Kettering University

The WorldScan device was suggested as part of an automated control method that could potentially decrease excess oil coatings and prolong the lifetime of the blank washer rolls. This method was more technically advanced in determining the part oil coverage than the Weigh-Wipe-Weigh process. Additionally, the causes of hydraulic marks, excess oil, and the frequency of filter replacements were identified.

In order for an emergency or standby power system to be NFPA compliant, all parts of the system must also be NFPA compliant, including automatic battery charging systems. This paper describes the product development cycle of a device that can provide NFPA-110 compliance for any 12 or 24 volt, 10 Ampere automatic battery charger. The device can also communicate charger status information over a Controller Area Network to other Kohler products.

This project investigated the effect of implementing solar systems on the efficiency of the plant by reducing auxiliary power consumption, and in turn lessening the use of fossil fuel and making the operation of the plant more environmentally friendly. The efficiency is inversely proportional to the net heat rate of the plant, which measures the ratio of the fuel energy input to the net generation output. Improving the ability of the plant to consume less of its generated power would increase the net output thereby increasing the efficiency. The solar systems were designed as alternative power sources for some of the plant¿s auxiliaries and for lighting and air conditioning during the day.

The Automated Electrostatic Discharge (Auto ESD) control unit is an electronic module that can control three stepper motors from a computer's USB port. When paired with a tri-axis table, the control module has the ability to accurately control three dimensional position, and can effectively introduce automation into testing procedures such as the electrostatic discharge test performed in the EMC Lab at Robert Bosch LLC in Plymouth, MI.

Behr-Hella Thermocontrol, Inc designs and develops climate control units for multiple original equipment manufacturers (OEMs) worldwide. A variety of controls are produced, including black box controls with dummy panels, manual climate controls, and automatic climate controls. Many of the controls produced utilize segmented displays to correspond temperature, blower speed, and other information to the vehicle operators. As new technologies develop, it is necessary to investigate them and weigh them against each other as viable options for current and future projects, based on cost and performance. This thesis focuses on two types of segmented displays; liquid crystal displays (LCDs) and vacuum fluorescent displays (VFDs).

The use of electricity in United States is growing, with respect to other forms of energy. (Energy Information Administration, 2007) With the increase in demand of electrical energy, the nation?s utility transmission system is being subjected to congestion, which is putting stress on critical assets such as the high voltage transformer, making it paramount to implement devices, such as the GE Faraday tMedic, to monitor and run diagnostics on the transformer to avoid catastrophic failures.

Current hybrid electric vehicles (HEV) utilize nickel-metal hydride battery cells. To determine how they are constructed, a Ford Escape Hybrid's is to be deconstructed and analyzed to determine electrical connectivity and cooling system implementation. In addition, a detailed investigation into lithium-ion battery cell technology will be conducted to determine the feasibility of implementing their chemistry into HEVs. The results show that the current design of HEV battery modules is simply series connected cells. It was also determined that lithium-ion technology is currently not feasible for use in HEVs, but will be in the not-too-distant future.

A driver for the Agilent 4395A Spectrum/Impedance/Network Analyzer is developed using National Instruments LabVIEW software. Methods and procedures are described regarding the development of the programming in relation to the functionality of the analyzer. The intention of the project is to assist future students and faculty in the use of the analyzer by guiding the them through calibration, testing, and data acquisition.

To evaluate boundary scan tools to optimize use of boundary scan. In addition, to develop specifications, requirements and Design for Testability (DFT) rules for Electrical Engineers to design circuit boards to enable utilization of boundary scan technology capabilities.

The objective of this thesis project is to determine which relays in a substation create a transient voltage that may be harmful to solid state equipment and need spike suppression devices such as Metal Oxide Varistors (MOVs). This thesis goes through the process by which the following types of relays were tested and the results of each test: Auxiliary Relays Auxiliary Voltage Relays (AVR) Control Switch Relays (CSRs) Lockout Relays (LORs) Time Delay Relays Trip Indication Relays(TIRs)

This thesis project expands the capabilities of current hardware-in-the-loop (HIL) test benches by providing users with the ability to remotely submit tests and receive results without having to manually configure the bench and monitor tests as they are run. The focus of the thesis is the development and testing of the prototype version, the various approaches taken and the respective problems encountered, as well as suggestions for further development.

This thesis is a culmination of research the author has conducted over several months regarding the use of Cognex¿s VisionPro and Microsoft¿s .NET APIs, the C# programming language, and using Microsoft Visual Studio. Development of UEI Multi View, the name of the software application short for Utica Enterprises Incorporated Multiple View, occurred at Utica Enterprises Incorporated, a top company for designing and implementing automation systems at automobile manufactures¿ facilities. The division for which UEI Multi View was developed is for the vision group, which integrates vision guidance systems into automation.

This thesis details the implementation of a battery monitoring system in Robert Bosch LLC¿s Plymouth, MI Electromagnetic Compatibility Lab. The design process for the battery monitoring circuit is documented providing information on component selection, schematic creation, and the construction of the printed circuit board layout. In the battery circuitry, a microcontroller receives inputs from current, voltage, and temperature sensors attached to the battery and data is transmitted wirelessly to a base station that tracks data on all batteries. The information for each battery is also displayed onboard via a selectable LED display. This thesis documents the creation of a prototype battery monitoring circuit and suggestions for further improvement.

The GLock 19 pistol has under gone failures of casing ejection during critical situations for police and military alike. The cause of this failure is determined, using signal analysis and high-speed video data acquisition. In addition, a proposal of how to help prevent the problem is discussed.

McNaughton-McKay Electric Company is the largest distributor of Allen-Bradley components, providing automation solutions for customers. The role of McNaughton-McKay is to provide products and solutions that satisfy customer?s electrical needs, from simple electrical devices as relays or contactors, to complex automation products like Programmable Logic Controllers (PLC). Recently, as governmental and non-governmental organizations set safety regulations, companies must comply in order to sustain themselves. Governmental organizations like Occupational Safety and Health Administration (OSHA) establish laws to ensure safe and healthy working conditions. Compliance to OSHA standards is mandatory (unless specifically noted) and responsibility of employer to establish that environment. Non-governmental organizations such as the International Organization for Standardization (ISO), International Electrotechnical Commission (IEC), and European Norm (EN) set voluntary standards that help companies adhere to OSHA standards. This project showcased an integrated Category 4 safety system incorporating Variable Frequency Drives, Programmable Logic Controller, Ethernet communications, and an Operator Interface. This allows customers to learn about the benefits of safety systems, help them integrate into their exisiting architecture, and protect their employees. Such a system opens new doors of opportunities for McNaughton-McKay's sales and engineering groups.

This thesis covers the development and testing of feedback controllers to control electric current through an electromagnetic coil housed in an all-wheel-drive torque transfer device. Six controller styles using Classical and Modern controls are developed with each being tuned for an underdamped and critically damped response. A final controller is selected based on performance, ease of tuning, and reliability under harsh operating conditions to be incorporated into BorgWarner Controls.

The Thesis is about two different vision systems that were installed for Ford. One of the cameras was a retro-fit of the existing camera system that was installed this is because Ford wanted to have a more reliable vision system. The second vision system is a new design and the need is based on how much downtime is caused by the wrong part being installed. If the wrong part is installed it can take anywhere from 5 - 25 minutes depending on where in the manufacturing process, that the problem is caught. The Vision systems were installed, and debugged after they conceptualized. After the debug process was completed the vision systems had to then under go a run off test. This means before FORD would by off that the jobs were complete that the visions systems only had one false failure in 500. The vision systems will not save Superior controls any money, but will save FORD money.This is because Superior Controls was contracted to do the work for FORD, and that is who the visions systems will affect.

