F11 75-nish team 75 final proposal

SEC

Cardboard Bumper
Assembly Jig for the
NISH AbilityOne Design
Challenge
Client:Specialized Training for Adult Rehabilitation

Semester: Fall 2011
Ref: SEC F11-75-NISH

Team Members:
Ben Blair, ME
John Hughey, CpE
Jordan John, ME (PM)
Linden Eason, EE

Prepared by: Saluki Engineering TeamP75 g e
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SEC

8 November 2011

Specialized Training for Adult Rehabilitation
Attn: Kathy Baumann, Executive Director
P.O. BOX 938
20 North 13th Street
Murphysboro, Illinois 62966

Dear Mrs. Baumann,

The letter is in response to your request for proposal for the NISH AbilityOne Design Network
Challenge. Our team, SEC Team 75, has developed a cardboard banding jig designed for
production and completion of cardboard bumper systems through START and its subsidiaries.
Further, we believe that our design will not only increase production numbers dramatically, but
will help to aid and assist the operator of said jig.

This proposal is based on simple, clean, and efficient incorporation of electronic and mechanical
systems. The goal of this design is to be able to create cardboard bumpers rapidly and easily
through the use of racking, clamping, and counting assemblies. Overall, START is producing
approximately 1200 units per week while their demand from their current subsidiary is 4000
(Please see Appendix A). We hope to exceed this projected number through our jig.

Finally, SEC Team 75 would like to thank you for the opportunity to submit a design proposal to
your company and we hope to hear from you soon.

Sincerely,

Jordan John
Project Manager – Team 75
Saluki Engineering Company
jjohn89@siu.edu
(618) 303-0975

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Executive Summary
The Saluki Engineering Company in collaboration with the Institute for Economic

Empowerment has put out a request for proposal that states, “Client wants a device or a

system that will solve a real workplace problem for at least one group of severely

handicapped workers.” The goal is to design a cardboard bumper assembly jig. The

design will be simple, efficient, and cost effective. The approach to this request is a

multifaceted design that will increase ease of assembly as well as increase production

rates by a projected 233.33%.

The project will consist of an electrical and mechanical subassembly working

together to create an overall project. The assembly will consist of the following:

The mechanical system will be a racking and clamping system. The rack will be a

plate that will be supported by rigid rectangular shafts. As the cardboard pieces are fed

into the rack, the electrical system will allow for the user to know if the system is under

filled, filled, or overfilled through the use of LED indicators. These indicators will be

housed and attached to the racking system and controlled by a microcontroller. Once the

rack is filled, the clamping system will swing downward and hold the pieces together

allowing the operator to band the cardboard slivers.

The final design of said project will conclude in early April with a detailed design

report submitted by April 19th, 2012. The estimated cost of the final design will be $248.

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Non-Disclosure Information

The information provided in or for this proposal is the confidential, proprietary property

of the Saluki Engineering Company of Carbondale, Illinois, USA. Such information may be used

solely by the party to whom the proposal has been submitted by the Saluki Engineering

Company and solely for the purpose of evaluating this proposal. The submittal of this proposal

confers no right in, or license to use, or right to disclose to others for any purpose, the subject

matter, or such information or data, nor confers the right to reproduce or offer such information

for sale. All drawings, specifications, and other writings supplied with this proposal are to be

returned to Saluki Engineering Company promptly upon request. The use of this information,

other than for the purpose of evaluating this proposal, is subject to the terms of agreement under

which services are to be performed pursuant to this proposal.

