located in southeast Oklahoma City. Tinker has numerous buildings whose functions have changed since the original design, or have outdated HVAC systems that do not meet current occupant comfort and energy requirements. Building 4057 has changed from being mostly classroom space to a high tech office building housing the 38th Cyberspace Engineering Installation Group. The current HVAC system is highly inefficient relative to modern standards and poorly suited to the building’s new mission. In order to come up with a retrofit recommendation, 5 potential replacement systems were selected and analyzed based on initial capital costs, energy usage, cost of operation, and return on investment. Energy simulations, using the DOE-2 energy modeling software eQUEST, for Building 4570 show potential annual energy savings of 52% to 67% resulting in an annual savings of up to $2919 over the existing system.
PAGE | 8
2016
S4
AME Capstone Projects
Creating Rumble Strips in Fresh Asphalt
The current method of creating rumble strips is grinding into asphalt after it has been compacted and cooled to its final form. This process requires additional days on the work site and cleaning of the debris, which can be costly. The purpose of this project is to determine a proof of concept for an idea to fabricate rumble strips in fresh asphalt that can be attached to existing Volvo equipment. Our project is explored through looking at similar projects and understanding the behavior of asphalt to justify the development of an improved concept. In order to pursue this project further, we suggest Volvo conduct physical experiments to determine the necessary pressure to create the required geometry, how the rumble strips deform over time under real-world conditions, and how this component will affect the compactor performance. After determining this information, tests must be conducted in order to change the regulations currently in place by many Department of Transportations.
PAGE | 9
2016
S5
AME Capstone Projects
Mechanical Seal Test Stand
Our mechanical seal test stand should be able to test 7 different diameter size of mechanical seals in the range of 1.68� to 2.47� for operating about 3 weeks while subjecting it to the specific simulation conditions, for example: radial vibration, axial shaft movement, temperature variations and abrasive present as sand. Also, mechanical seal need to keep the clean motor oil separate from dirty fluid and particulates. Test stand mainly consist of housing holder, three different sizes shafts, heating band, bearing, labyrinth seal, and coupling connector. A 2HP single phase motor with 3600 RPM is used to supply power to operate test stand, and power will need to be adjusted based on initial rotating speed start up. The goal is to deliver engineering drawing with bill of materials to sponsor company for manufacturing and provide other available parts source in the market. All potential cost should be controlled within $8.5K.
PAGE | 10
2016
T1
AME Capstone Projects
Design of a Test Setup for Multiple Butterfly Valves
Cameron International is a leader in providing flow equipment products for oil and gas and industrial applications. In order to ensure the quality of their equipment meets customer needs, their engineers have asked for assistance from the Aerospace and Mechanical Engineering Department at the University of Oklahoma. The DEMCO butterfly valve, commonly used in multiple industries, uses a rubber seat to create an airtight seal when closed. The quality of these valves is crucial in the field to prevent leaks. It is important when Cameron gets a new supplier for rubber valve seats that the valve is tested to ensure valve lifespan and effectiveness. An automated test stand to fatigue test DEMCO butterfly valves was requested. Using fundamental engineering principles, design software, ergonomic factors, and finite element analysis software, engineers at the University of Oklahoma delivered a fully-functioning test stand that met all design requirements.
PAGE | 11
2016
T2
AME Capstone Projects
High RPM Rotary Seal Test
The purpose of this project is the design, prototype, and validation of an experimental setup with multiple parameters including temperature, pressure, and RPM control for testing rotary ceramic sealing configurations. The specific parameters associated with this setup include an RPM range of 3000 to 5000, pressure range of 0 to 100 psi, as well as an operating temperature of ambient to 225 째C. To validate the ceramic sealing configurations, measurements gathered during testing using multiple data acquisition modules will be recorded and analyzed including torque, temperature, leak rate versus pressure, and wear rate. As this is an ongoing capstone project carried over from a previous semester, one of the main focuses is the continuation and improvement from the lessons learned previously.