The study evaluates several different vision guidance packages that have the potential for success in robotic bin-picking applications, ultimately arriving at a decision tree that guides the end-user toward the correct solution. The differences between the methods of structured and random bin-picking, part types that are suited to each, and additional robot cell design considerations are also explored at length.

Internet protocol version four (IPv4) is the current Internet protocol widely used by Internet users today. IPv4 uses a 32 bit addressing scheme. When IPv4 was released in the 1980's, the number of available addresses was not thought to run out. However, nearly 30 years later that thought is becoming a reality. The next version of the Internet is Internet protocol version six (IPv6) and utilizes a 128 bit addressing scheme. U.S. Government agencies have been mandated to make the transition from IPv4 to IPv6. With this transition security issues arise. Firewall security is the issue that is currently important. This thesis was performed to gather a greater understanding of the vulnerabilities IPv6 posses on U.S. Government firewalls. In order to produce results, configurations were established to test certain problem areas in IPv6. These test configurations utilized a firewall, a chassis to pass traffic, and several computer programs to capture data. The first test configuration was for a general functionality test. The second test configuration was for header attack testing. The third test configuration was for IPSec testing. Once the tests were performed, several vulnerabilities were concluded. These vulnerabilities include reconnaissance attacks used for identifying locations on a network, and no ability to view packet payload using IPSec tunnels. In addition, several mitigations were established to help prevent those types of attacks from occurring. With the vulnerabilities concluded, IPv6 firewall security was strengthened. The firewall was strengthened through a list of best practices generated with mitigations identified during testing. Although the thesis provided several vulnerabilities, more complex vulnerabilities exist that could not be tested. It is recommended that more testing be done to identify further vulnerabilities.

This thesis covers the design and building of an automated test stand to administer performance life testing on the hydraulic seals for The Minster Machine Company's Infinitely Adjustable Stroke option. The main focus of the thesis is on the design of a control panel which controls the automated process of cycling the mechanical testing components.

This thesis describes the development of a simple device to emulate the Restraint Indicator Light on the dash of modern automobiles. This device is needed because the Restraints Control Module (RCM) no longer has direct control of this indicator, and must send a message to the instrument cluster through the CAN (Control Area Network) bus to control this indicator. Currently, a PC with CAN interface card is needed to simply check if an RCM is functional. This device will replace the need for a PC for basic testing and development tasks.

Wireless communication and information transmission, especially low power wireless devices, are key components in today?s technological advances. Understanding and being able to design such devices is an important part of keeping up with today?s technology. Mixers are a relatively un-researched technology, but are a key component in wireless receivers. This thesis details the concepts, features, and circuit elements of a mixer component. It also describes the specifics of designing a low-power radio frequency mixer circuit chip. Furthermore, it explains the entire process of researching, designing, submitting the overall component for fabrication, and the final results of testing the fabricated component. The thesis shows the final mixer component chip layout as well as describing the successful results of testing. Results of this thesis add to the research being performed on low power devices as well as mixer technology in general.

The goal of the thesis was to improve a timing issue for a fiber optic cable link to be used in electromagnetic compatibility testing. The original link was thoroughly examined. The optical components used were examined, as well as alternative optical components. The PCB layout of the board was examined as well.

An investigation of the most efficient way to design a control system for a new manufacturing line is presented. Standard schematics and HMI screens were created to decrease confusion from multiple General Motors PowerTrain specifications. This thesis divulges into all aspects of a control engineers job at Saginaw Metal Casting Operations including control hardware and software.

In the automobile industry, production line throughput and efficiency is crucial to the viability of the business. Moreover, verifying and maintaining the integrity of an assembled product is equally or more important. At General Motors, the end-of-line test tools are responsible for performing these verification tests on the assembly line. As with all equipment in the manufacturing environment, potential for errors and incorrect configurations on the test tools increase over time. In the event of an error, a series of manual checks on hardware and software configurations is conducted. Manually checking configurations on the test tools can be a tedious, time-consuming, and error prone. This thesis presents the development of a quicker and more efficient alternative to diagnosing errors. By researching past known failures, it is apparent that validating the registry settings, running processes, file integrity, event log and the Modular Vehicle Interface against expected results will aid in identifying the issue. Through an application built on Microsoft C# technology, the process of finding a resolution is automated and thus reducing any possible downtime. The utility can be also be used as pre-emptive maintenance by validating new test tools with fresh software and hardware installations or tools that have been recently returned from repair.

To monitor robotic cycle time in order to find robotic bottleneck in stations and cells. This thesis displays robotic cycle time on a GUI screen using the software Cimplicity. When the robot cycle time exceeds a marginal tolerance, set an alert for the viewer.

The conventional method of checking the tooth contact pattern of an automotive rear axle assembly is performed by a human operator, which suggests purely subjective results. With the use of an automated vision system, the error in these results can be accounted for. Prior to the check, a gear marking compound is applied to the rear axle by a dispense system, which has flaws of its own due to uncontrolled parameters. The author of this thesis set out to find a solution to this problem, and made some interesting discoveries while going through the procedure.

this thesis concerns the design of a wirelessly controlled LED based Light bulb.

This thesis "Parallel Connections of Cells in Li-Ion Batteries for Eflex Architecture Electric Vehicles" examines allowable variation in cell manufacture, and the results of said variation on battery performance. It evaluates the effect that resistance, capacity, and self discharge variation have on cell terminal voltage, cell heating, and amp-hour throughput during US06 drive cycle charge depleting drive cycle, and charge sustaining drive cycle. The thesis also explains the model that was created in MATLAB Simulink for modeling parallel cell connection of cells.

This thesis project was undertaken to develop new software that would allow engineers quickly access information over Controller area Network. It was written in Visual Basic to allow future improvements to be easilty added. An aditional benifit of this thesis is a hardware cost saving. By replacing The current Vector CANcard with a USB to CAN hardware dongle a significant cost savings of roughly $500 per unit will be achieved.

Academic Thesis: To teach Mechanical Engineering students how to solve, analyze electrical circuit problems with System Vision for future applications in their careers.

Johnson Controls Inc. is currently developing a GPS embedded phone for the next generation telematics group. This phone is the first GPS device that will be produced by Johnson Controls. In order to produce this product, and to secure the future production of GPS products, Johnson Controls needs a bench GPS validation tester. This tester will allow Johnson Controls to demonstrate to its customer that the GPS devices are meeting specifications.

This thesis offers design procedures employed by Motor City Electric Company (MCE), in the creation of drawings and engineering work. This thesis describes and offers a new electrical engineering employee at Motor City Electric Company, with the necessary principles involved in executing an engineering job at MCE. This thesis is intended to explain the fundamental responsibility and demonstrate the tasks involved throughout the completion of his/her assignments.

The purpose of this document is to determine why parts are failing the final tester. Once the causes are determined, this document does an in-depth look into the two failure modes that account for the majority of the fallout. This document then gives a brief overview of the remaining causes of fallout. Finally, methods which could lead to the reduction and possibly the elimination of the fallout causes is given.

The design of a new simulator for 1.5 and 1.6 avionics ScanEagle aircraft at Insitu, Inc includes a payload emulator. The payload emulator is used to interface real, emulated and simulated payloads with the main emulator. To do this a signal routing circuit board is necessary. This thesis documents the design of the signal routing circuit board for the payload emulator.

For this thesis the author had the task of creating a standard on substation grounding. To do this the author reviewed various standards and conducted interviews with engineers and contractors. The author then compiled the information into a draft and had it reviewed by various engineers within the company. The final approved standard is revealed in the thesis as well as discussion on the sections within it.