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Table of Contents
Transmittal Letter (JJ)……………………………………………………………………………..2
Executive Summary (LE)..………..………………………………………………………………3
Nondisclosure Statement……………………………………………………...…………………..4
Table of Contents………………………………………………………………………………….5
List of Tables and Figures…………………………………………………………………………6
Introduction (JH)...……….………………………....………………………………………..……7
Literature Review (All, Revised by BB)………….……....………………………..………..……8
Project Description (JJ).……………………………………………………………………….…18
Project Specifications (JJ).…...……………………………………………………………..……20
Design Basis (JJ)…....……………………………………………………………………………20
Project Organization (JJ).…...……………………………………………..………………..……21
Scope of Work (JJ)……………………………………………………………………………….21
Subsystem Design………………………………………………………………………………..22
Clamping System (BB)……………….…………………………………………………….22
Racking System (JJ)…………………....…………………..………………………………23
Power Source (LE)…………………...…………………………………………………….26
Control Circuit (JH)……………..…….…………………………………………………....27
Microcontroller (JH)……..…………...…………………………………………………….28
Sensors (JH)………………………….……………………………………………………..30
LEDs (LE)…………………………….……………………………………………………32
Ventilation and Filters (LE)…………….…………………………………………………..33
Training Aids (JH, LE)………………….………………………………………………….34
Material Selection (BB)…....………………………………………………………………….…34
Action Item List (All)……...………………………………………………………………….…35
Draft Schedule (JJ)…..…………………………………………………………………………...36
Resources Needed (JJ, JH)…………………………………………………………………….…37
List of Analysis (All)…………………………………………………………………………….37
Works Cited……………………………………………………………………………………...39
Appendix A: Communications……..……………………………………………………………41
Appendix B: RFP Documents…………………………………………………………………....42
Appendix C: 3-D Renderings of Mechanical System (JJ)…………………………….…………50
Appendix D: Microcontroller Wiring Diagram…...…………………………………..…………53
Appendix E: Resumes……………………………………………………………………………54

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List of Tables and Figures
Figures
Figure 1: Cardboard Bumper Picture…………………………………………………………….11
Figure 2: Jig Design………………..…………………………………………………………….13
Figure 3: Cost of Binding Machine..…………………………………………………………….14
Figure 4: Banding Machine…….………………………………………………………………..15
Figure 5: Shirt Press……....…….………………………………………………………………..17
Figure 6: Block Diagram………………..…………….…………………………………………19
Figure 7: Supports………………………………………………………………………………..24
Figure 8: Racking Plate………………………………………………………………………..…25
Figure 9: Draft Assembly……………………………………………………………………...…26
Figure 10: Circuit Logic Diagram………………………………………………………………..27
Figure 11: Pin Assignment Diagram…………………………………………………………..…28
Figure 12: Microcontroller Wiring Diagram……………………………..…………..………….30
Figure 13: Sensor Placement Diagram………………………………………………..…………31
Figure 14: Sample LED……………………………………………………………….…………32
Figure 15: LED Setup…………………………………………………………………..………..33

Tables
Table 1: Production Rates………………………………………………………………………....8
Table 2: Project Specifications………………..…………………………………………………20
Table 3: Basis of Design…………………………………………………………………………20
Table 4: Organizational Chart………………………….………………………………………...21
Table 5: Material Selection Matrix………………………………………………………………34
Table 6: Action Item List……………………………….………………………………………..35
Table 7: Proposed Schedule…………………………….………………………………………..36
Table 8: Resources Needed………………………………………………………………………37

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Introduction
In the early 1960’s a movement began; A movement that would finally allow those with

severe handicaps, mental and physical alike, to no longer feel ostracized in the workplace. This

movement, known as the Disability Rights Movement, would lead to numerous national

organizations aimed to aid those with handicaps to find work and succeed in industry. One of the

organizations formed during these trying times was the National Institute for the Severely

Handicapped (NISH).

Through the years, NISH has developed into an international organization helping

hundreds of thousands people find work despite their handicaps. One of the biggest challenges

NISH has encountered is being able to place clients in to work that has numerous restrictions.

These restrictions are often based on ergonomics and movement controlled assembly. Because of

this, NISH has developed the AbilityOne Network Challenge.

The NISH AbilityOne Network Challenge sponsors competition throughout the nation

aimed at the design and manufacturing of “enabling devices”. These devices seek to aid those

with handicaps to perform complex tasks easily. In other words, these devices create a solution

to problems affecting those with handicaps in the workplace.

Specialized Training for Adult Rehabilitation (START), a NPO based out of

Murphysboro, Illinois that is a subsidiary of NISH. START has in house facilities in which they

employ individuals with handicaps. One of their current projects is creating cardboard bumpers

that are used by local companies for shipping and packing. Currently, they are able to produce

1200 units per week. Their current client has increased their demand to 4000 units per week.

