Force feedback control of SWM (spot welding machine) system

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14 Νοε 2013 (πριν από 3 χρόνια και 9 μήνες)

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FINAL YEAR DESIGN PROJECTS OF MECHANICAL ENGINEERING

200
8
/200
9


Force feedback control of SWM (spot welding machine) system



Group size:
5
-

6

students



Supervisor:

Professor
Lilong Cai


(
E
mail:
me
lcai
@ust.hk
)


Descr
iption:




This FYDP aims to develop a
n automatic system to
control the welding force applied during the whole
welding process. This project

shall include
building
a

force analysis model, constructing a specific
hardware signal processing circuit, and desi
gning a closed
-
loop force control module
. The

force
analysis model is responsible for analyzing the force distribution based on the architecture of the
welding machine and meanwhile predicting the optimum force effect point to place the force sensor,
the s
pecific hardware circuit is used for sampling and processing force signal, while the closed
-
loop
module is dedicated to implementing force control algorithm

and controlling the welding process.



T
o achieve this objective, the FYDP team
will conduct
the fo
llowing tasks:


(1)

Understand the engineering background.
Through a l
iterature review

and data collection, t
he
students
will

understand the
importance and effect of welding force during the
welding process,
the force distribution analysis based on the archite
cture of welding machine, method

of
force
signal sampling and processing, and ways of
automating the
signal control
process.
Based on
this survey
, the target
specification

of
the
automatic

system

will

be proposed.


(2)

Build a force analysis model
.
In order
to sample the welding force signal precisely, we should
determine the optimum point where the force sensor can be placed.
Here,

a
force analysis model
will be built to analyze the force distribution based on the architecture of the welding machine.
Possibl
e software, such as ANSYS, could be utilized.


(3)

Construction

of a

specific hardware circuit for signal processing
.

T
he

circuit

should
consist
of filters, amplifiers and some ICs.
Th
is

module should be able to

effective get ride of the noise
existed in the s
ampled force signal. The processed signal will then be a controlled input for the
closed
-
loop force
-
control module
.


(4)

D
esign
of a closed
-
loop force control module
.



Digital feedback control is need to be designed. Most likely, C++ is needed to wri
te up the
control algorithm. Experimental tests need to be conducted to verify the effectiveness of the
proposed controller.


Job assignment among the team
:

2

students are responsible for
building the force analysis model
.

2

students are responsible for t
he
construction of specific hardware circuit for signal processing.

3 students are responsible for the closed
-
loop force control module.

All
7

students will participate in the
integral test
and data analysis.

The project leader will coordinate the whole p
r
oject.






FINAL YEAR DESIGN PROJECTS OF MECHANICAL ENGINEERING

2008/2009


Development of an Ozonation based Catalytic System for

Gaseous

Pollutant Treatment


Group size:
5
-

6

students



Supervisor:

Prof.

Christopher Chao

(email:

meyhchao
@ust.hk)



General Description
:


Ozone is a strong oxidizing agent and can break down organic pollutants into simpler products.
However, pure ozonation in air leads to poor performance due to short physical time of contact among
pollutants and the reaction agent an
d the leftover ozone residues can be a second pollutant causing
health problem. Passing ozone over micro
-
porous catalysts can sustain better reaction performance and
at the same time help retain intermediates in
adsorbed

phases in the porous materials. The

reaction
temperature can be lowered which provides energy saving incentive for industrial treatment processes.
In indoor air condition, VOCs can also be removed at an enhanced efficiency via the combined
ozone/
catalyst

arrangement. This project will look
into designing such kind of system and evaluate its
performance over different conditions. Various porous materials can be studied such as recycled ash
materials from biomass burning which provides cheap alternatives to indus
trial contaminant treatment.



Scope of Work:




Identifying target gaseous pollutant and selection of suitable test gases for performance
evaluation




Identification of porous materials for use as adsorption media and catalysts (existing
commercial materials or biomass based recycled mat
erials)




Calculation of ozone dosing requirement, quantity of the porous materials in the ozonation
catalytic reaction system




Design of casing and other flow parameters, low pressure drop design and low noise level
consideration, regeneration set up, etc.




Design of protocol for system performance evaluation




Experiments and Performance Evaluation


Some of the above scope will involve all students to work together. Then the
students

will be assigned
with individual tasks. Both laboratory
-
based experimenta
l works and system fabrication in mechanical
engineering workshop will be required. It will be an added asset if some students in the group have
good chemistry background.

FINAL YEAR DESIGN PROJECTS OF MECHANICAL ENGINEERING

200
8
/200
9



Precision Adjusta
ble Workholding Devices and Experiment Design


Group size:
5
-

6

students


Supervisor:

Prof.

Yongsheng Gao

(
E
-
mail: meygao@ust.hk)



General Description


Mechanical devices will be developed to offer enhanced functionality and performance for precision
gr
inding systems, which are very important in precision engineering and nanotechnology. Due to
workpiece mounting and size errors, efficient and accurate adjustment of workpiece orientation and
position will be required prior to an actual machining process.
This is particularly important for
machining applications in optics and semiconductor industries in which material stocks to be removed
are typically very small. Currently an adjustment process of the type is very lengthy in time and as
such productivity i
s significantly affected. In addition to mechanical device development, experiment
design and experimental testing studies will also be conducted for precision machining research.


An objective of this project is to design, manufacture, and test mechanical

devices as smart auxiliary
tools for precision machining to offer efficient and accurate workpiece orientation and position
adjustment to solve the above problems for precision grinding. This process is widely used in
manufacturing, photographic goods, op
tical and electronics industries. Another objective is to conduct
experiment design and experimental testing studies for precision machining research.


The students of this project team will gain knowledge and experiences in precision design and analysis,
FEA, pneumatic device, precision optical measurement, precision machining, experiment design,
mechatronic devices, and data processing. The knowledge and experiences should be useful in many
industries.


Scope of Work


Mechanical devices are expected to be

developed in this project as precision grinding auxiliary tools
with enhanced functionality and performance compared with existing designs. Experiment design will
be delivered and experimental testing studies will be conducted.


For the mechanical device
development, two designs are expected to be delivered to facilitate efficient
and accurate workpiece holding and fine position and orientation adjustment for both thick and thin
workpieces. For the first design, the mechanism of mechanical clamping will be

used to deal with thick
type of workpieces. For the second design, the mechanism of vacuum clamping will be used to deal
with thin and easy to break type of workpieces, which are very typical in semiconductor industries and
micro optics industries.


For b
oth designs, the feature of compact size and the feature of easy and efficient position and
orientation fine adjustment are expected. The fine adjustment functionality should be a key feature for
the two designs. In addition, the stiffness of the designs i
s expected to be high to facilitate micro/nano
precision machining.