This thesis provides information on the development, and testing of the forensic analysis tool Find Camera. Find Camera is a new tool create by the FBI stemming from research completed at Binghamton University. This tool was developed to create an efficient way to determine if an image has been manipulated. A series of test were completed to determine the validly of the results produced by Find Camera. These tests were designed to test different aspects of the Find Camera technology to insure a wide range of possible scenarios were included. Analysis of the data completed using the correlation data, which is an output of each test ran using Find Camera. This data was then compared to our expected findings, and other correlation data to determine if Find Camera was stable to be used in casework. The methods used in the thesis were validated by the alignment of our results and expect outcome. These methods proved that Find Camera is stable enough to be used in FBI casework.

In search of the best performance and value for their customers, General Motors utilizes a supplier bid process to determine the manufacturer of each audio system. In this process, multiple suppliers (Harman, Alpine, Bose, etc.) are provided with preproduction vehicles and challenged to design an audio system that meets the design specifications provided by General Motors engineering and marketing. The manufacturer that best meets the design criteria is rewarded with the contract to design and supply the audio system. Among the design criteria is a single number Listening Technology (LiT) score that summarizes the sonic performance of the system. General Motors currently relies on DLC Design to provide this score as a benchmark of vehicle audio system performance during the design and validation process prior to production. The LiT score is the composite of individual subjective audio quality judgments over several distinct performance categories: tonal balance, sound staging, imaging, ambience, distortion and noise, maximum output performance and soft clarity. In recent times, the operation of DLC Design has proved to be inconsistent. As a result, General Motors management wishes to bring the evaluation process in-house however, it currently lacks the infrastructure to perform these evaluations internally. Among the deficiencies is a functional reference listening room, a standardized evaluation procedure attune to internal resources and a training program for building and maintaining critical listening skills. These deficiencies are addressed in this thesis. The result of the investigation is a flexible software-base listener training program, a simplified subjective audio evaluation procedure suited to internal resources and the establishment of reference listening room. Additionally, a portion of this thesis discusses alternative testing methodologies and provides recommendations on future evaluation development.

This thesis examines the steps necessary to design and implement an data collection system in Microsoft Excel by implementing the Visual Basic code, which gathers and stores data from Allen Bradley Programmable Logic Controllers. This data gathering and transferring occurs over a corporately controlled Microsoft Network. This thesis deals with questions such as file architecture, scheduling frequency, scheduling methods, and overall design.

The new line of six speed transmissions being produced here at Warren Powertrain comes with a new line of equipment to assemble them. These new machines have a computer that will let the operator know when something has gone wrong with a fault message and some of the new messages that come up can be misleading to the maintenance department when they are trying to figure out what went wrong. When the maintenance department has to waste time trying to figure out what some programmer meant in a fault message or spend time searching for the problem no parts are being made which costs the company money. By making some of these confusing messages more to the point the machines can be fixed much quicker so they can get back to making parts. Also by adding a visual alert to where a problem with the assembly line itself is they won't have to keep walking up and down the line to find the problem. If the maintenance department already knows what and where the problem is they can go right to fixing the problem and get the line running that much faster.

Within the GM BodyShop there are roughly 33 different applications. They range from being applied by a moving robot arm, to applied using an operator to apply a clip of adhesive by hand. Also there are applications where there is a stationary gun, but the robot holds and moves the parts. One of the major issues in the BodyShop is sealer or adhesive ooze out, and problems on Class A metals. This is very costly, and slows production down greatly due to the time to clean the adhesive off of each part. If the adhesive happens to get past the inspectors and is heat treated it hardens and may have ruined the part all together. Another major issue is that the improper application of sealer may cause bleed through. This causes out and in dents on the part. A great example of this is when too much adhesive was applied to an area of the truck bed causing it to be deformed. The result of this was over 100 Boxes were to be scrapped. Another is problems with Hem flanges if the sealer isn?t located correctly; the Hem misses or is defective. If I can come up with ways to reduce or stop this from happening, it will be a significant cost reduction for the Plant.

The author reviewed the project costs for several soldering applications which OEM Dane Systems produced for Apollo Seiko. The old design process was responsible for high costs. The author reduced project costs nearly $2000 per machine, by creating and implementing standard hardware and software designs for new soldering applications. Continued use of the standard designs is recommended to improve their implementation process.

The goal of this thesis was to develop for the purpose of academic demonstration an operating D.C. to three phase A.C. inverter. The inverter should be programmable for different frequencies in the range of five to twenty kilo hertz. The device should also be capable of converting a 280 volt D.C. hybrid battery voltage to three phase A.C. source. Three phase D.C. to A.C. Converters have several uses, their major application is to control the speed of induction motors by varying the out put frequency. D.C. to three phase A.C. inverters are also used to retrieve stored energy in D.C. battery and to change solar panel D.C. output to A.C. source. For the purpose of this thesis the use of converting stored energy in a D.C. battery will be converted to a three phase A.C. source. The frequency of the three phase A.C. will be variable to show the difference of the outputs to be used as a teaching aid. A D.C., or direct current, is the continuous flow of electricity at a constant voltage. In an A.C., or alternating current, the voltage changes from positive to negative in a sinusoidal pattern. In a three phase A.C. system the three current sources A, B and C are 120° degrees out of phase with each other. Signal A is 120° degrees out of phase with signal B and signal A is 120° degrees out of phase with signal C. This is also referred to as a balanced a three phase system. The frequency of the A.C. signal is the rate at which the output wave form changes from a positive to negative voltage; this output is a sinusoidal wave form. The period of the wave form, or T, is the time it takes for one full wave form to occur. The frequency of the wave form is given by the following equation. T= 1/f Equation 1 The frequency of the A.C. three phase output will be adjustable, or programmable, to produce a frequency output between a ranges of five to twenty kilo hertz. With this device it will be easy to demonstrate the change in output from a D.C. to Three Phase A.C. Converters for various frequencies. With this device, an instructor can demonstrate the changes between frequencies to a class. Therefore, this device will eliminate the need for having several devices and multiple setups to deal with.

The current designs for Consumers Energy's High Voltage Distribution lines are either unreliable or too expensive. The wooden crossarm and brace design has small conductor spacing and requires many parts that could fail. The current horizontal post design has very large conductor spacing and requires taller poles to meet clearances. By using a shorter horizontal post insulator, the reliability of the horizontal post design can be achieved while also using shorter poles.

This thesis proposes a new method for modeling two dimensional non-rotational collision contacts. It includes the dynamics of both the collision forces and friction forces.

The final area at the General Motors? Lansing Grand River assembly plant is called Final Process and contains repair and alignment/configuration areas before the vehicle is shipped. In order to obtain high productivity and efficiency in the area, this study uses the real time flow data of the vehicles gathered by the WhereNet Wireless Tracking system installed at Lansing Grand River to analyze the throughput of Final Process. The data is studied statistically and then used to create a simulation model to test various hypotheses that can improve the throughput of Final Process.

The development of a demo room is expected to provide McNaughton McKay customers with a better understanding of the Integrated Architecture features of Rockwell Automation and Control Products. This is achieved through including multiple processors, safety devices, drives, motors, HMI's, etc. and organizing them into applications which might be seen on the manufacturing floor.

As technology continues to improve and advance, wireless data acquisition systems become more reliable and cost effective for the manufacturing industry. This thesis project proposes a wireless real time run time tracker system for a fastener manufacturer to monitor production and machine utilization and provide real time reports to supervisors and managers. With this system, the manufacturer can optimize their manufacturing process and have visibility on the shop floor; and therefore become more competitive in the fastening industry.