PAGE | 12
2016
T3
AME Capstone Projects
Experimental Setup to Evaluate Life of Dynamic Polymer Seals in Fluids with Particulates
Polymer seals are used by Schlumberger in rotational pumps at well sites and since sand and particulates are pulled up along with the oil the service life of the seals is significantly decreased. This project is to design an evaluation system that can be used to better predict the failure of a seal when exposed to heat (200 C), pressure (1000 psi), fluid with particulates, and a rotating piston (1000 rpm). In this project, failure criteria is defined as a sudden loss of pressure in the test chamber, meaning there has been a catastrophic failure of the seal, or leakage around the seal amounting to one liter. The life of the seal is expected to be much shorter when exposed to “dirty fluid” than simply oil, therefore a modular design that makes it easy to replace the seals as well as simple and relatively inexpensive to replace components that are exposed to the particulates is necessary for the continued operation of the setup. For this modular design, a brass insert is designed to fit into the test chamber where the fluid and particulates are contained so that damaged seals can be easily replaced and also so various inserts with different gland dimensions can be used in the test chamber without having to replace the entire setup. The tabletop layout is also designed so that the test chamber remains stationary during the seal replacement process. This means that the pressure sensor, thermocouple, and heat rods do not have to be detached from the test chamber or the data acquisition, simplifying the replacement procedure and making the design more user friendly. Other design considerations are the dimensions and layout of the tabletop that the evaluation setup will be affixed to. The entire setup fits on a 24’’x36’’ aluminum table that is designed to fit on a counter top. This design is to ensure that minimal lab space is used during the testing of these seals. The main goals of this project are to design a modular test chamber where parts can be easily replaced, where different testing scenarios can be accommodated, and where the table top design minimizes the amount of space the testing set up occupies.
PAGE | 13
2016
T4
AME Capstone Projects
Experimental Setup Lubricants & Metal-Metal Galling
Galling is a form of surface damage developing between two sliding solids. This project rates lubricants’ ability to prevent galling by testing conditions under which lubricated materials gall. This test method uses an H–frame with an attached hydraulic bottle jack capable of maintaining a constant, compressive load between two flat specimens. One specimen is slowly rotated one revolution while the other specimen remains fixed. Two lubricants will be used to resist galling. The criterion for whether galling occurs is the appearance of the specimens based on unassisted visual examination. If the specimens have not galled, a new set of specimens is tested at increasing loads until galling occurs. Appropriate load intervals are chosen to determine the threshold galling stress within an acceptable range. The higher the threshold galling stressing, the more galling resistant is the test couple.
Seafloor
PAGE | 14
2016
T5
AME Capstone Projects
Cable Permeability Setup
Cables used to run electronic data collection equipment down oil wells are experiencing permeation through the cable wall membrane. This permeated gas makes its way back up to the surface where it expands and causes damage to equipment and personnel. Thus, it is necessary to design and setup an experiment that will be able to test the amount of radial permeation through the cable membrane. The resulting experiment utilizes nitrogen gas to create a 1000 psi pressure gradient across the cable membrane from the outside of the cable while testing at room temperature and 200째C. Preliminary results show an increase in the amount of pressure in the low pressure volume, suggesting permeation through the cable membrane as demonstrated in real life application of the cable.
PAGE | 15
2016
T6
AME Capstone Projects
Design and Development of a Low Velocity Impact Tester
Impact resistance is one of the most important material properties for engineers and designers to consider during the design and testing process. In addition, it is difficult to quantify materials’ and structures’ impact resistance properties numerically. The most reliable method to obtain data of these material properties is to perform experiments. The impact resistance of materials is, in many applications, considered as a critical measure of service life. This project focuses on the design and development of a drop weight low velocity impact tester for Dr. Liu and his research team at the University of Oklahoma. The impact tester will be used for experimental characterization of the impact resistance and fracture mechanism of advanced composites such as carbon fiber. It can also be employed to test other materials as well as products such as ceramics, armors, and sports protection helmets.
