College of Engineering

Department of Mechanical Engineering

Spring 2016-17

Senior Design Project Report

Project Title

In partial fulfillment of the requirements for the

Degree of Bachelor of Science in Mechanical Engineering

Team Members

Student Name Student ID

1
2
3
4
5

Project Advisors:

Advisor Name:
Co-Advisor Name:
Below is a sample of the way to write the abstract. You see that there are two paragraphs.
One gives some background, while the second explains the aims of the project and gives
some information about the achieved results. Please pay attention to spelling, grammar and
check the abstract with your advisor. You need to write an initial abstract and finalize it when
the work is done and the scope of the work becomes fully clear.

Abstract

Rotating machines are found in a vast array of industrial applications and, as such are
essential elements of industrial societies. Modern industry requires safer, reliable and
efficient machines and in particular these operating at high speeds and under heavy loads.
This has led to an increase interest in monitoring the health of machines using vibration
analysis to provide an early detection and diagnosis of emerging faults at the earliest possible
stage. The success in vibration analysis of rotary systems depends largely on the techniques
used in processing the vibration signals and by using an appropriate signal processing
method, it is feasible to detect changes in vibration signals caused by faulty components and
to judge the health conditions of the machinery.

In this Project, the aim is to develop a simple rotor test rig, where rotor faults can be inserted
and tested. The test rig is to be fitted to vibration sensors and data to be acquired using the
National instruments (NI) DAQ. The main fault to be studied once the test rig is constructed
is a cracked shaft fault (tested at different speeds and different crack condition (sizes)).
Further studies will include the effect of unbalance on the detection of Cracks. Results
show……….

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Please give proper acknowledgment to all the people who helped in completing this project.
You need also to acknowledge any support you received during the duration of the work.

Acknowledgments

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List of Acronyms (Symbols) used in the report:

4
List of Figures:

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List of Tables:

Table of Contents
Abstract................................................................................................................................................................2
Acknowledgments....................................................................................................................................................3
List of Acronyms (Symbols) used in the report:......................................................................................................4
List of Figures:.........................................................................................................................................................5
List of Tables:...........................................................................................................................................................6
Chapter 1: Introduction............................................................................................................................................8
1.1 Project Definition...................................................................................................................................8
1.2 Project Objectives...................................................................................................................................8
1.3 Project Specifications.............................................................................................................................9
1.4 Applications............................................................................................................................................9
Chapter 2: Literature Review.................................................................................................................................10
2.1 Project background...............................................................................................................................10
2.2 Previous Work......................................................................................................................................10
2.3 Comparative Study...............................................................................................................................12
Chapter 3: System Design......................................................................................................................................13
3.1 Design Constraints................................................................................................................................13
3.2 Design Methodology.............................................................................................................................13
3.3 Product Subsystems and Components..................................................................................................13
3.4 Implementation.....................................................................................................................................13
Chapter 4: System Testing and Analysis................................................................................................................14
4.1 Subsystem 1..........................................................................................................................................14
4.2 Subsystem 2..........................................................................................................................................14
4.3 Overall Results, Analysis and Discussion............................................................................................14
Chapter 5: Project Management.............................................................................................................................15
5.1 Project Plan...........................................................................................................................................15
5.2 Contribution of Team Members...........................................................................................................15
5.3 Project Execution Monitoring..............................................................................................................15
5.4 Challenges and Decision Making.........................................................................................................15
5.5 Project Bill of Materials and Budget....................................................................................................15
Chapter 6: Project Analysis...................................................................................................................................16
6.1 Life-long Learning...................................................................................................................................16
6.2 Impact of Engineering Solutions.............................................................................................................16
6.3 Contemporary Issues Addressed.............................................................................................................16
Chapter 7: Conclusions and Future Recommendations.........................................................................................17
7.1 Conclusions..........................................................................................................................................17
7.2 Future Recommendations.....................................................................................................................17
8. References......................................................................................................................................................18

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Appendix B: Bill of Materials................................................................................................................................19
Appendix C: Datasheets.........................................................................................................................................19
Appendix D: Program Codes.................................................................................................................................19
Appendix E: Operation Manual.............................................................................................................................19

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Chapter 1: Introduction

This chapter consists of four main sections.