This Thesis covers the design process for an electronic device used to super impose text over video. The device developed will replace an older device currently in use by Peninsular Technologies. This Thesis required project management skills throughout the development process.

This thesis is an investigation of devices for automating capacitor bank controls in a utility transmission system. This thesis illustrates the process of researching and selecting an appropriate solution for updating automated control of capacitor banks within the client's requirements. The existing capacitor bank controllers in the client's transmission system do not use the standard communication protocol used by their Supervisory Control and Data Acquisition (SCADA) system. There has also been a recent internal power supply failure problem in the existing controller devices, so the problem of establishing communication with or replacing the existing capacitor controller devices has become urgent. Prior to the separation of distribution and transmission assets, CE was using a program called Capacitor Bank Monitoring (CBM) to control and monitor the capacitor banks; this program runs at each substation containing a capacitor bank. The METC master station will be communicating to each substation?s remote terminal unit (RTU) through a wide area network (WAN) using ITC standard network protocol, Distributed Network Protocol (DNP). Since METC uses a different protocol to communicate between master station and substations, there is no way for the existing capacitor controllers to communicate with the METC master station. Upon obtaining the list of criteria to be met by the final solution, research into each possible solution could proceed. This solution is then proposed to the employer company as well as the client transmission company for approval. This thesis includes all aspects of the final solution developement including research, evaluation, design, implementation and testing.

This thesis outlines the design and validation of a diagnostic test unit that will evaluate a Remote Keyless Entry (RKE) system, more specifically the General Motors Remote Function Actuator (GM RFA) manufactured by Omron Automotive Electronics, Inc. Within this thesis hardware and software configuration of the test unit will be examined, and a full evaluation of each hardware component will be analyzed.

Superior Controls is a system integrator with one area of specialty in traceability. Superior currently utilizes various technologies to mark parts with two-dimensional data matrices. The two-dimensional matrices are then used to track the part throughout its lifetime. Superior incorporates such part markers into its gage systems and integrates them into various other applications. The requirements of the marker are based on the material and matrix size. The two-dimensional data matrix best practices database allows for the user to check the applicability of a given marker to the part desired for marking or if marking it is even feasible, thus reducing research and testing time each time a new part needs to be marked. The database includes laser and indent part markers and was created using Microsoft Access.

This thesis covers the design, build and test phases of constructing an electric motor dynamometer for car seat assemblies using a PLC and other industial equipment.

The General Motors Shreveport Assembly plant uses vertical lift transfer systems to maneuver jobs from zone to zone. When a transfer system breaks down, a lot of downtime is incurred. The thesis will address incorporating a preventative maintenance system that will warn tradesmen and engineers before the failure occurs. The motor current of the system will be monitored during production hours. Two methods of monitoring the current will be used. The first method will monitor for 8 consecutive increases in current. On the last increment, an alarm message will be triggered, which will notify engineers and tradesmen of the increases in current. The second method will use a maximum current as a high limit. If the current exceeds 10 percent above the maximum current monitored by the system, an alarm message will be triggered to notify tradesman and engineers of the abnormality in current. This process will allow for repairs to be scheduled before the system fails.

The Kettering University Electrical and Computer Engineering (ECE) Department has recently purchased a number of Lego Mindstorms robot kits. The ECE Department wanted a high-quality design for a self-balancing robot to use for demonstrations and possibly as a platform for control system classes. From this thesis, a robot was designed, modelled, and created. This robot maintains balance and internal stability despite disturbances and changes in environment. Along with the robot design, several programming environments were used to determine which is more suitable for the task. From this thesis, identical robots will be able to be created for the purpose of demonstrations in the ECE department at Kettering University.

This thesis outlines the operational parameters of interest for power regulation in automotive HVAC systems. It summaries the parameters and metrics of interest at a system and component level. Several test methods are discussed to improve and standardize testing of blower speed controllers. Testing is carried out and the results are given for several competitive devices. Recommendations for improved processes and product are given.

The Tool Monitoring Adaptive Control, or TMAC, system from Caron Engineering International is installed on the GEN IV Block line?s OP60-A as well as the GEN IV Crank line?s OP10-3 machines. The TMAC uses a horsepower transducer to monitor in real time the amount of horsepower it takes to cut each part. It stores the charts as well as the event log, containing the hard data. By utilizing horsepower limits to notify the operator of the condition of the tools and when they need to be changed, the TMAC is essentially eliminating the scheduled tool change. This process is extremely beneficial to the plant because by treating each tool individually, this takes into account whether or not it has been reground, or any other issues that would vary from tool to tool. The GEN IV Block line?s OP60 had caused a major warranty for the plant costing more than two million dollars in repair and scrap costs. The 709123 tool, a long, coolant-thru, gun drill cuts the high pressure oil holes in the engine block which were found to have hairline cranks inside of them allowing the coolant and oil to mix together. The TMAC system monitors the tool on this operation to ensure that they are cutting quality parts, with a large focus on the 709123 drill, which had chronic breaking issues in the past. The tool has since then stopped breaking and OP60 has had no more major warranty issues. The GEN IV Crank line?s OP10-3 machine is the bottleneck of the department. After a major coolant change, tool life extension was sought after in this department due to very high tooling costs. The 630703 two step drill showed much room for tool life extension after examining the horsepower that it was capable of safely reaching with both the old and new coolants. By safely doubling the tool life of the 630703 drill on OP10-3, it was safe to move this process to the OP10-1 and OP10-2 machines. By cutting the crank line?s 630703 drill costs in half and by preventing the 709123 drill from excessive breaking, the two departments have a gross savings of more than $4000 per month from just two tools. The TMAC system demonstrated the benefit of treating each tool individually by improving quality, decreasing costs, and increasing production.

Güdel press transfers are complex systems that require testing and debugging prior to shipment. Creation of a testing platform for these machines was a vital step toward making shipment and installation deadlines. A design was needed for a system to test press transfer hardware and software, as well as simulate the physical movements of a stamping press, simulate press transfer tooling signals, and simulate the interlocking signals between the press and press transfer. Both hardware and software were designed to maximize the utility of the system while keeping costs low. The system cuts down the time needed to engineer, build, and install every press transfer that Güdel U.S. sells.

Requirements management is becoming more important in the world of technology everyday. This is especially important in the world of safety critical electronics. Hamilton Sundstrand is on the cutting edge with aerospace controls and is currently revising their requirements management process as part of an overall process improvement initiative. Hamilton Sundstrand, along with all other United Technologies companies, use Achieving Competitive Excellence (ACE) as their process improvement framework. As a provider of complex safety critical systems, Hamilton Sundstrand recognizes the extreme importance of requirements management and is striving to have a ?best in class? process. Through benchmarking and process investigation, improvement opportunities have been documented. The investigation consists of research into best practices as well as process flow mapping.

The objective of this thesis was to create a demonstration system for part traceability for McNaughton-McKay Electric Company to use as sales tool for the products discussed in this thesis. A vision and traceability demonstration system is now operational to help McNaughton-McKay show its customers the benefits of part traceability. This thesis briefly describes the hardware and software used to create the demonstration system, but it spends the most time describing the operation of the demonstration system to the users.

The old prototype life cycle tester was no longer sufficient to meet the testing efficiency nor the customer's test specifications. A new tester was designed and built using a servo motor and an updated PLC to enhance both testing accuracy and efficiency.