Existing designs are available for reference. The existing designs have problems in clamping, stiffness,
and device size compatibility. The existing designs were not fully tested under gr
inding conditions.


The design elements include mechanical design, pneumatic system design, experiment design for
performance testing, and also experiment design for precision machining research.


Tasks and Job Assignment


For the mechanical device develop
ment, the tasks are:


(1)

Literature review of the existing workholding principles and technologies for understanding the
background information, examination of the existing designs, and specification development;

(2)

Concept design, modeling and FEA analysis, and

detail design;

(3)

Manufacturing, assembly, experiment design, precision and stiffness tests, and device fine
tuning;

(4)

Grinding tests, and system performance evaluation.


A sub group will be assigned to complete the above tasks.


For the experiment design and
experimental testing study work, the tasks are


(1)

Literature review for understanding the background information;

(2)

Experiment design, component design and machining for conducting the necessary
experiments, and modeling and computational analysis;

(3)

Experiment
setup, and fine tuning of the testing devices and equipment;

(4)

Experimental tests, data collection, and experimental data analysis.


Another sub group will be assigned to complete the above tasks.




FINAL YEAR DESIGN PROJECTS OF MECHANICAL ENGINEERING

200
8
/200
9


REDOX Energy Storage System in a Solar Photovoltaic System




Group size:
5
-

6

students



Supervisor:

Professor Chin
-
Tsau Hsu

(
E
mail:
mecthsu@ust.hk
)



General Description
:


One of the hindrances to the use of

renewable energy such as solar
and wind energy

is the
intermittent

nature of
these energy sources. For instance

in a solar photovoltaic power generation system
, shades from the clouds or
rain and the

earth
mass during the night
can
block the sunlight and

discontinue

the
solar energy
supply
to the
system
. E
nergy

prod
uc
ed from the solar photovoltaic system can be stored in the form of chemical potential
energy in rechargeable batteries such as lead
-
acid or lithium batteries
, which in turn

supply
the electr
ic power
when

the sun

power

is
not
availabl
e
. A newly
-
developed REDOX energy storage system is a flow battery
system
in which electrolyte containing one or more dissolved electro
-
active spe
cies flows through a power
cell/
reactor
where

chemical energy is c
onverted to electricity

during the
discharging

process and vice versa in
the recharging processes. In a REDOX f
low cell, both the anode and cathode reactions take place in solution

and

on the surface of inert electrodes acting as current collectors. The r
eactants flowing across these electro
des
come from containers connected to

the electrochemical cell; they are prevented from mixing in the
elec
trochemical cell by a specially
-
chosen membrane: an ion selective membrane or a micro
-
porous separator.

The obje
ctive of this project is to design and fabricate a prototype of REDOX battery

system

to store the
electri
cal energy

generated from an existing solar photovoltaic system to demonstrate the technical feasibility of
this new technology

for energy storage
.


Sc
ope of Work:


Task 1:

O
peration of the photovoltaic power generation system

A
photovoltaic

power generation system integrated with a
set

of lead
-
acid batteries
ha
s

been

installed on
the roof of the academic building. Operation data of this power generation

system under different
weather conditions
and
in different seasons of the year will be collected. Maximum power tracking of
the photovoltaic power generation system will be measured under different weather conditions with the
lead
-
acid batteries

disconne
cted,

to
obtain

the
maximum solar
power
available

for

charg
ing

the REDOX
flow batteries to be
designed and fabricated

in this project.


Task
2
:

D
esign and fabrication of a REDOX flow battery

A REDOX battery

system
consists of two electrolyte tanks

and an e
lectrochemical cell. The tanks
contain

liquid solutions of
electro
-
active species in different oxidation
states

separately
. These energy
-
bearing liquids are c
irculated through the electrochemical cell

by pumps. The
cell consist
s

of two
electrodes and
two h
alf
-
cells that are separated by a membrane.


In the half
-
cells the electrochemical
reactions take place on

the

inert carbon felt polymer composite electrodes from which
electrical
current
may be used to charge or discharge the battery.

In
REDOX

flow batter
ies the fluids contain dissolved
species that can be electrochemically oxidized or reduced to store the energy.


The cell membrane must
effectively block the crossover of the electro
-
acti
ve species from one half
-
cell to the other.

A prototype
of this ener
gy storage system will be designed and fabricated
.


Task
3
:

Performance test

o
f the REDOX flow battery in

the
solar
phot
ovoltaic power generation syste
m

The existing lead
-
acid battery in the photovoltaic power generation system will be replaced by the
REDO
X flow battery system.
Electricity produced by the solar photovoltaic power generation system is
used to charge the REDOX flow battery.

T
he

performance of the

REDOX flow battery
during

charge
and discharge
will be evaluated
.

FINAL YEAR DESIGN PROJECTS OF

MECHANICAL ENGINEERING

200
8
/200
9


Fabrication and characterization of GFRP Re
-
bars made from
nanocomposites for concrete reinforcement


Group size:
5
-

6

s
tudents


Supervisor:

Prof. Jang
-
Kyo KIM


(email: mejkkim@ust.hk)





General Description
:




Steel
corrosion in reinforced concrete is responsible for billions of dollars in repair cost each year over
the world. To remove this major culprit of the infrastructure decay problem, glass
f
iber
r
einforced
p
lastic (GFRP)
coposite re
-
bars have been developed as

the replacement of steel for reinforced
concrete structures. Although GFRP has already been employed for many years, their widespread
application is still limited by a number of concerns. The problems include: i) static fatigue of fiber
glass caused by th
e moisture diffused into the defects; ii) the corrosion of glass under high pH value,
leading to significant reductions in GFRP strength. To make things even worse, the combination of
moisture diffusion, alkali attack, and sustained loading can significant
ly reduce the strength of GFRP;
iii) weakening of GFRP performance in case of fire. Designers have to increase the thickness of
concrete additionally, making the material inefficient yet the available space even narrow.


To eliminate the above problems, a
feasible approach is carried out in this project to improve the
barrier properties of the polymeric matrix against alkali/moisture and to increase its heat distortion
temperature by incorporating organically treated nanoclay. In the previous FYDP, nanoclay

is
successfully dispersed in polymer matrices such as polyester and epoxy
-
vinylester resin to form
intercalated/exfoliated nanocomposites. We have already built up fixtures and devices to coat single
and bundle glass fibers with nanocompopsite resin for e
n mass automatic process.