In the first section you define the project and tell the reader about your intention from
working on this project. In the second section, you list the objectives of the project. These are
those that we want to see when you finish the work on the project. In section 3, you provide
the reader with an idea about the specification of the project, i.e sizes, power, load, capacities,
etc. Finally, you list a number of good applications where you can see that you can utilize
your project and make use of it.

Please consult with your advisor closely and make sure that you understand what you are into
so that the reader can see what your intention and become curios to read you report to find
you the details of the work

1.1 Project Definition

What is it you are designing, creating or researching??

Example: (Please write as much as you can so that the reader can see what the project is
about and understand its importance)

This project is intended to design and manufacture a simple rotor test rig, where rotor faults
can be inserted and tested. The test rig is to be fitted with vibration sensors to enable
collecting data and use it to monitor the health of machines. The project is very important to
industry as through understanding the characteristics of failure, time and money will be
saved. This is also very important from the safety prospective as this will lead to a safe
operating environment for rotary machines.

1.2 Project Objectives

List main project objectives (why offering product or working on this design/research? i.e.
reduce pollution, use clean energy, solve certain problem, understand more about a certain
design, increase awareness about impact of energy, security, safety, etc …)

Example: (Think of as many objectives as you can achieve from your project. You may list
the objectives as follows :).

1. Design and construct a test rig to develop signal processing algorithm for crack
detection in shafts using vibration analysis
2. Study the change in system dynamic characteristic due to shaft crack.
3. Correlate the changes in the dynamic behavior with crack size and location.
4. Developing health monitoring techniques to prevent catastrophic failure from cracked
shafts.

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1.3 Project Specifications
 Draw diagrams; identify subsystems if applicable
 Show Photo of real system

List:
a. Metrics (Power, voltage, current, weight, speed, communication range, battery duration
in hours, system size or capacity like quad copter load, …)

b. Marketing features (economic, energy efficient, automatic, light-weight, portable, clean

energy, easy to install, environmental friendly …)

c. Engineering standards: Please quote the different local and

international standards you will be utilizing in your project. This relates
to the material, design selection and calculations, environmental
regulations, measurements limits and tolerances, etc.

1.4 Applications

Examples:

 Health monitoring system can be used in remote clinics; with elderly people in remote
locations for real time monitoring …
 Leak detection system used to locate leaks and save water ….
 Power monitoring system used to conserve energy …


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Chapter 2: Literature Review

2.1 Project background

The background description helps putting the project into the right context and gives
everyone involved a common view of the project.

In this section:

Briefly describe the current situation and the reasons for carrying out the project.
Where your project work fits (challenges, optimization, etc.)
Give information about the key words in your project title.

Example:

Rolling element bearings are core components of our revolutionary life and developments.
They exist in almost all rotary machines, supporting their dynamic forces and facilitating
their rotation. The failure of a rolling element bearing may have a catastrophic consequence
on the machine if it went undetected and without follow-up. We attempt to monitor these
vital components through observing their temperature, noise, vibrations, oil wear debris etc.
Among all these monitored parameters, vibration signals have proven to be of great
assistance for maintenance personnel, not only in detecting the presence of a fault but also in
locating its source. Most recently, information from vibration signals has been used to
provide analysts with an idea about the size of the fault and consequently enable prediction of
the useful remaining life of the bearing (prognostics). However, vibrations picked up by
accelerometers have to go through a number of rigorous processing steps to enable extraction
of the fault symptoms and identification and quantification of fault size.

2.2 Previous Work

Your literature review and research on the project goes into this section.
Perform research for previous projects and studies on the same topic as your project and
summarize the main features and results.
Identify key websites, journal articles, books, etc. Look into the latest and updated work in
the field in the last few years.
Ensure that you have in text citation and that your references are listed under (section 8 of the
report).
When you include a figure, make sure it has a caption and that you mention this in your text
so that the reader knows.
Please see the example below.

Show the advisor your writing for feedback.

Example:

Rolling element localized faults, e.g. spall/pitting, give rise to a series of pseudo periodic
(second order cyclostationary) bursts, which excites the natural frequencies of the structure
[1]. The bursts (figure 1, [1]), which are spaced at the rate at which the ball passes over the

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defect, are generally masked in the low frequency region due to the presence of deterministic
components and noise from other components in the system such as gears, blades, unbalance,
misalignment, electrical noise, etc. The actual ball pass frequencies are generally 1-2 % in
deviation from the theoretical calculated frequencies due to the slippage of the rolling
elements as a result of the variation of the load angle [2]. Slippage causes a smearing in the
defect frequencies and envelope analysis [2 and 3] is used for fault diagnosis.