In order to maximize the efficiency of the Shreveport assembly plant body shop, the automated system for door panel stacking will be used to relieve the operator from a monotonous task. The majority of the body shop is already automated. The robots of choice are the KUKA robotic arms that are used predominately for welding. The same robots exist in storage from a defunct process, meaning one can easily be moved over to the body shop and placed in the necessary area without any added cost of buying a new robot. One six axis robot will be programmed with the necessary path movements and connected to a mass communication system connecting it to a PLC that will dictate when the robot will make said movements. It will pick a door fixture from a door stand. Two racks will be placed on each side of the robot. as it finishes loading one rack, it will begin loading the second.

This thesis compares two IPv6 transition mechanisms. The first method transitions a computer network into a dual-stack architecture, which means that it is capable of supporting and routing IPv4 and IPv6 packets natively. The second transition mechanism that is researched and tested is the tunneling method. Tunneling allows an IPv4 packet to be encapsulated in an IPv6 packet head and vica versa. This thesis tests tunneling IPv4 over an IPv6 WAN and also tunneling IPv6 over an IPv4 backbone. Once these methods were compared and the data analyzed it was determined that transitioning the employer's network to a dual-stack architecture would be the best practice.

Product quality and costs are two of the biggest concerns in a manufacturing environment. CNC machine cutting tools are essential for product quality, and reducing scrap is essential for decreasing cost. Some applications have a history of cutting tool faults, and these faults not only reduce product quality, but increase costs due to scrap. This thesis project is about integrating a tool fault detection system into a CNC machine to detect tool faults before a large amount of parts get cut by a bad tool.

Political, environmental, and market pressures have forced the automotive industry to develop alternative vehicles. Hybrid electric vehicles have become the best long term solution to satisfying those pressures. The unique combination of increased fuel economy, reduced emissions, refueling time, and easily accessible fuel sources put the hybrid ahead of other alternative vehicles. Economies of scale will reduce costs over time. Marketing strategy changes will bring hybrids to mass acceptance in the automotive marketplace.

The thesis discusses the design of an electrical DC power module for use with a multiplexing system in vehicle applications. CAN communications are used to switch up to two (2) 15-A loads, which can reduce heavy gauge wiring needed to run to accessible switches, provide additional features such as dimming or motor speed control, and improve vehicle system integration.

Automation of a manual process will decrease time to market and save time and money in the development of new products. Using National Instrument's LabVIEW programming language, a PXI chassis, and a California Instruments power supply, the validation processs for the Comfort Alert 2 - Commercial was automated.

The idea of the project was to build an interface board and integrate it with a commercial cell phone for use of remote controlling multiple electrical component of a given system. There are several systems researched such as an automobile and its electrical components (power windows, power locks, starter, lights) and some smaller household systems like DVD or VCR players. The intent is to call a cell phone and send the device a numeric message (eg: 555). The interface board reads the message and triggers the desired electrical component connected to it. To interrogate the wireless device for the numeric message, the unit was investigated to determine what points of the phone that yields the numeric message to the display: this is the headphone jack. This was researched and determined before the interface board is designed and built. The interface board is designed so that when it receives the desired signal, a processor decides what component of the system will be turned on or off and for what length of time.

The design and testing of a custom air handling unit controller to fulfill the need of a controller that can be used as a standard when a specific control system is not specified by the customer. The system includes all the proper I/O to control a air handling unit including (8) Digital Out, (16) Digital In, (4) Analog Out, (4) Temperature In, and (4) Analog In.

This thesis project evaluates technologies, such as microcontrollers, communication protocols, and communication integrated circuits, for use with the distributed embedded systems used in the Vehicle Systems Department at Sandia National Laboratories. The project included two main components. First, a network of embedded systems was designed and developed, the "demonstration platform", consisting of three unique microcontroller-based embedded nodes and one computer-based node. Second, a knowledge base on various distributed embedded system topics and technologies was compiled to aid the department in future development work. This document provides extensive documentation of the design and development phase of the demonstration platform network. In addition, the document includes, as part of the knowledge base, a survey of embedded communication protocols and the identification of protocols that could be used with future embedded systems development in the department.

There are currently two validation procedures for testing printed circuit boards at the TRW Auburn facility. The formats are the In Circuit Testing of boards as well as utilizing an Automated Optical Inspection system (AOI). TRW Auburn uses these systems in the manufacture of remote keyless entry circuit boards and tire pressure monitoring sensor and receiver boards. The continued utilization of this process for inspecting boards will be what is necessary for production unless significant changes are made to the packaging of ICs or chips we utilize on our surface mount process. These changes include but are not limited to BGA style solder joints, as well as stacking components on both sides of the PCB.

A tonnage monitoring process for the Lansing Regional Stamping Plant was in place before this project started. However, most plant personal were not following the recommended guidelines for the process to function correctly. This was due to a lack of understanding about the overall tonnage monitoring process, the lack of a standardized process, and the lack of training in the entire process. The process once correctly in place will help keep the presses safe from extreme tonnage situations that might cause harm to the press or die. It will help notify employees in changes in tonnage that could correlate to quality problems. The successful process will allow plant personal to understand and function inside the process without extensive knowledge not pertaining to their respective area. The process will be standardized in order to remain constant part to part and run to run. In order make this process successful a modified press curve was chosen to help protect the press and dies. Autotrak was chosen to help monitor part protection. The method of lowering the press curve was tested and validated during the test of GMX-966 B 3849 production part. Job element sheets were written to instruct plant personal in adjusting press protection curves, entering new die recipes and troubleshooting the tonnage monitors. Also general information and detailed troubleshooting guides were constructed and placed on each press line in the plant. The Autotrak test was not validated due to complications with the press ladder logic. Job element sheets were written to instruct plant personal on how to setup and use Autotrak once the logic changes have been completed. The continued implementation of the tonnage monitoring system to more production parts will help ensure any available means to protect the plants vested manufacturing assets will be correctly used.

Guage replacement of grinding application. Understanding of human to machine interface, as well as the components required to obtain the interface.

This project was to design an office chair seat back adjuster that is distinctive amongst the market and is cost effective. The design was incorporate into the angled J-bar of Gill Industries?, Inc., hereafter Gill, Genero tilt. Benchmarking will be utilized to create a best in class adjuster. The design development utilized Computer Aided Design (CAD), mockups, and Finite Element Analysis (FEA). The designs were evaluated on cost efficiency, customer's voice, and robustness of design.

To improve the shop floor production by networking drafting dept. and manufacturing equipment computers together.

The current "Hunt-and-Find" methods of document verification are very time-consuming and tedious. Boards can have from 50 to over 200 parts and take anywhere from 30 minutes to over 2 hours to check all the documents. Time and accuracy can be improved for engineering and manufacturing with a Module Repair Roadmap. The Repair Roadmap Generator should be implemented and the grid layout drawing completed to improve the document verification process.

Research different methods for wireless tilt and telescoping steering column control, as well as high speed streaming data networks for automobiles, and suggest best fit options based on research. Functional model covers wireless tilt and telescope control.

The purpose of this thesis is to document the development process of the CORE Data Acquistion PCB embedded softare.

This thesis evaluates three different ways of upgrading the distribution system in the Oscoda area. This data is then taken and evaluated to decide what is the most cost effective and reliable. The one that was decided on is both the most cost effective and the most reliable of all of the possible alternatives. This will allow Consumers Energy to make the necessary changes over the next ten years to maintain a reliable power system.

The thesis investigates the feasibility of implementing a special repair process that focuses on eliminating scrap and improving quality on certain parts of the truck that are prone to defects. This process will require additional manpower, facility modifications, as well as intensive training, but once complete, should move smoothly.