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2016
I1
AME Capstone Projects
Automated Guided Vehicles to Improve Plant Efficiency & Safety
Hitachi wanted to determine how to implement an Automated Guided Vehicle (AGV) to eliminate non-value added work on their manufacturing floor while increasing safety. An investigation was performed on the trash hauling task from the assembly areas to the trash compactor. After looking into each assembly areas trash production a decision was made to only focus on one area with the highest throughput of trash. In order to investigate all alternatives for implementation within Hitachi’s facilities five AGV companies were investigated as potential options. Once the five companies were decided on, a list of the requirements that the AGV must meet were compiled to help with the selection process. For this project we found that one specific company met the most specifications leading us to recommend Company A for implementation. In addition to the AGV recommendation, any other additional equipment that might be needed for implementation will be provided.
PAGE | 17
2016
I2
AME Capstone Projects
Tinker Air Force Base Alternative Process for Part Cooling
Due to the tight tolerances of jet engine parts, The 76th Propulsion Maintenance Group (76 PMXG) utilizes thermal contraction to assist in the assembly and disassembly procedures performed to actuate the inspection of engine parts at Tinker AFB. Our investigation has worked to improve this process by searching for new coolant alternatives as well as improvements to the current process. After exploring various potential solutions including a cryogenic freezer, improved insulation installments, dry ice blower, and fan attachments to current systems, we found that liquid nitrogen baths solved the problem to the greatest extent and would provide the improvements to the current process that the customer was interested in. This alternative will drastically improve cooling time, be flexible to a wide variety of parts, and nontoxic while being comparable in cost to the current process and safe to handle. Biomechanical modeling allowed team to choose how each diffuser and attachment is loaded to ensure worker safety. Modeling register attachments to fit each diffuser size allows system to impart load to all diffusers. Test system utilizes steel frame to support maximum loading (~65,000 lbs.) and .25� thick walls to protect worker during testing.
PAGE | 18
2016
I3
AME Capstone Projects
Error Free Part Identification
The Propulsion Maintenance Group (PXMG) at Tinker Air Force Base utilizes chemical baths to clean jet engine assemblies as part of a refurbishment process. Due to human error, parts are being misidentified and ruined when put in the wrong chemical baths. In order to resolve this issue, a technology capable of identifying metals was identified. The selected technology, a portable X-Ray Fluorescence (XRF) gun, utilizes fluorescent x-rays to determine elemental composition of materials. This technology was selected through the process of researching various methods of metal identification, narrowing down the methods using a requirements list, and finally selecting the best technology based on a set of criteria and statistical analysis. Pairing this technology with a computer program allows the parts to be easily and correctly identified. In order to ensure the safety of personnel and the device, measures such as a safety stand and foam sleeve were constructed.
PAGE | 19
2016
I4
AME Capstone Projects
ESP Warehouse Productivity
Our team has focused on space utilization, inventory control policy, and communication protocols for GE’s warehouse productivity issue. Regarding the inventory control policy, we have collected and analyzed the frequency of use of the parts in the ESP warehouse and broke the parts into ABC groups. There is a plan for each part in the new inventory control policy. To address space utilization, we mapped out the locations of the parts which are switching places to ensure they will fit. For the communication protocols for “hotshots,” or parts needed immediately, we recommend a KANBAN two-step stock transfer in SAP, which will be implemented in the near future. These changes to the system will make the ESP warehouse more productive by reducing “hotshots” and increasing the inventory of the most used parts. The ROI is between -28% and 117% and the annual savings will be approximately between $14,000 and $45,000.