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Through the development of an assistive jig, SEC Team 75 hopes to expedite their current

assembly process to meet this demand.

Current Production Requested Production Increase Needed
1200 units 4000 units 2800 units (233.33%)

Table 1: Production Rates

As table 1 shows, the increase needed to reach the goals set by START’s client is around

2800 units, or 233.33%. The concept of this design includes a jig in which they will be able to

rack, clamp, and count cardboard pieces allowing faster wrapping and assembly of cardboard

bumpers.

Literature Review

The American Heritage Stedman’s Medical Dictionary defines handicap as a physical,

mental, or emotional condition that interferes with ones normal functioning [1]. When most

people think of the word handicap, they instantly envision someone in a wheelchair; however,

there are other disabilities such as being hearing impaired, having a long term illness, a brain

injury, or even intellectual disabilities just to name a few.

The 2010 census reports that in the United States as a whole, around twelve percent of

the population, nearly thirty-six million people have some level of disability. Individuals who

suffer from disabilities have reported difficulties in obtaining jobs, keeping a job once obtained,

and performing job duties. The average employment rate of disabled citizens across the United

States is a paltry 33.4 percent [2].

NISH, the National Institute for the Severely Handicapped, is an organization that is

focused on helping people with disabilities gain employment. NISH’s mission is “Create

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employment opportunities for people with significant disabilities.” [3] NISH been helping

handicapped people since 1974. NISH is affiliated with the AbilityOne program. The AbilityOne

program is composed of 600 nonprofit organizations across the United States. One of these

organizations is START in Murphysboro. These organizations are dedicated to providing work

to disabled people and providing them income. They work toward finding jobs for people with

all types of disabilities, from the blind to those with mental disabilities like autism. The

AbilityOne network currently employees around 47,000 people, making them the largest

employer of disabled people in the United States. [3]

Every year NISH supports a competition called the AbilityOne Design Challenge. In this

competition students are encourage to make something that can assist people with disabilities in

their everyday careers. These designs are required to help make their daily task easier. The teams

must registered by the 20th of April. In their entry each group must submit a final report with full

details of their design, as well as a video of their design in use.

These designs are put though strict judging criteria. These criteria are based on a series of

questions.

“• Is the assistive technology device/system a solution to a barrier

that prevents a person with a significant disability from entering or

advancing in the workplace? If the answer is “No”, the submission

will not be reviewed further and will be considered to be out of contention.

• Was a prototype built? If the answer is “No”, the submission will not

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be reviewed further and will be considered to be out of contention.

• Was the device/system designed in collaboration with a person who

has a disability? If the answer is “No”, the submission will not be

reviewed further and will be considered to be out of contention.

• Is the device/system currently being used or intended for use?

by the end of the current school year? Additional consideration

is given to those devices that are in use.

• Was the design developed with consultation from a NISH affiliated

NPA? Additional consideration is given to those that worked with a NISH affiliate.” [5]

The final results depend on how well each group answers the questions above, as well as

a few additional things such as safety and overall ease of use. The better the design solves a

problem but at the same time meets these judging criteria the more highly rated the entry will

place in the competition.

Workforce Concerns

The closest organization in the AbilityOne network is Specialized Training for Adult

Rehabilitation Inc., also known as S.T.A.R.T. This not-for profit organization has been around

since 1969. The S.T.A.R.T. program caters to disabled adults by offering six different

rehabilitation programs that serve over one hundred and fifty, not limited to just working

opportunities. The organization had very humble beginnings, when it was first founded it

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operated out of a church basement. Now the program utilizes over thirty-six thousand square feet

of space for its programs [6]. “Work opportunities include mobile custodial crews,

subcontracting services for area businesses, janitorial services at the rest area on Interstate 57,

and state of the art microfilming and digital scanning services.” [6]

Current System and Proposed Design

The S.T.A.R.T. factory in Murphysboro currently uses a binding system that workers use

to double-bind stacks of cardboard strips. This system relies heavily on the use of human labor,

because the current system calls for the stack to be manually counted, stack, held, and bound.

These stacks of cardboard strips are used as packing bumpers by Penn Aluminum. Penn

Aluminum uses the bumpers to pack and protect the products they send out on a daily basis.