Motivation Proper testing of Steering columns is essential to ensure they perform to the design specs. The steering column tester built for this thesis project could play a vital role in the verification of functionality and safety systems. Problem Statement Existing prototype steering column electronics testers have been characterized as being inefficient, inflexible and unreliable. Therefore, a new test system is needed that will correct these conditions. Approach A new system was built to be an end of the line tester. It sits in a converted assembly station that is in concordance with the flow of assembly. The tester uses very efficient and reliable hardware and software from National Instruments to make measurements and collect data. The software program written in LabVIEW was easy to use and provided the flexibility needed for testing future steering columns. Results The tester met all customer specifications for testing steering columns. Despite the projects tight restrictions the project was completed on time and on budget. The tester was installed at the customer?s location without issue and did not hinder the assembly process in any way. Conclusions Because of the project?s scope and short time window it was difficult but rewarding at the same time. Using National Instruments hardware and software was a very good idea due to the ease with which they interact. The project in its entirety was a great success.

The need for an "intelligent" power management system in the test vehicle has been present for many years. General Dynamics Land Systems hopes to develop a new power management system that is based heavily on the technology of the reference vehicle. It is feasible to use a reference vehicle-based power management system in the test vehicle. If the vehicle loads are effectively assigned to specific Remote Switching Modules, the design would be successfully developed.

Siemens VDO needs a power source to produce enough voltage and current to supply a wireless transmitter for a wireless wheel speed sensor. The writer must design a system that is an adequate source for this application. This includes the testing of the power supplied from the VR sensor to the transmitter, and the lifetime of the system including the backup battery's assitance during low power generation.

The laboratory technology at our facility did not allow remote monitoring capabilities for lab equipment, which can result in out-of-tolerance test issues for lengthy periods of time. A communication system was developed, taking advantage of wireless technology, to allow remote monitoring capabilities for the lab environmental chambers. It was setup as a preliminary system, and can be improved by replacing the current computer used with a dedicated computer, which can be accessed through VPN.

This thesis was a design project, where a system was designed for a wastewater treatment center settling tank. The purpose of the design was to make a system that would integrate up to date technology and put the system on such a network that the information could be viewed and analyzed over a mile away at a remote station. In the end, the hardware for the system was researched and selected, and a test program was designed in order to prove the system could operate in the way that was necesssary.

This thesis outlines the development of a plastic component which is used to replace a metal component. Steel stampings are inserted into the plastic to make for a fire fail-safe feature. This thesis results in a cost reduction for the employer and the employer's customer.

The purpose of my research is to combine image processing techniques for tracking moving objects with data mining algorithms that categorize events, and attempt to automatically sort out which videos had objects that moved differently from other videos. The method used to track objects is the Lucas-Kanade method which finds points of high contrast in an image, and then tracks those points from one image to the next. This generates a 2 dimensional x,y movement history of the object. The movement history is then parameterized by an algorithm I developed which counts objects that move straight up and down as different than objects that move in circles or diagonals. The different samples are then clustered by using the k-means algorithm. This sorts all the samples into a user chosen amount of clusters. The videos most similar to each other as chosen by my algorithms criteria end up as part of the same cluster. This is all accomplished by C++ programming using an open source library for image processing called Open Computer Vision.

This thesis is a feasibility study of processing a polycarbonate hatch glass through the Bowling Green Assembly Plant. This thesis discusses the various issues created by processing the polycarbonate hatch glass through the current system and details out solutions for each problem with respect to cost and cycle time.

The gains made by the electronics industry in increased speed and decreases in size and cost have often come at the cost of component robustness and reliability. Currently NASA is mandated to renew emphasis on human and robotic interplanetary exploration, and commercial electronics components and packaging methods are often inadequate to fulfill this mandate. As part of continuing research and development efforts into electronics design and packaging, a technology called the fuzz button was proven to be an effective and reliable vertical interconnection for electrical signals. Fuzz buttons have low impedance to high frequency signals and resist thermally induced stress and mechanical shifting. Further work is planned to refine the technology for possible use to increase reliability of NASA's electronics designs, including systems in the new Ares I launch vehicle currently under development.

SourceOne Power Technologies utilizes the Infrared Thermography as a means of surveying our client's facilities to assess how their equipment is operating under full load. We are able to determine whether equipment is heavily loaded, connections within a system are loose or dirty, or whther or not circuit are unevenly loaded. These are some of the ways we are able to use this technology to offer our clients preventive maintenance recommendations that will assure them of their facilities well being. This thesis illustrates why SourceOne's Infrared Survey would be helpful for facilities.

Presents the results of the investigation to develop an efficient maintenance system for Saginaw Metal Casting Operations.

As an industry leader, General Motors is implementing energy saving initiatives in its plants. One initiative is 'Welding in the Dark', which reduces the illumination above manufacturing cells unless a condition requires fluorescent fixtures above the cell, to turn on. This can be achieved by modifying the standard controls architecture and software, by adding a new ControlLogix module and introducing another communication protocol. Since the initiative will be employed in future plants as well, I created a simple, comprehensive tutorial to aid future users in proper setup of all nonstandard devices. The package includes all software required, as well as diagnostic tools.

Implementing energy analyzer units were to control cycles run on an induction heat treating machine. The energy analyzers read power for a set number of time segments. The goal is to find the range of power at a specific time segment to give the print required effective case depth. The calculations to convert the energy analyzers time segments into a standard time in seconds allows me to locate the exact power inserted at any given moment during a cycle. The ability to correlate power versus case depth allows Machine Tool & Gear the option to track the necessary power during an entire cycle checking for power slumps or spikes. If the signature of a cycle runs outside the set parameters, the monitor will send a signal to the PLC to fault out at the end of the cycle identifying a bad part. With the implementation of these energy analyzers we have reduced the number cuts, the number of cut-off technicians and the supplies needed to cut the parts. The final graphs produced give a range of data to allow for specific parameters to be set on the energy analyzers themselves.

This thesis validates the tooling motion time listed in the General Motors Sequence Development Program (SDP). This program is used to aid in design for new automated production tools by visually listing the sequence of operation of the tool and estimating the cycle time needed to meet production rates. The time for the tooling motions have been examined by recording data from the field and comparing them to the time in the SDP.

It is very important for a design and test facility to know the measurement capabilities of its testing equipment. The acoustic bench in a previous study had shown a large variation due to GR&R. A new GR&R study was conducted along with automated data analysis of the complete frequency range. After the first two trials, the 20-300 Hz range was unacceptable according to industry standards. This problem was solved by changing the microphone spacing to 25 inches.

This project explains the development of a testing station for the electronics on an assembled Numatis valve manifold. The main focus bing that of the PLC program and construction fo the operator interface within the machine. The purpose which is to further the frowth of sales of the product line and expand on the quality of the shipped products.

A recommendation of the most practical and cost effective method of implementing servo actuated welding for hard-automatic fixture applications.

Design of a safety PLC and its ancillary components.

GM is replacing an existing self-contained fully-wired diagnostic tool with one that will function in a distributed wireless environment. The areas of concern include, but are not limited to, latency and throughput values under various wireless network conditions. The author performed tests that analyze the effects of bus and network loading on the parameters in question with and without enabled security algorithms. The typical dealership environment and the available wireless technologies, relevant to the project, will be discussed. The document provides the results of the test as well as a thorough test plan development with explanation of the software used to collect data.

This thesis covers the reserach, design, implementation, and testing of a supervisory control and data acquisition (SCADA) system over a wireless network. This system collects predefined system parameters from furnace and mix batching PLCs, and allows users to remotely view these predefined system parameters in real-time. Data is also collected from the PLCs and stored on the Globe Metallurgical network daily in a Microsoft Excel report.