Envelope analysis, which is the basis of fault diagnosis in rolling element bearings, was first
proposed in 1974 by Mechanical Technology Inc. [3]. It was originally called the high
frequency resonance technique (HFRT), and is now known by further names such as
amplitude demodulation, demodulated resonance analysis, narrow band envelope analysis or
only as envelope analysis.

Figure 1 Typical vibration signals generated by local faults in rolling element bearings
(stationary outer race) BPFO = ballpass frequency, outer race; BPFI = ballpass frequency,
inner race [2].

References: These will appear in the references section

[1] Randall, R.B and Antoni, J: Rolling element bearing diagnostics- A tutorial, Mechanical Systems and Signal
Processing. 25, 485-520 (2011)
[2] Ho, D. and Randall, R. B.: Optimization of bearing diagnostic techniques using simulated and actual bearing
fault signals. Mechanical Systems and Signal Processing,. vol.14 (5), pp. 763-788(2000)
[3] Darlow, M.S., Badgley, R.H. & Hogg G.W.: Application of high frequency resonance techniques for bearing
diagnostics in helicopter gearboxes, Us Army Air Mobility Research and Development Laboratory, Technical
Report, pp. 74-77, 1974.

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2.3 Comparative Study
In this section you need to do a targeted literature review to list and present similar
undergraduate projects (Capstone projects) that were conducted recently. List no less than
three projects in a similar area. Show images and discuss what they achieved.

Write one paragraph into how your work will be different and what will distinguish you.

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Chapter 3: System Design

1. How you set your product/subsystem target specifications and Standards (ABET
outcome c1)
2. How you considered multiple alternatives in your subsystem design (c2)
3. How you selected appropriate components that meet the target specifications and
Engineering standards (c3)
4. How you implemented your design (activities) (c3)
5. How you verified your subsystem/system performance: simulation, experiments (c4)

3.1 Design Constraints and Design Methodology

Start with your project architecture diagram and explain the methodology (approaches,
strategies) followed to implement and verify your design.

List and describe here the design constraints taken into consideration or addressed in
designing the system/sub-systems of your project, such as:

o Geometrical Constraints
o Engineering Standards (Please add an appendix to show more details)
o Sustainability
o Environmental
o Social
o Economic
o Manufacturability
o Safety
o Ethical
o Risks
It is a good idea to show an exploded drawing of you intended design to give the reader an
idea about how you final design will look like. (Assembly and exploded drawing as you
studied in MEEN 3394)

3.2 Engineering Design standards

3.3 Theory and Theoretical Calculations

Give some background into the main calculations required and then show detailed
calculations to your design.

Refer to Engineering Standards where applicable

3.4 Product Subsystems and selection of Components

Show how you selected the most appropriate item.

Examples:
Bearing selections, sizing of motors,

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Refer to Engineering Standards where applicable
3.5 Manufacturing and assembly (Implementation)
System integration ….describe and explain the procedures of how you put everything
together to become your system of interest.

Emphasize all design aspects

Refer to Engineering Standards where applicable

3.6 Economic Evaluation of the Project

Please check the Economic Evaluation of Engineering Projects word file and cost template
excel file on blackboard

Chapter 4: System Testing and Analysis

4.1 Experimental Setup, Sensors and data acquisition system

Show a image of the setup and who the locations of the sensors.
List the specification of the sensor and explain why you chose them.
List the testing parameters and explain clearly your approach.
Refer to Engineering standards where applicable (add appendix for more details)

4.2 Results, Analysis and Discussion

Analysis:
Sample Table and Figure: Notice Figure caption goes under the figure, but table caption goes
above.

Discussion: ??? Discuss your results

Distance [cm] Photocurrent [uA]

d Iph
0 130
20 32
30 15
50 5

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 Photocurrent (uA) 150

Measured
100
Model Eqn

50

0
0 20 40 60
Distance (cm)
Figure 4.2. Measured Si photodiode output current with 1mW Laser.

Testing activities MUST emphasize:

 Identify experiment/test goals and resources required (instruments, setup, …)

 Execute experiment procedure and collect data
 Analyze data, interpret results in light of goals set
 Report results (tables, plots, …), with discussion of any errors and conclude mentioning any
challenges.