In the coming year’s FYDP, we focus on examining the long
-
term mechanical performance of the
nanocomposite coated glass fibers and the GFRP bar after ageing in simulated adverse service
conditions, including alkaline solution an
d high temperature. Thus, the present project aims at
establishing methodologies, optimizing material and processing parameters for developing
nanocomposite reinforced GFRP rebar prototype. Fabrication of samples will be performed using the
tools and fixtu
res developed previously: i) preparation of coating resin incorporated with nanoclay; ii)
coating of glass fibers with resin; iii) molding of coated fibers to form desired shape of specimens and
rebars. Characterization of their mechanical properties will
be carried out, including water/alkaline
solution permeation test, tensile loading after alkaline corrosion, mechanical tests after exposure to
elevated temperatures.


This project is supervised jointly by Prof. CKY Leung (Civil Eng), Dr Steven Lee (AEMF)

and Mr.
LIU Mingyang, (PhD student).


FINAL YEAR DESIGN PROJECTS OF MECHANICAL ENGINEERING

200
8
/200
9



Vertical Axis Wind Turbine


Group size:
5
-

6

students


Supervisor: Dr. S.C. Kot



(Office: Room 2560; Tel; 2358 7187; e
-
mail: mesckot@ust.hk)



General Description:


Wind power is a matured renewal energy source. Most of the commercial wind turbine for electricity
generation is of the horizontal axis type. The other type, vertical axis wind turbine has the advantage
of not having to swing into t
he wind direction for maximum efficiency. Its nickname is “egg beater”.
Compared with horizontal axis wind turbine, it is more visually appealing. Some land developers
would like to incorporate vertical axis wind turbines into the design of their “green”
housing estates.
They could be installed on the roof
-
tops or in open areas and double up as kinetic sculptures. The aim
of this project is to design and build a kilowatt class vertical axis wind turbine. The size of the turbine
is approximately one to t
wo meter tall.


Scope of Work:


The group leader will perform the system integration of the following subsystems and oversee the
keeping of the work schedule. He should check the correctness and then optimize the design.


An aerodynamicist is required to d
esign the aerofoil shape of the blades and the attachment to the axis
plus control flaps if necessary.


A structural analyst is required to calculate the stresses under operating and typhoon conditions and
design the supporting frames etc.


A material expe
rt is required to determine whether metal or composite material should be used for
fabrication with regard to the stress calculations and ease of manufacturing.


An electrical expert is required to design and build the system for electricity generation, st
orage and
conversion to AC power matching the power generated.


One manufacturing specialist is required to oversee the manufacturing and assembly of the parts and
devise testing procedures to validate the designed power output.




F
INAL

Y
EAR

D
ESIGN

P
ROJ
ECTS

OF

M
ECHANICAL

E
NGINEERING


200
8
/200
9



Development of a
Remote
Controllable

V
ertical

Take
-
off Aircraft

Group size:
5
-

6

students


Faculty supervisor: Prof. S.C. Kot and Prof. Kai Tang

Description

The project is to make a remote controllable model co
pter,
which

has the distinctive features are vertical take
-
off
and sufficient stability
, including
suspending

at a specific position in the air. The aircraft has two or more
heading
changeable

propeller
s, which can provide the lift for vertical take
-
off wi
th the propellers heading
vertically up. Meanwhile, shown as
direction 1 in the
Fig
ure

1, changing the heading of the propellers to
horizontal could make the aircraft similar to the normal propeller model plane. Furthermore, rotating the
propellers as dire
ction 2 would
enhance

the
agility

of the
aircraft.


Objective

Our ultimate objective is using the knowledge we learnt
to produce an aircraft with new ideas. During the
manufacture and design processes, we could have
chances to learn more specific knowled
ge and the skills
of management.


The product objectives are vertical take
-
off, stability, and
agility. As the add
-
on objectives, automatic lock
-
on, tracking moving object and collision avoidance would be
the additional challenges.


Content & Fields

with K
ey Difficulties

O
ur project will mainly focus on the following
contents and
corresponding

fields



Wings and propellers with well modified profiles
-

F
luid dynamics/ aerodynamics



Properties of stability/balance performance and material
-

S
tructure/ solid mec
hanics



Enhancement of stability
and

agility
-

C
ontrol principles and application



Remote control


Wireless signal communication



Aero photography

with a little camera


Electronic device add
-
on




S
ome add
-
on features/attachments



Automatic lock
-
on and track m
oving objects


Control techniques and applications



C
ollision avoidance


Sensor and control techniques and applications


Key Difficulties



Equalization

the thrusts of the propellers via the method of pitch angles modification



Maximization of wings performa
nces, especially in relatively low speed



Stabil
ity and balance control during the critical
trans
ition periods



Control during tracking on the moving object, which was locked on


Job Allocation

In the project, there are three parts, which are mechanics, elec
tronic & control, and out
-
looking. Two of
the
six
student
s will mainly take charge of
each

part.

Figure
1

Presentation of rotating propellers

FINAL YEAR DESIGN PROJECTS OF MECHANICAL ENGINEERING

200
8
/200
9



Design and Prototyping of Microneedle Patches for Drug Delivery



Group size
5
-

6 students



Supervisor:

Prof. David CC LAM




(e
-
mail:
david.lam
@ust.hk
)



Description:


Hypodermic needles insert into flesh and cause pain and bleeding. Microneedle patches can deliver drugs
with minimal pain and minimize blee
ding. The project aims to characterize the drug delivery behavior of
drug coated microneedle patches. The team will design microneedle patches, coat drug onto the
microneedles and characterize the amount of drug delivered to porcine flesh. The team aims

to identify the
best combinations of microneedle patches, drug coating configuration and administrating procedure for
consistent drug dosage release to the flesh.



(1) Background on microneedle patch drug delivery



Background review on medical usage, requ
irements and specifications



Identification of shortcomings associated with traditional drug delivery and advantages and
current issues associated with microneedle patch.



Development of biological, chemical and structural requirements and specifications



Dev
elopment of characterization methods



Process selection



Describe the tasks within


(2) Design of microneedle patches



Adaptive design and CAD models



Parametric structural analyses for structure and array design



Material selection and process design


(3) Drug

coating design on single microneedle and fabrication



Material selection and process design



Parametric structural analyses for the coating of insulin


(4) Characterization of

single microneedle drug delivery



Testing procedure design



Validation of the te
sting procedure and the dosage release consistency


(5) Drug coated microneedle patch p
rototyping

and penetration characterization



Parametric structural analyses for the coating on the microneedle patch



Characterization of the amount of insulin delivered
to porcine flesh



Recommendations on best achievable drug delivery of drug
-
coated microneedle patch



Job assignment among the team
:

Task 1: all members; Task 2: 3 members; Task 3: 3 members; Task 4: all members; Task 5: all
members. The team will prototyp
e drug
-
coated microneedle patch and administrating procedure
for drug release


FINAL YEAR DESIGN PROJECTS OF MECHANICAL ENGINEERING

200
8
/200
9


Design and Prototyping of LED Solid State Lighting Modules for the
Drop
-
in Replacement of Indoor Fluorescent Lig
ht Tubes

(RL
-
1)


Group Size:
4

students

Supervisor:

Prof. Ricky Lee
(Office: Room 25
56
; Tel: 2358
7203
; e
-
mail:
rickylee@ust.hk
)

General Description

Light emitting diodes (LED) have been used for instrumentation sign
als and message displays for a
long period of time. In recent years LEDs are further used for traffic signal and personal lighting. Most
applications of existing LED devices are mainly for point source

or narrow area

lighting. With the
evolution of high
po
wer

LEDs, there are more and more demands for wide area solid state lighting
(SSL) using high
power

LED

array

modules to replace the conventional fluorescent light tubes.