Based on review of historical data from years of production, it had come to the attention of Magna Donnelly Electronics that elimination of voltage and current calibration on the Gen II VBC module may be feasible. The elimination of calibration is possible based on the positive results obtained from the final functional, locked rotor, and IPM tests. If the company should implement the calibration elimination, time and money would be saved in the process.

To show that HBAS EMC is capable of transitioning radiated emissions internal. Such a decision will eliminate the need for continual external testing which has demonstrated to be a timely and costly endeavor. In addition it will be shown that both facilities meet the requirements set by the customer and are able to perform the test in accordance to the specification. After testing is complete and the results are reviewed and compared a final determination will be made if HBAS EMC is capable of transitioning radiated emissions internal.

The current gage management system does not meet the specifications of the company. The goal is to have globally implemented software that meets or exceeds the desired specifications. I will determine whether we can identify, purchase and implement a qualified gage management system or create a Product Quality Management System (PQMS) based gage system.

The extent of this thesis is to determine how to properly shield a 24 inch diameter dual-axis Helmholtz Coil Compass Tester from all external field interference, without compromising the environment inside the Helmholtz Coil. The Helmholtz tester is used as a final line verification for the compass system located in Magna-Donnelly, now Magna Mirrors, mirror applications. Enclosure design will achieved by selecting a magnetic shielding material that is capable of repelling external magnetic and/or electric fields that may affect the tester set-up. The first step toward solving the problem is to first gain an understanding of the magnetic diffusion theory and how it pertains to the Helmholtz Coil environment. This will help to decide how fields react when a foreign object is placed inside the test field. The next step is to examine the object (the electro-chromatic mirror), being tested within the Helmholtz coil to understand how it responds to the field being created by the coil and how test parameters are established in order to deem the part as a pass/failure. Once reviewed, the next step is to investigate potential materials that may be used to shield the Helmholtz Coil. After a number of materials have been chosen, calculations are made in order to determine which material is the best candidate for the enclosure. A shielding material is chosen based on a number of factors such as attenuation level, permeability level, and dimension. Finally a proposal for the enclosure including cost per set-up is included within the document.

Development of Pocket PC inspection technologies has rendered paper inspection methods obsolete. Completely replacing these methods by implementing Pocket PCs is not feasible at this time. However, these devices could be used for yearly or biyearly inspections and data collection. Due to the disconnected substation environments, the devices will be difficult to use effectively.

Lack of an official method of controlling software backups has created a potentially dangerous situation. In the event of program loss, an outdated or nonexistent backup of machine software will lead to unnecessary downtime. An in house manual backup system would save approximately $50,000 by not hiring an outside firm of purchasing expensive software.

Quality control problems on the Export Veneer Clipping Line led The Freeman Corporation to contact Daqota Systems for a solution. Testing Demonstrates that machine vision along with motion control will lead to shorter cycle times, value optimization of veneer, and increased throughput upon completion.

The use of capacitive touch switch technology, OLED and EL lighting are examined to determine if they are a viable alternative to mechanical switches in an the interior setting of an automobile.

The GNUCAP circuit simulator is not yet a feasible alternative to commercially available simulators. By adding nore functionality to GNUCAP it may become a viable alternative to commercially available simulators. Addition of a lossy transmission line model to the GNUCAP simulator will add increased function- ality. A model described by Kenneth Granzow would allow for implementation of a lossy transmission line model for the GNUCAP circuit simulator.

This thesis explores the process of finding the best test buck for Magna Steyr?s needs. It will provide: (1) research that defines the needs that the buck should fulfill, (2) suppliers capable of providing the buck, (3) the options that each candidate supplier offered, (4) analysis of each of these options and (5) the recommendation for purchase based upon analysis of various systems

The purpose of this thesis was to discover the root causes of high and low g-force faults experienced at the sand compaction process at the General Motors Defiance Lost Foam Powertrain plant. The method of research was to use statistical engineering techniques to systematically analyze data pertinent to the process. All supporting data and the associated tests used to arrive at the conclusions in this thesis are documented within this report. In addition, preventive maintenance systems to prevent downtime attributed to g-force faults are discussed.

Due to the stamping process used, only half of the pre tin finish was wiped on to the contact point of Lear's Tuning Fork Terminal. Since a bare contact point could lead to fretting corrosion, which could result in terminal failure, post plating is necessary to market the terminal to Asian OEM's. After comparing various materials and post plating compositions, C18080 TR08 should be used as the base material and a post tin with a nickel underplate should be used as the post plating finish for the tuning fork terminal.

Design and creation of a programmable waveform generator.

This thesis provides a centralized reference guide that provides new employees with the ability to learn about new building construction. This thesis gathers organization procedures and design procedures used at Motor City Electric in a single document. Topics presented include: AutoCAD, power, lighting, and circuiting. Examples in each of these topics are presented for greater clarity. Calculations based on the National Electric Code and standards in Motor City Electric drafting provide an understanding of building/design procedures.

An analysis of Woodbridge Fremont's electrical distribution using NFPA 70E Arc Flash Standards is used to combat the increasing risk of electrical accidents in the workplace. Ageing electrical systems are being pushed to their limits causing the need to work on live systems to avoid lost production. The analysis will determine the proper personal protective equipment to wear for each electrical panel.

Automated Focus Algorithm for Forward Facing Imager Products illustrates a clear understanding of a focus model for automotive imager products using Micron CMOS imagers. Subsequently, the model will be used as a guideline to develop production imaging software and hardware. A clear method of focusing a lens to an imager, optically and mechanically, for any of the automotive CMOS imager applications in development was not clearly defined in a usable mathematical solution. Several images were collected using Micron?s MI-360 CMOS imager, a custom image viewer/logger, and a linear positioning stage with one micron resolution which provided a repeatable platform in which to collect line profile data as a lens was passed through its focal range. The images were post-processed using line profile slopes to uncover the contrast between white and black targets. The results from this thesis provide a clear path by which CMOS imagers used for processing roadway images can be focused precisely and quickly in a repeatable manufacturing process.

This thesis presents the investigation of the current energy usage of Cadillac Casting, Inc. and several solutions to reduce energy costs.

The i3 oven/press has the ability to adjust specifically for an IG unit?s characteristics. The oven/press is not currently operating to its potential because there is no way for the oven to accurately determine IG unit characteristics. A barcode system is a feasible approach for the oven to obtain the required information. A fully automated system is not a cost-effective solution to obtaining the information but a handheld barcode system is a feasible approach.

By developing a demonstration piece that shows distribution of control for an Advanced Front-lighting System, Visteon Corporation can show diversity to customers. Until now Visteon has only been able to supply a centralized system to customers, which limits the applications that AFS can be incorporated. By incorporating the system packaging, EMC, and EMI constraints can be overcome. This gives Visteon the ability to offer two control AFS systems.

The current apply algorithm of the Electric Parking Brake uses a constant current of 15 A to achieve and acceptable load. This strategy does not allow for consistent load at 0?C and below. Through the implementation of the look-up table that controls that apply current, acceptable loads can be achieved, down to -20?C. This look-up table allows the Electric Parking Brake's control algorithm to have a greater functionality.

The current data acquisition (DAQ) and analysis procedures used by AAM lack efficiency. The current DAQ system is reliant on a physical connection and takes up unnecessary space and the analysis is restricting on the engineers due to a required physical link between their laptop and DAQ. By replacing the DAQ with a device that communicates wirelessly and utilizes small-sized removable memory, engineers can store and analyze data in the field more efficiently.

There exists an increased interrest of fuel cell energy as a possible replacement fuel source for automobile engines. Eaton Corporation seeks an adaptaion of one of their products, superchargers, for the purposes of being an air delivery system for a fuel cell system. This system is a first attempt at producing the air delivery system, which is also a donation system for the Mechanical Engineering Energy Systems lab with a possibility for joining with a fuel cell stack. As such, the system is controlled using National Instrument's LabVIEW graphical development software.

