Drumstick Sanding and Cutoff Process Design at Vater Percussion

The objective of this project is to help Vater Percussion implement a new sander in their Holbrook, Massachusetts factory. Our secondary objective is to advise Vater in finding new ways to improve their cutting process. The rationale for this project was to increase Vater’s throughput - back to pre-COVID levels, and to improve the efficiency and safety of the cutting process. The state of the art is that Vater needs a new sander that is both more efficient and easy to use for operators, and an alternative cutting step that is small, efficient, safe, and flexible for potential modifications. The methods we used in the completion of this project included direct observation of Vater’s processes, benchmarking of Vater’s competitors, an axiomatic design decomposition, and value stream mapping. The results showed that Vater’s new sander had a significant effect on the process. The takt time of the process significantly improved, and the percent of non-value added time decreased. In addition, the cost benefit analysis of a potential bandsaw purchase showed that a new bandsaw would be a worthwhile investment for Vater. We concluded that Vater is already in a much better position in improving their throughput than prior to our project, that a new bandsaw is a necessary next step in process improvement. Vater does, however, still have room to improve their process in the future

GaN-Based DC/DC Converter for Fuel Cell Applications

Our team developed a lightweight DC/DC converter to interface with Honeywell’s 600 W, 51 hydrogen cell stack for unmanned autonomous vehicle applications. Using gallium nitride (GaN) FETs, the converter minimizes size while handling an input voltage of 20-60 V and providing an adjustable 18-65 V output. The project followed a timeline through research, simulation, schematic design, and PCB layout to achieve a prototype board for Honeywell.

Standard Error Estimates for the Survivor Average Treatment Effect

This project presents a novel method for estimating treatment effects in trials with high attrition or dropout rates. Specifically, the study builds on a principal stratification approach to estimate the average treatment effect for students who would take the post-test regardless of treatment. Previous work developed causal estimators for principal scores, and this report extends that by introducing a method to calculate the standard errors of these scores and effects. The study applies this approach to an educational experiment evaluating two online learning programs among middle school students during the COVID-19 pandemic

Developing an Intelligent System for Maximizing Photovoltaic Array Output Power Based on Varying Environmental Conditions

Photovoltaic power generation is highly sensitive to environmental factors such as sunlight intensity and temperature, directly impacting output power. Maximum Power Point Tracking (MPPT) algorithms are employed to continuously adjust the operating conditions of the panel, such as the voltage or current, to optimize power with changing environmental factors. While traditional MPPT algorithms like perturb and observe (P&O) are computationally efficient, they struggle with oscillations and inefficiencies. More advanced MPPT algorithms can be more efficient but have increased computational complexity. This project developed a hybrid MPPT system that combines multiple algorithms and environmental sensors to dynamically select the most effective algorithm in real-time

Development of an MRI-compatible mock circulatory loop

This project involved the construction and analysis of a mock circulatory loop that is compatible with Magnetic Resonance Imaging (MRI) and can replicate flow conditions in vitro. Several experiments that involve flows which may be encountered in biological conditions were carried out and the relevant data was collected. In all cases, the SONOFLOW CO.55 Flow Sensor was used to read the flow to provide a reference value to the data collected. The first experiment involved Particle Image Velocimetry (PIV), where a video of the fluid flowing in a clear tube was analyzed using associated software packages, in this case PIVLab. Subsequentially, experiments utilizing Phase Contrast-MRI (PCMRI) were employed, conducted using the GE Signa Premier 3T located at PracticePoint and supervised by an MRI Operator. Over several trials, the magnitude and direction of flow were varied to observe how the velocity profile of the fluid changed under these conditions. From the PCMRI Experiments, a series of Digital Imaging and Communications in Medicine (DICOM) files were obtained and post-processed in MATLAB to obtain the readings of velocity and flow at each position. The same technique was applied in our Backward Facing Step (BFS) test section, which allowed us to image the more complex flow that arises from this geometry. This project provides the basis to which future projects can build off of, with this project demonstrating how both PIV and PCMRI can be used to analyze the flow of fluid through a subject and post-processed using the relevant software. This project has important implications for helping to resolve issues relating to heart disease and other health conditions that pertain to fluid flow in the human body

