Non-destructive examination is a group of analysis techniques used in industry for evaluating the integrity of a material, component or system without causing any physical damage. NDE is used as quality control in advanced manufacturing. There is a wide choice of measuring techniques available to meet the demand of examining a wide variety of materials such as metals, plastics and rocks, as well as different structures and sizes ranging from semiconductor chips to nuclear reactors. At the same time, physical measuring techniques are used to examine parts of construction assemblies for hidden imperfections and defects.

The NDE Laboratory asked our team to design a single-channel, multi-band, and multi-resolution sensing system that includes a prototype of a single-channel probe and a platform that is geometrically flexible for complex structures and materials that can move sensors in an x-y-z direction. Two sensors: 1) LiDAR, to plot the 3D surface image of the object, and 2) microwave sensor, to show the surface and subsurface of the object, will be implemented in this platform. VNA will be used to integrate the signal from EM sensors at different frequencies, and we will develop a software to collect the data and process it into images.

Michigan State University is interested in developing a human-robotic integration system. This technology will use human gestures and eye-movement to control a ground robot, providing solutions in a wide variety of applications. It could be used to aid in the mobilization of the physically disabled, where paralyzed individuals could transport themselves using limited body movement. The system could also be used in industry to explore or operate under conditions not suitable for humans. Whether the application is the deep sea, outer space, or in your living room, humans and robots need the capability to communicate effectively. A human- robot integration system aims to accomplish this task. There is a lot of potential for a system like this.

Our team is particularly focusing on developing an eye-tracking system and a head-motion tracking system to control the robot and a camera mounted on it. This will involve two subsystems responsible for different types of commands. The head motions detected with the system correspond to different movements of the physical robot. The eye-tracking system will measure the user’s eye positions to control movement of the robot’s camera, and the robot’s camera will send the real-time video footage back to the computer. Then, the computer will display the video footage on the screen so that the user has a clear idea of what the robot is looking at and where to move it accordingly.

Diamond has numerous electronic properties which make it very attractive in semiconductor technology. Compared to the most common semiconductor material used today (silicon), diamond is superior in many aspects. The process of growing diamond is accomplished by a chemical vapor deposition process and MSU’s ERC has been a part of this process since the early 1980’s.

Currently, constant feedback is needed to ensure the diamond will grow to their satisfaction. The primary objective of Team 4 is to provide information about the diamond surface as it is growing (i.e. in real time). We will implement a laser measurement system that will scan the top surface of the substrate and give slope information (angle/direction) at various points. Since growth rates are on the order of a few microns per hour, maintaining a high degree of accuracy as well as repeatable measurements is paramount. In addition, sample sizes ranging from 3mm x 3mm to 25mm by 25mm must be scanned in 200 seconds or less. In the future, this project will be implemented as a feedback subsystem for the chemical vapor deposition process

Techmark, Inc. is interested in designing an impact recording device (IRD) for measuring the bruising of fruits and vegetables that occurs while being processed from the farmer to the consumer. Techmark, Inc. currently has an IRD product in place that works with large fruits and vegetables like potatoes, tomatoes, apples, etc, but they would like a new IRD for smaller fruits and vegetables such as mushrooms, blueberries and strawberries. The goal of this project is to create a small IRD capable of measuring impacts for the smaller size fruits. Continuing of the project started in Fall 2016, our team will create an IRD that will meet all requirements from Techmark, Inc. With the new IRD, farmers will have an easier time detecting when and where the most bruising to their products occurs during the handling process.

The IRD will have one 3V battery, a centralized accelerometer, a micro-USB port, and a 4-layer PCB to accommodate and perform as required. The sensor will last 3-4 hours and accumulate voltage drops and other useful information via the accelerometer. Once the sensor completes the process, the microcontroller will send the data to the PCIRD sponsor software for further action.

MSU is currently constructing a 10 MW solar array in parking lots 83, 89, 91, 92 and 100. IPF (Infrastructure Planning and Facilities) is looking for a technical solution to increase the reliability of the micro-grid system and to reduce the total cost of utility operation. Our team is consulting with MSU in order to determine viable solutions that can provide stability when operating the solar array.

Our team is developing solutions to reduce costs and power fluctuation in the solar array. We are also considering methods to predict cloud covering weather patterns.