Penn has been a long-time contractor with S.T.A.R.T., starting nearly fifteen years ago, and

S.T.A.R.T has been producing these bumpers for them nearly the same amount of time.

Figure 1: Cardboard bumper

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Recently, Penn has led S.T.A.R.T.to increase the production of bumpers per month to double

what their current production rate is at making the current quota nearly 4000 bumpers a month.

While S.T.A.R.T. has been able to slightly increase their production of the bumpers, they are not

able to fully meet the demand at this point. With a slight amount of simple adjustments the

productivity will be able to be increased to meet demands set forth by the client.

To make the bumpers, employees currently hand count out 15 pieces of cardboard of a set

length and width. Then they hold the cardboard pieces together and wrap them in tape on both

ends, producing the cardboard bumpers. One problem is that it takes a lot of motor skills to hold

all 15 pieces together while wrapping the bumper with tape that is dispensed from a wet tape

machine. This causes production to be slow because many of the disabled people that work at

START have disabilities that limit their motor skills. When our team visited the factory during

production hours they noticed that even though S.T.A.R.T. has two tape dispensers, they are

unable to use them because there is only one worker per shift with the necessary motor skills to

hold the cardboard bundle while simultaneously cranking out a length of tape and then wrapping

the tape around the cardboard.

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Figure 2: Jig Design

As seen in Figure 2 above one idea on how to assist the operator is to include a jig device

to hold the cardboard stacks in place as the operator binds the stack. Another idea is to build a

system that allows the pieces to be held, much like the clamping system above, but also to rotate

to ease the process of wrapping the band around the unit.

While a system that uses mechanical components to lessen the amount of dexterity

required to perform the task is great, a completely autonomous system is not what we are striving

for. The whole reason S.T.A.R.T. exists is to help people with disabilities find work. Rather than

creating an expensive machine to do the task for them, we are striving to make an efficient,

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affordable, and easy to use mechanism to assist the process. The plan is to incorporate

electronics into the design via sensors and possible electro mechanics, but due to the nature of

S.T.A.R.T the design must not be a financial burden on them, therefore target unit cost is

between two and five hundred dollars. Most automatic banding units cost over one thousand

dollars, with high-end units selling for nearly ten thousand dollars.

Model Cost

Pac SM65 Arch Strapping Machine $9986

Signode TABLE-TYER Plastic Strapping Machine $2566

Signode 430999 Power Strapping Machine $1082

Figure 3: Cost of Binding Machines

The current tape dispenser system looks much like the machine in figure 4 below.

S.T.A.R.T. had considered helping to make the job easier by buying automatic tape dispensers,

but even those units were much too expensive. By utilize the existing units in the design, since

they have proven reliable and the employees are used to using them, the total cost of the design

may to be reduced.

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Figure 4: Banding Machine [7]

The way the strips are stacked is a major point that could be improved. By

decreasing the time required to count out the strips and then arrange them in a neat row could

significantly increase daily output of the cardboard bumpers. The amount of time that is takes to

make count the bumpers and stack them is close to 2 minutes.

To make the job of counting the strips easier, the idea to using sensors to detect when the

correct number of cardboard strips have been placed into the machine. The most cost-effective

option seems to be using an infra-red sensor and connecting it to a microcontroller inside the

unit. Infra-red sensors are widely used in robotics and are fairly cheap and easy to maintain most

costing roughly $25-$100 [8].

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There are a couple different ways to program the sensor. The first way, and probably the

easiest is to program the sensor to count each strip as it is loaded into the holding tray. When the

sensor has counted the correct number of cardboard strips, a green LED will light up on the unit

and the employee will know that it is time to activate the holding system and wrap the tape

around the bundle.

The second way to program the sensor would be to make it so that the green LED lights

up after the cardboard reaches a certain height. The microcontroller for the unit will also be fairly

inexpensive and will probably be the best option to handle the input from the sensor

A third way is measure the weight of the stack and allowing the sensor to engage between

a certain tolerances, which would again activate a green stating the jig is full. Included in all of

these would be a red light that allows the user to know when the jig is overfilled.