The
advantages of such replacement include lower power consumption, smaller form fact
ors, and longer
operation life.
It is predicted that most of general lighting will be replaced by SSL within 10 years.

In
order to achieve such a goal, advanced packaging technologies and optimized system design must be
implemented to improve the thermal
-
m
echanical, electrical and optical performance. A R&D project
sponsored by MTR Corporation of Hong Kong
was

launched to investigate the feasibility of using
high
power
LED array modules to replace conventional fluorescent tubes for the saloon lighting on th
e
subway train

(
http://www.seng.ust.hk/publications/files/infocus11
-
6.pdf
)
. MTR Corporation installed a
number of prototypes developed
by the previous project teams

on a car
of

their

subway train

for field
test

for more than one year. The first generation prototypes were flat panel array modules (Fig. 1),
which required a lot of manual assembly processes. Consequently, the quality of prototypes was not
uniform enough, resulting in ce
rtain reliability issues. The current project is intended to design and
fabricate a new type of high power LED solid state lighting modules resembling conventional light
tubes (Fig. 2) for drop
-
in replacement. As a result, the on
-
site installation will bec
ome very simple.

Scope of Work

This project consists of several essential elements, namely, mechanical design and assembly, thermal
management, selection of diffuser and optical characterization, and optimization of electrical power
consumption.
Participat
ing students will develop design, assembly and characterization skills from
prototyping LED array modules. Both team work and individual efforts will be emphasized. Each
student will be responsible for one of the following tasks:

1.

Mechanical Design:

design

the substrate carrier and develop the surface mount process
.

2.

Electrical Design:
design the electrical interconnections and evaluate power consumption
.

3.

Thermal Management:
design the heat transfer paths for thermal management
.

4.

System Assembly and Optical
Characterization:
assemble the whole system for optical evaluation
.






Fig. 1: MECH/HKUST Prototypes Installed on
MTR Train


Fig. 2: New
Design of High P
ower LED
Solid State Lighting
Modules
for Drop
-
in R
eplacement
of Fluorescent Light Tube



FINAL YEAR DESIGN PROJECT OF MECHANICAL ENGINEERING

2008/2009


Development of Chip
-
to
-
Wafer and Wafer
-
to
-
Wafer Bonding Processes for
3D Packaging

(RL
-
2)


Group size: 3 students


Supervisor:

Prof. Ricky

Lee
(Office: Room 25
56
; Tel: 2358
7203
; e
-
mail:
rickylee@ust.hk
)

General Description

The demand for miniaturization and system integration is the on
-
going trend of microelectronics. This
demand is mainly accommodate
d by 3D packaging technologies (i.e., with more than one level of IC chip
in the thickness direction). Nowadays most consumer electronic products such as mobile phones, PDAs,
and MP3s……etc. have some compact components or modules with 3D packaging. The cur
rent 3D
packaging configurations are mainly implemented by chip stacking and/or package
-
on
-
package (Fig. 1).
Although most companies can stack 2
-
4 levels of ICs or packages, further miniaturization and integration is
still in demand. The emerging 3D packag
ing is mainly implemented at the wafer level. The enabling
technologies include thinning of wafers, forming and plugging of through silicon vias, and bumping for
interconnection. Furthermore, chip
-
to
-
wafer and wafer
-
to
-
wafer bonding processes (Fig. 2) are

required in
order to complete the packages/modules. This project is intended to develop certain processes of bonding
technologies for 3D packaging. It will involve substantial microfabrication in the clean room.


Scope of Work

This project consists of se
veral essential elements, namely, wafer thinning and bumping, microfabrication
and patterning, bonding process development, measurement of warpage and characterization of bonding
strength. Both team work and individual efforts will be emphasized. Participa
ting students will work
closely with PG students and research staff. Each project team student will be responsible for one of the
following tasks:

1. Interconnection Fabrication:

design and make interconnection for bonding
.

2. Bonding Process:
develop

and implement chip
-
to
-
wafer and wafer
-
to
-
wafer bonding processes
.

3. Investigation of Reliability:
measure deformation and evaluate bonding strength
.



Chip Stacking






Package
-
on
-
Package

Fig. 1:
Current 3D Packaging Configurations




Chip
-
to
-
W
afer Bonding




Wafer
-
to
-
Wafer Bonding

Fig. 2:
Emerging Bonding Technologies for 3D Packaging


FINAL YEAR DESIGN PROJECTS OF MECHANICAL ENGINEERING

200
8
/
200
9


Low
-
Cost Micro Electroporation Cell Chip for Drug Delivery



Group size:
5
-

6 students



Su
pervisor:

Professor Yi
-
Kuen Lee





(Office: Room 2
563
; Tel: 2358
-
86
63
; e
-
mail:

meyklee@ust.hk
)



General Description


Electroporation, a physical process to create nanopores in the cell membrane for macromolecules to enter the
biological cells under the e
xternally applied electric field, is one of most commonly used methods in
biotechnology for gene therapy, drug development and so on. Although commercial electroporators, such as
Bio
-
Rad’s Gene Pulser, have been used in many biological laboratories, micro

electroporation technology is still
in the R&D stage. a This project is to fabricate low
-
cost micro electroporation cell chips using Printed Circuit
Board (PCB) which has been widely used in electronic packaging.


This FYDP project is to design, manufact
ure and test
low
-
cost micro electroporation cell chip.

The design
project includes five tasks: 1) Characterize and fine
-
tune the printed circuit board & electroplating fabrication
conditions, 2) Design and fabricate a PCB
-
based micro electroporation cell c
hip, 3) Design and fabricate a
battery
-
operated mini electroporator to provide required electric field for the micro electropration chip, 4)
Packaging of micro electroporation chip and the mini electroporator, 5) Design Labview and Matlab programs
for the
interface between computers and micro electroporation chips, 6) Biological cell sample preparation (cell
culturing, fluorescence microscopy, etc) for the characterization of micro electroporation chips.