PAGE | 20
2016
I5
AME Capstone Projects
Cable Preparation Cell in ESP Control Plant
In the current system that is used in cable preparation in the manufacturing of drives, there are three issues being faced: variable cycle time, operator fatigue, and repeatability factors. The proposed solution to solving these three issues are: implementing new equipment improvements, a new mechanical cable stripping mechanism, a new cable preparation cell layout, and an Excel Visual Basic process time calculator. By implementing these four solutions, the projected improvements are: 15% reduction in cycle time, 99% reduction in operator fatigue, and 47.7% reduction in travel time.
PAGE | 21
2016
AME Capstone Projects
I6
Technical, Political, and Recovery Factor Challenges in Shale Development
As part of the Baker Hughes 21st Century Co-Op, this project consists of laying the framework and research for three different Master’s degrees in mechanical engineering. The thesis topics are as follows: •
•
•
“Optimal Stimulation Methods in Eagle Ford Shale,” The problem that is considered in this thesis regards increasing recovery factors and production life while reducing the associated risks or negative impacts on the environment. It will primarily focus on different completion methods that usually lead to higher recovery factors and longer production life in Eagle Ford shale wells. “Addressing Complex Formation’s with Nodal Analysis of Reservoir and Production Systems,” The problem that is considered in this thesis is that of applying data analytics for the characterization of connectivity among all wells within a single reservoir and the surface equipment required to produce from said reservoir. The Nodal Analysis method will be utilized to investigate said connectivity. The reliability and utility of the connectivity characterization will also be analyzed. “Methods to Address the Subterranean Effects of Waste Water Injection.” The problem that is considered in this thesis regards the potential benefits of utilizing alternative methods of wastewater disposal to decrease the seismic effects caused by waste water injection wells, all while remaining profitable for oil and gas corporations.
We utilized the literature investigation surrounding the Baker Hughes challenge problem completed over the last two years and the sustainability triangle method to formulate three thesis topics by considering dilemmas and research gaps. Despite their innate distinctness, all three Master’s theses are interconnected and are rooted within the Baker Hughes challenge problem which will enable all three to be written jointly with a high level of collaboration.
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2016
V1
AME Capstone Projects
Sooner Racing
The Sooner Race Team Capstone involves 3 separate system designs to benefit the car and team in future years. One of the systems designed was a monocoque frame comprised out of carbon fiber and a core material to create a lighter, stiffer frame. This differs vastly from the traditional space frame design. The next system was a vehicle dynamics package to compliment the monocoque and investigate pull rods versus push rods for use in the suspension. Lastly was the design of an aerodynamics package that would aid in traction and investigate new design processes to help offset the reduced traction from a lighter frame. Combined together, these three systems cover all of the chassis design side of the race team on a yearly basis, leaving a solid knowledge base for that design next year.
PAGE | 23
2016
V2
AME Capstone Projects
Sooner Powered Vehicle
The Sooner Powered Vehicle team is a competition team that designs, builds, tests, and competes a recumbent bicycle versus universities from around the world. Currently the team designs the bicycle’s frame out of steel, and the tube profiling is outsourced to VR3 Engineering. Once the tubes are shipped to campus, the tubes are welded and the components are attached to the bicycle. However, in order to increase performance while maintaining under budget and manufacturing time, the team developed a process in order to develop a carbon fiber bicycle frame by 3D printing plastic male molds. The current process involves outsourcing the printing to Tech-Labs, and the carbon fiber layup process will be conducted in house. Currently we spend about $2000 making the steel frame, our estimated budget to create the new frame is $1900. The new frame also maintains performance and can be manufactured in a reasonable amount of time.
PAGE | 24
2016
V3
AME Capstone Projects
Sooner Off-Road: Semi-Trailing Arm Suspension
The Baja SAE Series is an international collegiate engineering competition that involves the design, planning, and manufacturing tasks found when introducing a new vehicle to the consumer industrial market. Teams primarily consist of students from U.S. universities and colleges, and they compete against each other to have their design accepted as a profitable and manufactural vehicle by a fictitious firm. The teams must successfully design, build, test, and race a vehicle within the limits of the rules. The focus of this project will be to research and design a superior independent rear suspension system that can be easily manufactured within budget constraints and that can perform efficiently with the other subsystems of the vehicle.