After looking at various competing systems, both in terms of binding and in terms of tape

dispensing, none of the other products seem to be near to what is needed by S.T.A.R.T., and if a

product is similar to a possible desired component design it is out of the price range that an

organization like S.T.A.R.T. could afford.

The option of a stacking system could also speed up the bumper production process. A

patent for a device that is used to stack fanfold paper was fold and reviewed. Creating a system

similar to this device will be of benefit to S.T.A.R.T. This design is a very good design because

of its simplicity. It uses very few moving parts and is fairly inexpensive [9]. The design allows

sheets to slide down a chute that only allows the sheets to fall flat on the bottom of a tank that

holds all of the paper. A problem may arise in the case when the cardboard trying to be stacked

may not fall flat. This is a very small flaw though, since employees could easily reach in and fix

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the problem. The design allows stacks to be made easily, by a simple process. This is ideal for

the design that can be used by the S.T.A.R.T. facility because the simplicity means it can be

easily used and taught to the employees.

The problem with the design mentioned above is that a hopper system would need to be

included to render the stacking system improvement. Due to the size of the cardboard strips,

11x2x.25 inches, a hopper that would hold a considerable amount of cardboard strips that would

allow steady production would have to be of substantial size. This depending on S.T.A.R.T.’s

work space may cause a problem by consuming to large of area making it impractical in

S.T.A.R.T’s limited workspace for this project which is 15x8.

The Last component the design could include is a clamping device. Since one of the

largest problems in production is the holding of the cardboard in place, a clamp may be put in

place to hold the stack steady in a jig while being bound. The clamp would resemble something

that is used in presses, with a handle the must be pulled down to lock in place until released. A

shirt press like seen in figure 5 below contains a sample clamp that would apply pressure on the

stack in the jig.

Figure 5: Shirt Press [10]

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The biggest considerations for the design are as follows. First, is ease of use? Since the

competition is focus on simplicity, but more importantly the S.T. A.R.T. facility is focused

toward providing jobs that mental disabled employees can accomplish. So the easier the design

can be taught and used the more useful the final product will be. The second thing is the cost of

the design. Since S.T.A.R.T. has limited funding the cost of the system must not place them in a

finical burden. Ultimately these constraints will determine which of the above options for design

will be able to be included in an effective manner.

Project Description
Team 75’s objective is to create a device that will assist the racking, holding, and banding

of cardboard bumpers. The basis of this design is to create a base racking system. As the operator

fills this racking system, three LED indicators will give insight on how full the jig is. The LED’s

will light up as the sensors indicate capacity either by means of a microcontroller or logic circuit.

The first LED will allow the user to know the jig is not filled full, but is actively powered. The

second will tell the operator the jig is at proper capacity (15 cardboard slivers). The last will tell

the operator the jig is over capacity. Once the jig is properly filled, a swing clamp will come

down and apply pressure to the bunch. Once this is done, the operator can then band the bumper

and production is complete. By speeding the counting process and assisting with holding while

banding, the operator will be able to speed production time and will also see an ease in doing so.

The organization of this jig is seen in figure 6.

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Overflow LED

Fill LED

Underflow LED
Arduino Uno
AC to DC Power
Electrical System Microcontroller
Supply
or Logic Circuit
Fill Sensor

Overflow Sensor
Carboard Banding
System

Ventilation and
Filters

Mechanical Racking Clamping
Feed (Counting) Taping
System Mechanism Mechanism

Figure 6: Block Diagram

Currently, the process is done completely by hand. Therefore, any implementation of

assistance will increase production. The current production rate is around 1200 units per week.

This figure is gathered during final shipment each week to the company they create the bumpers

for. The design team for this project has also confirmed these numbers by video taping

production and scaling the timing over the weekly hours. Overall, we are hoping to increase

production from 1200 units to 4000+ allowing not only the client’s demands to be met, but an

increase in salary for the operators. Currently, they are paid on a by-piece basis, so, if we are able

to speed units produced, we will also be able to help the operator make more during a shift. Our

final production rates will be calculated in the same manner, by averaging a piece-by-piece

production time through video taping and scaling this over the weekly hours.