Scope of Work

The design and manufacturing of the
prototype micro electroporation chip are challenging. Students will go
through training of basic MEMS design and analysis, hands
-
on
micro
fabrication in the clean room
(www.nff.ust.hk), packaging and testing of the microchip in this project. Both team work
and individual efforts
will be emphasized. Each student will be responsible for one of the following design and manufacturing:


1 Characterize and fine
-
tune the printed circuit board & electroplating fabrication conditions

Design objectives
:

characterize
and adjust the fabrication conditions of printed circuit board &

electroplating fabrication using Design of Experiments (DOE) ,

2 Design and fabricate a PCB
-
based micro electroporation cell chip

Design objectives
:

design a low
-
cost fabrication process t
o fabricate a PCB
-
based microchip,

3 Design and fabricate a battery
-
operated mini electroporator to provide required electric field for

microelectroporation chips

Design objectives
:

use commerical microcontroller chip to design a battery
-
operated mini el
ectroporator,

4

Packaging of micro electroporation chip and the mini electroporator

Design objectives
:
design the cost
-
effective packaging solution for the miniaturized electroporation

system,

5 Design Labview and Matlab programs for the interface between

computers and micro electroporator chips

Design objectives
:

design (a) Labview

computer program

for the

interface between computers and micro

electroporation chip, (b) Matlab program for the digital imaging analysis of micro electroporation results.



No
te that this project will be in collaboration
with

the engineers in Defond Corporate Engineering in
Chaiwan, Hng Kong.
All 5 students will participate in the
this group project
.

The project leader will coordinate
the whole project.



FINAL YEAR DESIGN PR
OJECTS OF MECHANICAL ENGINEERING

200
8
/200
9



DESIGN AND MANUFACTURE A MINI

ROBOT

FOR
SOCCER


Group size:
5

-

6

students



Supervisor:

Prof. Yang LENG




Industrial Sponsor:

RADAR Co., Ltd




(meleng@ust.hk)


Description


The project is to design and manuf
acture a remote
-
controlled
robot
. The
robot

should be able to

walk

stably in order to
compete in a robot soccer game.
The design project includes several primary
components:

power system, mechanical structure, control system, and aesthetic design. The
ma
nufacturing and assembling the model are challenge. Its performance and functions are expected to
reach a level of commercial
mini robot
, or even better. Students will go through training of a product
design and prototype realization in this project. Bo
th team work and individual efforts will be
emphasized. Students will be responsible for one of the following design and manufacturing:


1.

Power system and
walking

control

Design objectives
: provide sufficient power supply
for a 3 minutes soccer game

and
walk stably
and get up automatically when fallen down
.

2.

Mechanical structure.

Design objectives
: Make
robot

structure with sufficient strength to support all components and
minimize the total weight of
robot
.

3.

Aesthetic design

Design objectives
: De
sign the appearance of
robot
.

4.

C
ontrol system and search function

sufficient for a robot soccer game.

Design objectives
: Make
remote
motion control system and searching system.


5.

Computer software design:

Design objectives
:

Develop computer codes for rob
ot control motions.











Join the project, if you have
confidence to make
a
remote
control robot that is capable of
playing in a robot soccer game.


FINAL YEAR DESIGN PROJECTS OF MECHANICAL ENGINEERING

2008/2009



Heat Transfer Analysis and Design of CPU Cooling Systems


Group size:
5
-

6
students



Supervisor:

Prof.
Zigang LI

(mezli
@ust.hk)



General Description
:


It i
s well known that the life of a CPU is strongly related to its operating temperature. An increase of
about 20
C

in operating temperature may halve the life of a CPU. The heat generated by a CPU is
dissipated by a cooling system,

including a cooler and a fan. The cooler is in direct contact with the
CPU and transfers the heat generated in the CPU to ambient air. The fan is used to enhance the
convective heat transfer between the cooler and air. The convective heat transfer coef
ficient, to which
convective heat flow is proportional, depends on the speed of the fan. High fan speed, on one hand,
improves heat dissipation and keeps the CPU operating temperature low, on the other hand, consumes
much energy. Therefore, it is of grea
t importance to understand the heat transfer process of the cooling
system of a CPU in order to design an energy
-
economic and long CPU life favored cooling system.


In this project, theoretical analysis of the cooling system of a CPU will be conducted to

find the factors
that impair heat dissipation. Based on the theoretical analysis, an optimized cooling system of a CPU
will be proposed and developed. Experiments will also be carried out to test the newly designed
cooling system.



Scope of Work:


1.

A c
omprehensive review of CPU cooling systems on the market, including power generation
rate of some popular CPUs (Intel, AMD, Celeron, and their life
-
temperature relationships),
design of coolers (material, geometry) and fans (power).

2.

Theoretical/numerical a
nalysis of factors/parts that weaken heat dissipation to understand how
material and geometry affect the heat transfer processes.

3.

Identification of the factors that contribute the most to thermal resistance, based on the analysis
in 2.

4.

Design of a new
cooling system, including the cooler and fan by considering the energy
consumption of the fan. This includes material selection for the cooler and CPU
-
cooler
junction, design of the cooler, and the selection of fan power.

5.

Conduction of experiments to test

the new cooling system.

FINAL YEAR DESIGN PROJECTS OF MECHANICAL ENGINEERING

200
8
/200
9


A Micro/Nano Droplet Delivery and Measurement System


Group size:
5
-

6

students



Supervisor: Prof. Huihe QIU

(email:
meqiu@us
t.hk
)





The behavior of micro/nanodroplets impinging, spreading, coalescing and evaporating on a solid substrate is
relevant to micro/nanoprinting for DNA microarray manufacturing, spray painting and coating, microfluidic
droplet mixing, and microdrop
let soldering for microelectronic chips. The process is strongly affected by droplet
dynamics, properties, components, and the wettability of the substrate material. The characterization of the
transport dynamics and coalescence of spreading droplets with
different components on a heterogeneous
substrate is fundamental for understanding the fluid flows, heat and mass transfer in the design and optimization
of such processes. A micro/nano droplet delivery system will be designed to form required micro/nano d
ots on a
heterogeneous substrate. Precise measurement technique will be developed for the experiments. Experiments
will be conducted utilizing a phase
-
Doppler anemometer (PDA), a combined laser induced fluorescence and
micro
-
resolution particle image veloc
imeter (LIF
-
μPIV), a novel profile probing technique with a high speed
camera, and fast response MEMS temperature sensor arrays patterned on a transparent substrate. These
techniques provide the size, velocity and dynamic contact angle of droplets, the sur
face profiles of droplet
deformation and temperature distribution. The coalescence of droplets with different compositions will be
studied. The dynamic wetting and contact angle hysteresis will provide the boundary conditions for numerical
simulations util
izing a Lattice Boltzmann method. Based on the results of this study, an optimization method for
improving droplet formation processes will be suggested.