The Air Force Research Laboratories required the development of a portable tracking system capable of measuring the static rotation of various tracking technologies. A tracking algorithm was developed capable of measuring rotation from images obtained at different positions. This algorithm was then evaluated using software and hardware tests and determined if it had sufficient accuracy to test other tracking systems.

A comparison of RI testing in the ALSE chamber for the frequency range of 200 - 2000 MHz between HBAS EMC Laboratory and an accredited Third-Party Laboratory was done to determine if HBAS should transition ALSE radiated immunity testing internally. Such a decision would eliminate the need for external testing, which has proven to be expensive and time consuming. This validation experiment shows that HBAS is capable of performing RI testing that meet the requirements of a the customers specification.

The topic of this thesis presents the method of coming up with a method for combining range information and images by using laser scanning system to capture data. We are interested here in finding an algorithm that will help us apply edge detection and object recognition techniques for an image. The thesis is also expected to provide methods of image segmentation with range information by having an enhanced edge detection based on range gradient, time derivative of range, and information in successive frames as we have done using different types of filters. In this thesis we were able to find the answer about the ability to combine range information and images by using laser scanning system to capture data. Also, we found an algorithm that will help us apply edge detection and object recognition techniques for an image. The second phase of the project shall include an advanced experiment with a single 3D-plane & Image Capture. This recommended mechanism would be mounted on a vehicle with the ability to gather test data and have a 3D scan.

Multiple manual entry of project BOM information and inaccesibility of order tracking information has increased increased the potential for errors and miscommunication and complicated information gathering efforts. A custom integrated database system will improve the efficiency of BOM and PO processing and inter-department communication. If the designed system were implemented, it would eliminate multiple entry inefficiencies and make all information available to all employees.

This thesis contains design work and development materials for the fabrication of a tapping machine that operates with less downtime and improved user and machine controls. Newly developed diagnostic features in a more advanced ladder logic program design will keep the machine operating faster and more safely than similar equipment of an older vintage. The thesis will also discuss the adoption of a schematic drawing ideology and technique that is customized for optimal functionality in a specific manufacturing environment. Likewise, it will help to ensure machine operation can be maintained.

The Power & Free overhead conveyor control system is failing to meet production schedules. The current system was installed in 1970 and aging components are no longer supported by the manufacturer. Replacing the controls with an Allen-Bradley ControlLogix PLC provides for continued reliability and support. The addition of the PanelView Plus terminals and the HMI will aid in troubleshooting and maintaining the system. A modern system will also meet NFPA70e arc flash suppression safety guidelines.

The validation of the SmartBar? would take many hours to complete each cycle of validation. It was explored to see if the automation of the validation would be cost effective and what the best ways were to automate the system. It was found that the timesavings over the short and long term would make this product desirable. Different ways of automating the system were explored. It was found that using a combination of LabVIEW with sensors and actuators would achieve the desired results. The methods used to research and built the system were explored and explained. A final system was developed and deployed.

This thesis evaluates the accuracy of digital imagers with rolling shutters relative to digital imagers with global shutters. It explains how the imagers work and the difference between the two. Then, after testing, it shows the amount of error in each.

The methodology in this thesis was developed from a detailed analysis of the fault data collection systems used at Flint Engine South. Extensive data was collected from each system and each was individually analyzed as to its relevance to the overall goal of the project, which is to minimize machine faults in order to increase production up-time. The methodology created meets the goal of the project and can also be implemented into other departments to achieve the same goal.

This thesis investigates the feasiblity of implementing a process that will enhance the facility engineering process. Through this process, the employer facility will become more efficient in setting temperature controls as well as using manpower more efficiently.

The Thesis entitled "Machine Control System: Design and Program" documents the process of designing and building an automated industrial machine from start to finish. The thesis covers the process from the quotation stage, through the design and build, and finally the installation of the machine.

DP Tool & Machine's previous method of checking DC motor frames was insufficient for the volume of frames being produced. The purchase of a shop-floor CMM and subsequent proper programming provides the ability to resolve this issue. The new methodology has proved effective in both reducing the amount of time spent inspecting frames as well as increasing the total number of frames inspected.

Current PC controllers have run into software and hardware limitations due to age of equipment and lack of new developer updates. This leaves the systems open to viruses and hard drive crashes that could be cause severe downtime, thereby crippling production. By upgrading to newer PLC controllers, increased stability and protection from viruses ensure that production lines stay running without controller malfunction. This will also decrease losses in both maintenance and production.

This thesis project addresses a common problem in the brake evacuation and fill process: the inability to achieve consistent and accurate predictions of the amount of time required for the process to completely evacuate a brake hydraulic system of air prior to filling with hydraulic fluid. The following paragraphs give a brief introduction to this problem.

The development of electronic control modules (ECMs) for automotive applications presents the need for an electrical signal monitoring device, which should be inline and independent. Electrical signal inputs and outputs to the ECM must be monitored during development and validation of the control system. If a small quantity of Observer devices were produced, accurate signal measurements would be available to the Electronic Control Systems engineers.

This thesis provides the methodology by which an injection mold will be statistically proven to be capable of producing parts which meet all company specifications given a controlled operating environment to meet FDA regulatory requirements.

Over the process of several years, General Motors Powertrain Bay City Plant has caused several customer disruptions due to lack of chamfer on the Piston Pins that they machine. To detect Piston Pins without chamfer, vision inspection systems have been designed and installed by engineering companies for two of four lines in the Piston Pins machining department at a cost of roughly $24,000 each. The creation of a vision system similar in function but with a reduced cost to be implemented on at least one of the remaining lines will provide for improved output quality of General Motors Powertrain Piston Pins. By designing and creating the system at the plant, the company saved roughly $16,000.

This thesis documents original work done by the author to design and implement a manufacturing equipment data collection system at BD in Canaan, Connecticut. The intended purpose of the data collected supports Lean Manufacturing principles, Six Sigma initiatives, and product/batch traceability throughout the manufacturing process. The system implemented uses an Ethernet network to connect Allen Bradley PLC's (SLC, Micrologix, and ControlLogix) programmed with RSLogix 500 and RSLogix 5000. Rockwell Software RSSql was programmed to read information from machine PLC's and write into an Oracle database. Apriso Flexnet software is utilized for taking this data to report OEE and to automate transactions required by SAP R/3 software. The scope of this document includes the purpose of the data collection system, the strategy for collecting data, the creation of a network connecting 28 machines, and programming the PLC and RSSql.

General Motors - Controls Conveyors Robotics and Welding (GM-CCRW) deploys DeviceNet as a device level network with hopes to transition to an Ethernet based network by 2009. Evaluating Ethernet to replace DeviceNet with CCRW's desired functionality proves not cost effective until beyond this date. Ethernet is recommended to transition in steps where it offers advantages and overcomes DeviceNet limitations. This report provides awareness of issues and potential solutions when reevaluating Ethernet deployment.

The mission of this senior thesis project is to investigate current in-vehicle communication protocols; comparing them to the new SENT protocol and investigating the methodology of engineering the SENT signal to best fit the emission specifications prior to lab test time.

In order to reduce equipment and operating costs, vision guided robotics are a possible replacement for some expensive fixturing systems. The use of vision guided robots has the potential to allow operation designs to be simplified and the amount of hardware reduced. This also decreases equipment and maintenance costs while often increasing flexibility. Implementing vision guidance is recommended for use in appropriate situations to provide cost savings on initial installations and long-term operations.