In addition, we are developing solutions to implement external power sources such as batteries, capacitors, or hybrid energy systems in the solar array. We brainstormed multiple power systems and analyzed the pros, cons and cost- efficiency of each item. We then simulated electric and steam load shedding systems that would help conserve power across campus. As a side project, we are developing ways to predict coarse weather patterns either by using detection sensors or cloud image processing.

Jervis B. Webb, an industry leader in factory automation and material handling, has tasked our team with performing predictive maintenance on their SmartCart line of automated vehicles. With the ability to detect abnormality in subsystems before failure, downtime is minimized, as there is an opportunity to pull the SmartCart off the factory floor before progress is halted, increasing efficiency in productivity.

The deliverables to Jervis B. Webb include a set of general failure modes and an algorithm to detect these failure modes for any component. This way the software can be applied to any new component added. The goal is not to detect a specific failure for a specific component, rather to develop detection methods that can be applied to any component.

Also, there is a desire to integrate this software solution into Jervis B. Webb’s existing codebase. To facilitate this, a solution will be developed in C++ on a Linux Debian platform. A Raspberry Pi Model 3 B was chosen to be the platform for this software solution.

Advanced Metering Infrastructure (AMI) technology allows for two-way communication between utility meters and their companies. Consumers Energy has begun to implement AMI smart meters across their market but currently lacks any meaningful analysis or visualization of the collected data and information. By analyzing and utilizing this data, Consumers hopes to better service customer demands. Consumers Energy has asked us to develop a tool to assist in data utilization as well as to simplify data visualization. They would particularly like to focus on the most important events, which may require immediate elicited response from Consumers.

Our team has chosen to focus on three types of events: power loss and outage, tampering and major voltage changes. For each event, we plan to create software that will simplify/ break down large datasets, analyze the event capture and flag the event occurrences of great significance. Flagged events are those that need attention, due to the possibility of theft or vandalism or repeated power outages. Our software will contain a simple graphical user interface (GUI) to display our results and use latitude and longitude data to place event occurrences onto a map. In addition, important flagged tampering events, those we consider very likely to be theft, are marked for review operations personnel by our GUI accessible function for easy access and rapid response.

Delphi is currently developing advanced powertrain systems that are one-of-a-kind with few spare parts available. To protect these engines, Delphi has implemented a watchdog controller to shut down the engine in order to reduce damage to these prototype engines. The current controller is effective but expensive. Delphi is looking to develop a low-cost watchdog controller. The new controller will provide the same functionality as their current controller but reduce the cost of future builds.

Our team will be developing a custom Printed Circuit Board using TI’s TMS320F28377SPZPQ 32-Bit microcontroller to meet the requirements specified by Delphi. A JTAG debugging port will be included in the design to facilitate flashing via Simulink. Implementing bulk converters will allow the watchdog to operate at a 9-16 V range. Other additional circuitry includes 2 CAN channels, 16 analog inputs and 12 analog outputs. Constructing an adapter harness enables the new watchdog to interface with the existing components. Our goal is to design a working watchdog controller that mimics the functionality of the existing controller within the budget of $500. Lowering the cost of the controller will allow Delphi to implement the prototype engines in more vehicle applications.

Communication systems are essential for a variety of applications, ranging from small- scale video surveillance to large-scale utility monitoring systems. Michigan State University currently relies on fiber connections for adding new applications to the network. Laying fiber is both time-consuming and expensive because of the obstacles that the urban campus presents. Additionally, many of the applications do not require the throughput and bandwidth available through the fiber connections. Additionally, many wireless point-to-point connections currently on campus utilize Sub 1Ghz technology that only provide limited throughput for small applications.

MSU is interested in testing and exploring the potential of using a WiMAX communication system over campus. For a proof-of-concept, MSU is looking to set up a wireless connection between the sensors at the wells that supply water to MSU. The WiMAX 007 team has been tasked to research and set up a WiMAX network that would replace the current system for adding network applications. This wireless network would be a time-saving and cost-effective solution for the current system. Our team is also going to be laying the foundation for a larger WiMAX communication system that would work with other utility applications such as traffic intersection surveillance, parking lot surveillance, etc.