1. Micro/nano droplet delivery Sysyem

Design objectives
:
Micro/nano droplet delivery system based
on piezoelectric devices

will be developed.
The
device

can be
controlled by computer
.

2
.

Measurement Systems

Design objectives
:
Measurement techniques based on advanced optics and laser will be developed for
probing the deformation of micro/nano droplet
s

3
.

Heating and evaporating system

Design objectives
:
Heating and evaporating
of micro/nano droplets

on a patterned substrate will be
controlled by a XY positioning system


4.
Programming and Data Processing

Design objectives
: Program will be develop
ed for
measurments, control
, including data acquisition,
communication, simulation and signal processing
.

5. Fabrication of patterned surface

Design objectives
:
Different patterned surface charges will be fabricated on Silicon and glass surface to
which

are built for experiments. Different zeta potentials will be considered using different materials
.



Hydrophobic Coating
Hydrophilic Coating
Hydrophobic Coating
Hydrophilic Coating
Hydrophobic Coating
Hydrophilic Coating
Hydrophobic Coating
Hydrophilic Coating
(a)
(b)
(c)
(d)


FINAL YEAR DESIGN PROJECTS OF MECHANICAL ENGINEERING

2008/2009



Title:
G
reen energy generation by using smart materia
l

--

Phase II


Group size: 5

students



Supervisor:

Prof.

Qingping SUN


(email:

meqpsun@ust.hk)




General Description
:

The creation of pollution free green energy has become one of the main concerns in our modern
society and energy industry. This

proje
ct
a
i
m
s to
improve the existing
design and manufacture
(
the
work done in
P
hase I
) of a

prototype green solid engine using
the
shape memory
alloy
(
TiNi
) wires or
micro
-
tubes
.

The project includes several primary components:
Design principles,
mechanical
str
ucture
,

electric and thermal
-
fluid parts, design and

manufacturing
,

and assembling

and testing. They

are all
very interesting and challenging.

The

performance and functions
of the engine and the
efficiency
are
expected to improve the work done in Phase I

s
o that it can be used to nicely attract
the high school students in the Outreach Day of the Department and the Engineering School
. Students
will go through
a series of
training
in

both

product design and prototype realization in this project.

Both team w
ork and individual efforts will be emphasized.
Each student or a group of students
will
focus on and
be responsible for one of the following
work
:


Scope of Work:


5.

Design Principles
, C
riteria and Objectives:

to give working principles and detailed
estimat
e of the work output of the green energy and the green engine.


6.

Selection of the materials and test characterization to evaluate the load capacity of the
wire
:

to complete the material testing and data acquisition.


7.

Mechanical design and actuation contro
l, especially on how to achieve an efficient
cooling
:

to finish all the required mechanical, electrical and thermo
-
fluid components.

8.

Manufacturing process
:
to produce all required components, especially on the reliable
welding or joining of NiTi actuator.


9.

Assembly and testing
:
to demonstrate that the designed and manufactured engine can
perform all the designed functions.



Job assignment among the team
:


All the 5 students are required to

partici
pate in the design, fabrication and

tests
processes but wit
h
different focus of concentration
.

The project leader will coordinate the whole project.








FINAL YEAR DESIGN PROJECTS OF MECHANICAL ENGINEERING

200
8
/200
9


Intelligent Design for Panel Layout Patterns

(KT
-
1)


Group size: 4 students


Supervisor:

Prof
.

Kai Tang


(email:

mektang@ust.hk)




General Description
:


Most architectural designs in civil and other related engineering eventually go through a stage called panel
layout


the design surface must be covered by tiles with certain specified geometric

type and size. Only through
panel layout can the design on paper be finally made in reality. In the figure shown below, (A) is a highway
overpass whose slope side is covered by rectangular panels of the same dimensions (except near the edges), and
(B) is
the roof of a sitting area that is made of uniform triangular panels. Concerning panel layout, there are
several critical tasks:


(1)

Given the design surface and the geometric shape and dimensions of the panel, how to layout the panels
on the design surface s
uch that the
distortion

due to the layout is minimum, where the distortion is
measured by the difference between the original curved design surface and the real surface made of
panels


which is piecewise planar


and the number of partial panels


those n
ear the edges of the
design surface that are not complete in the original shape.

(2)

Given the design criteria and constraints of the surface, and the geometric shape and dimensions of the
panel, how to design a surface as well as its panel layout whose distor
tion is the smallest among that of
all the surfaces that meet the design criteria and constraints.


Currently, both the above design tasks are done in practice in some ad
-
hoc manner without a systematic strategy
or methodology.








(A)








(B)

Figure: Panel layout on a surface


Scope of Work:


In this project, the students will design and implement a computer system that will utilize the powerful
Generic
Algorithm

and
Texture Mapping

techniques to a
chieve tasks (1) and (2). In addition, the students will perform
physical experiments

to verify their solutions


they will use NC machine to cut surfaces of their optimal
designs, layout the panels on the cut surfaces according to their solutions, and act
ually compare them. Of the 4
students of the group, 2 or 3 of them will be responsible for tasks (1) and (2), while 1 or 2 of them will be
responsible for the NC machining and physical experiments part.




FINAL YEAR DESIGN PROJECTS OF MECHANICAL ENGINEERI
NG

2008/2009


Intelligent and Computerized Design of Medical Braces

(KT
-
2)


Group size: 4 students


Supervisor:

Prof.

Kai Tang


(email:

mektang@ust.hk)



General Description
:


Reports have shown that more than seven million physician office visits
per y
ear in the United States are related to problems with wrist joints
suffering from the repetitive strain injury. The dramatic increase in the
use of computers and various kinds of automatic equipments is,
unfortunately, a major contributor to this spate. El
astic braces are the
most commonly used assistive medical devices for joint injuries, whose
purpose is to restrict the motion of the injured joint so that it will
eventually heal by itself. A same brace, however, will exert different
biomechanical effects
on different individuals since they have different
joint shapes. Therefore, for better and faster treatment of an individual
patient, more and more physicians now request custom
-
made braces
specifically designed for the individual patient, rather than choo
sing
from off
-
shelf and mass
-
produced ones. A brace is made of a piece of
elastic fabric with certain material characteristics. To restrict the motion
of the joint, the brace should be in a “positive tensile” state


it must be
stretched so that normal pre
ssure can be generated upon the joint. The
design task of a brace is to find a planar pattern/geometry of the brace,
which is called the “rest or relaxed state” as no stretch or compression
occurs at this time, so that, when worn, the brace generates the d
esired
normal pressure distribution. In most cases (though not every), the
planar pattern is sewed at two matching seams so to form a relaxed
closed cylinder
-
like shape. The figure at right shows such an elbow
brace. Currently, this design is done in pract
ice in a very crude trial
-
and
-
error manner and no systematic or automatic methodology is
involved.