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2016
V4
AME Capstone Projects
Design of Green-Energy Tricycle
The Green Tricycle Team designed an affordable, battery powered, motor-assisted adult tricycle that appeals to commuters. Through design research and discovery of current tricycles on the market, the team initially developed a detailed list of feature systems to incorporate into the tricycle design. A rear hub motor and battery combination was selected to provide both power and exercise. The tricycle can travel at a top speed of 25 mph without the rider pedaling, and the battery allows the rider to travel up to 21 miles on a single charge. The final design also features rear steering and suspension, a weather-protecting Plexiglas cover, an adjustable recumbent seat for riders ranging from 5’4” to 6’, and a simple two-loop aluminum frame that provides easy access to the seat. The team created the detailed tricycle design in SolidWorks and validated its structure using finite element analysis, flow simulations, and both dynamic and kinematic analyses.
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2016
AME Capstone Projects
AE1 AIAA DBF Crimson Skies Crimson Skies has been working towards the 2016 DBF competition since September of 2015. The competition rules were released August 31 of 2015, and the capstone group promptly began scheduling team meetings and developing conceptual ideas of the aircraft. The rules centered around the following structure: ● ●
There would be two aircraft, a manufacturing support (MSA) and production (PA) The PA must be capable of fitting inside of the MSA. This can be accomplished by breaking the aircraft into smaller “subcomponents.” The fall semester was spent optimizing a flying wing aircraft, the chosen design for competition. The beginning of the spring semester was heavily focused on manufacturing the first test aircraft, flown in late March. Stability issues associated with the production aircraft during takeoff were discovered and handled in the weeks before competition, which occurred April 15-17, 2016. The Crimson Skies aircraft were highly competitive, placing fifth out of eighty teams internationally. This is the best placement the University of Oklahoma has ever had at the AIAA Design Build Fly competition.
Mission Guidelines
Mission
Aircraft Flying
Payload
# Laps
Window
1
MSA
None
3
5 minutes
2
MSA
PA subcomponents
Total number of subcomponents
10 minutes
3
PA
32 ounce Gatorade
3
5 minutes
PAGE | 27
2016
AME Capstone Projects
AE2 Unmanned Aerial System (UAS) Dynamometer The dynamics associated with UAS scale electric motors and propellers are often obtained from incorrect references made openly accessible to the public online. Understanding the torque, thrust, RPM, voltage, and current associated with a particular combination is critical to the design of an efficient aerial system. The objective of this project was to develop a portable, rigid, semi-solid state measurement device capable of capturing this critical information associated with small scale electric motors. After several design iterations a final product was machined and underwent calibration and static testing. Thrust and torque data were captured using load cells processed by an Arduino Micro. Blade speed and battery voltage and current were captured using a laser tachometer and wattmeter. Results showed that the UAS Dynamometer could independently and reliably measure the torque and thrust associated with a given propeller and electric motor combination during static testing. Furthermore, a thrust and torque profile for a motor (AXI 2217/12), propeller (APC 9x4.5E), and battery (12 pack of Elite 1500 cells) was generated using the dynamometer as an initial test.
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2016
AME Capstone Projects
AE3 Lockheed Martin Supersonic Jet Trainer The objective of this project was to conceptually design a Supersonic Jet Trainer that will replace the aging T38 fleet and allow for the training of 5th generation fighter pilots. Design requirements include a maximum speed of Mach 1.08 at sea level and Mach 1.3 at 30,000 ft, sustained 7.5 g and instantaneous 8.0 g turns, a maximum angle-of-attack capability of 25 degrees, a ferry range of 1,140 miles, a landing distance of 7,000 feet, and a take-off distance of 6,400 feet. These requirements were satisfied by a prototype design with a maximum take-off weight of 13,000 lbs and an empty weight of 8,000 lbs. The aircraft features a wing with 31 ft span and 4% thickness and a 43 ft long fuselage which houses the single Snecma M88-4E engine. The prototype accommodates both, pilot and instructor, with separate flight controls for each, satisfying the role of a trainer.