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Chapter 5: Project Management
5.1 Project Plan

 Breakdown into list of tasks.

 Map tasks to team members.
 Put a time duration for each task.


5.2 Contribution of Team Members

List here the tasks performed by each team member towards the successful completion of the project.
Also, specify the contribution of each team member as a percentage with individual contributions
adding up to a 100%.

5.3 Project Execution Monitoring

List various activities:

 Meetings with Advisors

 Team meetings
 Other activities: testing, …

5.4 Challenges and Decision Making

Challenges Faced: Describe all challenges you faced in the project and how they
impacted the project schedule, scope or expected results.

 Problems with team members not cooperating/meeting.

 Problems or delays in procuring required parts/components/tools.
 Problems with equipment or components not working or malfunctioning.

Decision Making: write about how you solved these challenges or found a way around them.

5.5 Project Bill of Materials and Budget

Final Budget: In this section, you list all the expenses incurred in completing your project
for things such as hardware, software, and related costs, etc. If you exceeded the original
estimated budget, give details about and justification for the extra expenses.

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Chapter 6: Project Analysis
In this section, you will analyze your project in terms of the following:

6.1 Life-long Learning

In this section, list and describe the new knowledge, skills, and experiences you acquired on
your own (by way of self-learning, independent learning) while working on this project. You
could write about the following things you learnt in this project:

 new hardware devices (such as myRIO, Arduino, sensors, GSM, WiFi, Bluetooth,
XBee, etc.),
 new software tools (such as LabVIEW, Matlab/Simulink, etc.),
 project management skills,
 time management skills,
 etc.

Also write about what tools (internet/Google, library, books, etc.) you used in acquiring the
above.

6.2 Impact of Engineering Solutions

Discuss here the impact of your project on the society, economy, environment, etc. You can
write about how your project can help or the advantages it brings to, the society, economy,
environment, etc.

6.3 Contemporary Issues Addressed

List and describe the contemporary issues addressed by your project; issues faced by Saudi
Arabia in particular and the GCC/world in general. These issues could be related to health,
safety, water usage and conservation, power generation, power consumption and power
saving, renewable energy resources, regional economy, social aspects, etc.

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Chapter 7: Conclusions and Future Recommendations

7.1 Conclusions
 Summary of main results
 Any unique contributions compared to previous work (projects) made in the
field.
 Individual: Project experience, challenges
 What you learned….

7.2 Future Recommendations

 List design changes and features that you recommend to improve system .

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8. References

 List references you used (books, websites, ….)

 make sure each reference is cited in the report body exactly where it was used (e.g. LED ref in LED
chap and section, Solar Ref in appropriate Chap …)

Example:
[1] Earth Policy Institute (EPI), Report 2007, www.epi.org.
[2] International Electrotechnical Commission (IEC) Standard 61724. Photovoltaic system performance monitoring—guidelines for
measurement, data exchange and analysis.
[3] T. Oozeki, T. Izawa, K. Otani and K. Kurokawa, “An evaluation method of PV systems,” Solar Energy Materials & Solar cells, vol.
75, 2003, pp. 687- 695.
[4] T. Yamaguchi, H. Wakabayashi, T. Yamada, K. Hasegawa, T. Agarashi, K. Sakuta, T. Takashima, and K. Otani, “ Measurement and
analysis of residential PV systems in Japanese monitoring program,” 3rd World Conference on PV Energy Conversion, Osaka, Japan,
May 11-18, 2003, pp. 2463-2465.
[5] J. D. Mondol, Y. Yohanis, M. Smyth and B. Norton, “Long term performance analysis of a grid connected photovoltaic system in
Northern Ireland,” Energy Conversion and Management, vol. 47, 2006, pp. 2925-2947.
[6] ……

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Appendix A: Progress Reports
Includes copies of what you have already submitted.

Appendix B: Engineering standards (Local and

International)

Appendix C: CAD drawings and Bill of Materials

List of all components used, quantities and cost

Appendix D: Datasheets
Include only key components and only main pages

Appendix E: Program Codes

Example:
 Labview codes,
 Matlab codes
 Microcontroller codes….

Appendix F: Operation Manual

Include guidelines steps that can be used to:
 Run projrct prototype,
 Run the codes
 List expected outputs


Please add other appendices as you see fit

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