Scope of Work:


The four students will achieve the following tasks:


(1)

Design and manufacture

a device that can change the boundary of a brace worn on a
prosthetic model.
Besides the intelligent and user
-
friendly way in which the boundary of the brace can be altered, the
device should also have a sensor system that will be able to dynamically measure the pressure at any
points on the model.

(2)

Establish a sta
tics model

that can predict the pressure of a brace at any point on the model based on the
material properties of the brace, the boundary of the brace in relaxed state, the geometry of the shape on
which the brace will be put on, etc.

(3)

Conduct experiments

t
o validate the model established in (2) with the data from (1).

(4)

Design and implement
a computer system that will, given the shape of the model and certain points on
the shape with specified pressures, automatically find the boundary of the brace such that,

when worn
on the shape, the brace will exert the specified pressures at the indicated locations.



FINAL YEAR DESIGN PROJECTS OF MECHANICAL ENGINEERING

2008/2009



Design and fabricate a temperature cycling oven for microelectronic
package reliability t
est


Group size:


5 students



Superviso
r
:


Prof. J.S. Wu (email: mejswu@ust.hk)



General Description
:


The students will design and make a lab size temperature cycling oven according to JEDEC standard
JESD22
-
A104 to perform temperature cycling test from
-
65C to 150C. The oven should have two
chambers with one at high temperature and the other at low temperature. It will also have a mechanism
to transmit samples between chamber
-
1 and chamber
-
02 after a pre
-
set treatment time in each of the
chambers automat
ically.


The task share of the project could be as follows: (1) design and making of high temperature chamber;
(2) design and making of the low temperature chamber; (3) design and making automatic sample
transmitting mechanism; (4) design and making of te
mperature control unit; (5) Assembly of the oven
and coordinate the project (Group Leader).



FINAL YEAR DESIGN PROJECTS OF MECHANICAL ENGINEERING

200
8
/200
9


Small
-
Scale Horizontal
-
Axis Wind Turbine



Group size:
5
-

6

students



Supervisor:

Professor Wen
jing Ye





(Office: Room 25
48; Tel: 2358 7194
; e
-
mail:
me
wye@ust.hk
)




General Description:


The global energy crisis has put a pressing demand on utilizing renewable and environmental friendly
energy sources. Wind energy is one of the attractive energy
sources that could be replenished in the near
future. Although extracting power from wind was an ancient concept, the development of wind turbines to
generate electrical power is a relatively new effort and has not been pursued fully particularly in Asia
and
North America.


This FYDP aims
at developing a prototype of a small
-
scale horizontal
-
axis wind turbine that can deliver a
minimum of 10w electricity. It is hoped that through this exercise, students will have a general knowledge
of wind turbine operat
ing principle and design methodology, and will gain basic skills of wind turbine
design and manufacturing.


Scope of Work:


(1)

Background study and literature research





Principle of wind turbine design



Existing wind turbines in Hong Kong


(2)

On
-
site wind data

survey and performance estimation




Survey on local wind condition



Feasibility study



Performance estimation



Preliminary design on major parameters


(3)
Detailed design which includes the following major subsystems



Rotor



Torsional drive system



Control sy
stem A popular residential wind
turbine



Supporting structure

Depending on the scale and the available resources of this project, other important elements of wind
turbines such
as the electric generator may be purchased.


(4)
Manufacturing and Testing




Environmental
-
controlled testing (wind tunnel testing)



On
-
site testing (if feasible)







FINAL YEAR DESIGN PROJECTS OF MECHANICAL ENGINEERING

200
8
/200
9


Polymer Electronics P
rinting System

--

Phase II

(MY
-
1)


Group size:
4

students


Supervisor:

Prof. Matthew M F YUEN (email: meymf@ust.hk)





Objectives:

The project is aimed at developing a micro
-
printing system for polymer electronics applications. The
printing system will p
rint polymer electronic materials on flexible substrate to produce functional
circuit for RFID and display applications.


Scope of Work:

The project is to evaluate the design of a micro
-
printing system for printing polymers on flexible
substrate for appli
cations in RFID and flexible display system. The system will be using transfer
printing as the primary method of printing. The project team will work with postgraduate students and
sponsoring companies to build the machine.


The students can work in the fo
ur main areas:


1.

Machine structure and motion system

The machine is to perform a reel
-
to
-
reel operation delivering the substrates to the printer head in an
indexed manner. The printing process is based on contact printing and the different processes will
i
nitially be explored. This will involve mechanical design of the of the substrate delivery system.


2.

Printing Process

The printing machine will be designed to print polymer materials in layers on flexible substrate. The
minimum feature size will be in the r
ange of 20 µm and the minimum pitch is 30

µm. The process is
UV activated and has to be matched with the substrate material used. The process window has to be
defined to optimize the process.


3.

Control system

The machine will be computer controlled to deli
ver the substrate to the printing head. The control
system should be designed to provide the accuracy as required. The positional accuracy and the
tensioning of the substrate are important parameters.


4.

Polymer electronics material development

The work will

involve the design and synthesis of polymer electronics materials including conductive
polymer, polymer capacitors and inductors for the use of the polymer electronics circuit. The material
has to be matched with the requirement of the printing process an
d the substrate material.


The group will have to hold weekly project meeting and will be working under the supervision of a
group of research students.



FINAL YEAR DESIGN PROJECTS OF MECHANICAL ENGINEERING

2008/2009


Fabric Pattern Cutting Head

(MY
-
2)


Group size: 3 students



Supervisor:

Prof. Matthew M F YUEN (email: meymf@ust.hk)





Objectives:

The project is aimed at developing a cutting head for a garment pattern cutter. The cutting head will be
able to deliver a cutting accuracy of

2 mm using p
rimarily a reciprocating knife cutter.



Scope of Work:

The project is to evaluate the design a cutting head for garment pattern cutting on a flat bed pattern
cutter. A prototype machine is already completed and available for testing in Shenzhen. The proje
ct
team will work with postgraduate students and sponsoring companies to re
-
design the machine.


The students can work in the three main areas as following:


1.

Cutting head structure

The cutting head is to be re
-
designed to provide the necessary rigidity for

the cutting operation. It
should minimize the vibration level and move smoothly to execute the cutting operation


2.

Cutter mechanism and cutting operation

The cutting mechanism of the reciprocating knife cutter should be reviewed to ensure that the cutter i
s
able to deliver the accuracy of

2 mm. It should be able to handle the cutting of patterns with sharp
corners.


3.

Control system

The control system should be matched with the control system of the entire machine to deliver the
accuracy in the cutting proce
ss.