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2016
AME Capstone Projects
AE4 Bergey Aerospace High Altitude Research Plane (HARP) The High Altitude Research Plane (HARP) is a cooperative project between Bergey Aerospace Co., Inc. and the University of Oklahoma School of Aerospace and Mechanical Engineering. The objective of the project is to fabricate and fly a high altitude research aircraft designed to reach an altitude of 60,000ft, setting the world record for propeller-driven aircraft. The spring 2016 HARP Capstone Team had four main objectives for the semester. The first of these objectives was to provide a physical engine compression system mock-up for the aircraft, which included selecting the turbochargers, sizing the intercoolers and designing the piping for the system. The remaining objectives were to provide a physical mockup of the engine mount, perform a compression system thermodynamic analysis, and finally provide a CAD model of the engine, compression system, and mount.
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2016
AME Capstone Projects
AE5 Northrop Grumman Reusable Spaceplane The objective of this project was to design and manufacture a working model of the XS-1 reusable spaceplane at the request of Northrop Grumman Aerospace Systems. The spaceplane to be designed must be capable of the following features: able to launch and ascend 1,000 feet, autonomously transition from rocket flight to gliding flight, autonomously land at a predetermined location, and record all phases of flight with on-board cameras. The spaceplane will adhere to the guidelines set forth by the NAR and AMA. Manufacturing of the spaceplane is complete and it has been tested in the wind tunnel to prove that it has capability for trimmed flight during both the rocket and gliding flights. Tasks that remain include flight testing to prove airworthiness during RC and autonomous flight and three launches to demonstrate the spaceplane’s capability to function as a rocket, transition from rocket flight to gliding flight, and autonomously land.
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2016
AME Capstone Projects
AE6 Composites Processes and Weather Rocket Design This Capstone project had three goals: creating a mobile vacuum bagging cart for future composite fabrication, making test parts to develop composite wet layup techniques, and building a lightweight data acquisition rocket for use by the National Weather Center at the University of Oklahoma. The test part chosen was a Frisbee. Three discs were created using a wet layup and two part aluminum mold. After completing the discs, work on the weather rocket began. The rocket is intended to collect low atmospheric data ahead of approaching storms. Launch must not require NAR/FAA certification, which limits vehicle and propellant weight. The payload is a 12 gram Windsond, provided by the Weather Center, which is carried in the nose cone. At apogee, the parachute deploys and the rocket body is discarded, while the nose cone can be recovered for future flights. Fiberglass and carbon fiber are used for the nose cone and fins, respectively.
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2016
AME Capstone Projects
AE7 IAS Weather UAS The goal of this project was to perform a conceptual design of an UAV to take boundary layer measurements in the Earth’s atmosphere. This design was to be based on a flying UAV, built empirically for a 3 lb payload, and on mission requirements dictated by the School of Meteorology. The modular aircraft is to carry a payload of 1.5 lb and reach an altitude of 10,000 ft, with a range of 60 miles. The aircraft resulting from the full conceptual design compared well to the existing one, with only minor differences, including a smaller motor, increased battery capacity, carbon fiber tail booms, and a relocated horizontal stabilizer. Although the payload was decreased from the original design, the increased range and associated battery weight offset any potential weight drop. After implementation of the necessary changes, the UAV will be certified and handed over to the School of Meteorology.
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2016
INDUSTRY SPONSORS
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2016
INDUSTRY SPONSORS
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2016
INDUSTRY SPONSORS
Bergey Aerospace
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