Axial Flux Motor Development for Reduction-Less High-Torque Robotics Applications

Motors in many high-performance robotics applications must provide high torque outputs at low duty cycles. A higher torque motor enables a more responsive actuator under load by reducing or eliminating the gear reduction in series with the motor. Due to the low duty cycle, the limiting factor in the torque output of motors in these applications is more often the magnetic saturation of the stator iron rather than the thermal properties of the motor. In this work, the authors provide a unique approach to torque optimization for this application, describe the process of designing, manufacturing, and testing a novel modular hybrid flux motor following these principles, and provide analysis and data on the torque performance of the resulting motor when compared to several common configurations

Elevating Well-Being; A New Vision for Health and Fitness

This project is a new vision and approach to elevating well-being, health, and fitness through a structural addition to the WPI Recreation Center. Our team researched elements that negatively and positively affect mental health and determined the important correlation between physical activity and mental well-being. This project proposes a new structural addition to highlight elements found in our research. We completed a structural analysis, architectural design and plan, schedule, and estimate to aid the new structure. The addition includes a functional fitness turf, green roof, individual workout suites, wellness hub, mind body studio, juice bar, walking pads, golf simulator, sauna and steam room, locker rooms, and other recreation center upgrades that will contribute to student and community wellbeing. This project outlines the methods used to develop the final deliverables and provides the results of our work, with discussion on areas of the project our team feels there is room for expansion by another MQP team in following years, with a list of future recommendations

Renovation of WPI Townhouses for Community Space

Worcester Polytechnic Institute has invested time and resources into exploring potential redesigns and renovations of the Townhouses to increase the housing option’s desirability. This Major Qualifying Project focuses on designing and renovating the Townhouses to incorporate a community space using architectural design and structural engineering analysis. The scope of the proposed renovation includes the design of architectural programming and concepts, the structural schemes of a wood structure and a wood-steel hybrid structure, and mechanical systems based on changes to the building envelope and building thermal calculations

Enhancing the Accessibility of Privacy Policies Using Generative AI

This project addressed the complexity of privacy policies, often inaccessible to users due to their length and technical language. To address this challenge, our team created a generative artificial intelligence (generative AI) WebUI tool for summarizing privacy policies. The tool uses user-specific inputs, including age and education level, to tailor privacy policy summaries to a user’s level of understanding. Furthermore, we incorporated prompt engineering and readability metrics for improved comprehension of privacy policies. The tool was developed and refined based on feedback received from surveying 100 WPI students and beta testing our tool with 5 WPI students. By simplifying privacy policies, this tool empowers users to make informed decisions regarding their digital privacy, and this tool has the opportunity to be further developed by future teams

Automating Resonant Frequency and Weight Characterization of Percussion Drumsticks at Vater Percussion

The objective of the project is to design an automated system to sort drumsticks based on weight and resonant frequency for Vater Percussion. The rationale for the project is that by automating this sorting process, Vater employees will be able to spend more time on other processes in their facility that require more human attention and industry knowledge. The state of the art is a manual, human-run sorting process with three workstations. The methods used include axiomatic design, time studies, financial analysis, CAD modeling, and an in-person simulation of our design with the use of a collaborative robot. The results show that we were able to design a sorting system with independent tasks that decreases processing time and necessary man-hours. Our team can reach two fundamental conclusions based on the results. First, an automated sorting system is effective in relieving personnel to focus on more important tasks. Second, an automated sorting system has a positive return-on-investment due to the man-hours it saves. Our proof-of-concept demonstrates the effectiveness of using a collaborative robot to automate the stick sorting process and achieve the results stated above