The group will have to hold weekly project meeting and will be working under the supervision of a
group of research students.







FINAL YEAR DESIGN PROJECTS OF MECHANICAL ENGINEERING

2008/2009


Design and manufacture of four
-
points
-
bending fract
ure apparatus for
piezoelectric

materials


Group size: 5 students


Supervisor:

Prof.

Tong
-
Yi Zhang


(email:

mezhangt@ust.hk)


TA:


Mr. Zhijia Wang
(email:

wangzhj@ust.hk
)


General Description
:


Piezoelectric ceramics are smart materials that expand or c
ontract when subjected to an electric field, while piezoelectric
materials generate an electric field under mechanical loads. Due to this unique feature,
piezoelectric ceramics are
commonly used as sensors and actuators in versatile technical fields like t
he automotive industry, medical technology,
metrology, and sonar applications. However, brittle fracture of
piezoelectric ceramics is frequently encountered in many
aspects of everyday life. The fracture resistance or the resistance against fracture, which

is called the R
-
Curve, of these
materials needs to be known for engineering design. Due to nonlinear effect near the crack tip, their fracture resistance
depends upon crack length.

In order to characterize the crack growth resistance of these materials, s
table crack growth is
necessary. However, it cannot be achieved by typical universal testing machine (UTM) because of its low stiffness. This
project aims to design and manufacture a displacement controlled four
-
points
-
bending fracture apparatus for piezoe
lectric
ceramics through high stiffness design. Using this apparatus, the crack resistances curve of piezoelectric ceramics can be
determined. A design of a

four
-
points
-
bending fracture apparatus by the Darmstadt
University of Technology
, Germany
,

is
avail
able and will be a reference for the designed project to design and manufacture two sets of such apparatus for two
different sizes of samples.


Scope of Work:


Five

students are needed to conduct the project. Both team work and individual effort will be e
mphasized. Each student will
be responsible for one of the following aspects:


1.

General design, materials selection, and progress management (
Group Leader
)

2.

Finite Element Analysis and Simulation (one student)

3.

Mechanical manufacturing of components (one stud
ent).

4.

Piezoelectric actuator and crack length measurement apparatus control (one student).

5.

Conducting example tests on piezoelectric materials for evaluating the performance of the apparatus (
one student
).


Appendix:





Figure 1:
Four
-
p
oints
-
bending fracture apparatus
designed by
the Darmstadt University of Technology, Germany.

FINAL YEAR DESIGN PROJECTS OF MECHANICAL ENGINEERING

200
8
/200
9



Development of a Direct Ethanol Fuel Cell Powered

Mobile Phone Charger



Group size:
5
-

6

stud
ents



Supervisor:

Prof. T.S. Zhao (
metzhao@ust.hk
)


Project Background and significance:

This project is about the use of

ethanol as a direct fuel in next
-
generation fuel cells
, which refers to as
direct ethanol fue
l cells (DEFCs).
Ethanol
as a fuel has multiple advantages over conventional fuels for
fuel cells,

like hydrogen or methanol
:


1)

Ethanol is available world
-
w
ide, is a non
-
toxic liquid that
eve
ryone can use easily and safely;

2)

I
t

can be produced from biomas
s (
corn, sugar, molasses, etc.); its
production is environmentally

friendly and the product itself is ecologically harmless
. Hence, ethanol is a sustainable energy
source.

3)

Ethanol is a hydrogen
-
rich liquid and it has a higher energy density (8.0 kWh/kg) comp
ared to
methanol (6.1 kWh/kg).

4)

Ethanol is e
asier handling, storage and distribution

than other gas and liquid fuels
;

Participating in this project, students will benefit from the followings:

• Opportunity to work in Prof. Zhao
’s

interdisciplinary researc
h group




Different engineering disciplines




Different talents (group leader, research, reporting, etc.)

• Develop project skills




Communication (oral, written, project documentation)




Teamwork




Project management

• Participate in

“hands
-
on” design of complex system




On the technological frontier




Outcome uncertain … couple with research

Project Goal
: The project is to develop a
n

alkaline
-
electrolyte membrane
direct
e
thanol fuel cell
(
AEM
-
DE
FC) powered
mobile phone charger
, which run
s

on ethanol stored in the block

and
oxygen

from the surrounding
air
. The
tasks

include design, fabrication, and test of a
n

AEM
-
D
E
FC stack and
integration with a
charger

into a prototype. Each student will focus on a key component of the
AEM
-
DEF
C stack
. He/she will study the mechanical and electrochemical phenomena occurring in the
component and come out his/her optimal design and fabrication of the component. Finally
, all the
group members will
participate assembly and performance test.


Studen
t #1: Overall system design of the fuel cell powered
mobile phone charger

Design objectives:


A student, acting as the group leader, is required to lead the group to come out with
the overall system design. The design can be different versions and all the
pros and cons of the
different designs must be presented in the final report. Particular attention has to be paid to the balance
between the size and the output power as well as the balance between the size and the run
-
time.



Student #2: Membrane assembly

electrode (MEA) fabrication and characterization

Design objectives:


MEA is the key component of the
AEM
-
D
E
FC. Student#2 will work together with
a PhD student to fabricate and optimize the MEAs for the
AEM
-
DE
FC stack. Particularly, the
fabricated
MEAs can

show high performance and durability.


Student #3: Design and fabricate of the fuel cell stack

Design objectives:


The student will design and fabricate the stack fixture and the bipolar plates for
supplying distributing reactants and for collecting elect
ricity.


Student #4: Design and fabricate the fuel
and oxidant
delivery system

Design objectives: Passive ethanol delivery system will be adopted in the
mobile phone charger
. To
e
xtend the run
-
time on a single charge,
ethanol delivery system should be pre
cisely designed to
achieve higher energy efficiency
without serious fuel loss.

Student#4 will accomplish the design work
together with Student#1 and fabricate the require components by himself/herself.



Student #5: Electronic design and integration.

Desig
n objectives: In addition to
AEM
-
D
E
FC stack and a
n

ethanol

fuel cartridge,
charger
and a
DC/DC converter are also key components in the
AEM
-
D
E
FC powered
mobile phone charger
.


The
student will conduct a survey, select appropriate components.


Student #
6
:
O
ptimize the operating conditions

Design objectives:
The operating conditions have to be optimized to achieve the higher performance of
AEM
-
DEFC stack. Student#6 will design, fabricate and test a single cell to optimize the operating
conditions which will b
e adopted in the stack operation.



Student #
7
:
Design and fabricate the case

Design objectives:
The student will design and fabricate the case for this prototype based on the fuel
cell stack design as well as the electronic design. The student will finall
y assemble all the above
components with the help of Students#3, #4 and #5.



All the students will participate assembly and performance test.








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