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Project Specifications

Project Specifications
Size 2'x2'x2'
Weight <20lbs
Cost <250
Productivity Rate 60 bumpers per hour
Operating Force 10lbf (projected)
Microcontroller Voltage Requirement ~8V

Table 2: Project Specifications

Design Basis
Documents Date
Request for Proposal 9-Sep-11
SEC RFP Project Definition 9-Sep-11
SEC RFP List of Deliverables 9-Sep-11
Draft Proposal 8-Nov-11
Final Proposal* 8-Dec-11
End of Proposal Memo 8-Dec-11
Progress Report 23-Feb-12
Design Report 19-Apr-12
Notebooks and End of Project Memo 5-May-12
Table 3: Basis of Design (Please see appendix B for home documents)

*Final Proposal overrules any statements made in the draft proposal

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Project Organization

Project Manager:
Jordan John (ME)
Responsibilities:
3-D Rendering/Material
Selection/Racking System

Linden Eason (EE)
John Hughey (CpE) Ben Blair
Responsibilities:
Responsibilities: Responsibilities:
Electrical Wiring and
Programming/Software Material Selection/Clamping
Integration/Harness Wiring
Mapping and Integration System/Fabrication
and Integration

Table 4: Organizational Chart

Scope of Work
List of Deliverables as Required
Literature Review
Technical description of all work done for every solution
Equipment, component, and materials take-off lists and costs for each solution
Technical Drawings
Selected solution with Pugh chart
Technical description of recommended system and how it works
Summary of lab tests and analysis performed relevant to solution
Complete specification including all drawings necessary for production and installation
as well as repair
Complete list of components and signal processes
Table of performance data
Technical list of problems and limitations derived during design and testing
Analysis of electromagnetic compatibility including coding
Fault analysis
Technical Manual

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Users Guide
Conclusion and recommendation section
Estimated cost of production
Timeline to construct, build, or manufacture
Appendix

Subsystem Designs

Clamping System

Summary of Components
Clamping device
Lever
Pressure applying plate
Jig Mounting Unit

List of Deliverables
Clamping Prototype
Analysis of maximum force needed on handle
Analysis of mechanical advantage
Analysis of minimum pressure needed for plate clamping
3-D Renderings

Due to the current problem that S.T.A.R.T. has with holding the bumper stacks while

taping them together, the use of a clamp will be included in the design. The clamp’s purpose is to

apply pressure to the stack so that it the stack will be firmly held in place in the jig.

The clamp does not need to apply a lot of force, only enough to keep the stack solid

seated in the jig. The clamp will resemble that of a shirt press machine. It will have a handle that

extends forward that the employee will be able to pull down with minimal force to apply the

pressure of the clamp. The clamp will be composed of a four bar mechanism which when the

force of the lever is applied the four bar mechanism will move until weigh is over center causing

the mechanism to lock in place. To release the mechanism the level will need to be lifted to

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allow the center of mass to return to its original position. The length of the handle will be

determined to allow the greatest mechanical advantage so it can be used by all employee’s at

START.

Racking System

RackJig
Supports
Racking Plate Assembly
Sensor Housing

Racking Prototype
Analysis of proper sensor placement
Analysis of maximum force applied on supports
Analysis of tolerance through system
Analysis of clamping attachment placement
3-D Renderings

The basis of the rack design will be a support set with a plate assembly mounted on the

inside of the supports. Along the back support, the clamping device will be mounted. First, for an

ease of visualization, please refer to appendix C. Appendix C has drawings that show the

proposed design on a drafted model. These drawings were made by using AutoDesk Inventor

2010.

The supports of the racking system will be made from steel rectangular tubes. The left

and right will be identical with drilled holes through the body of each to mount the plate

assembly. The back tube will be longer to allow the clamping device to be attached. As

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proposed, the left, right, and back tubes will be cut to 12”, 12”, and 14” respectively. Again, this

is just a drafted model and said measurements can change.

Figure 7: Supports

Next, the rack assembly will be mounted within the thresholds of the supports. This is

where the operator will put the cardboard slivers into the rack allowing the operator to work

hands free during this process. The plate will be cut to 11.5” W by 2” deep. The height of the

rack will be anywhere from 4.5” to 6.5” depending on the final design.

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Figure 8: Racking Plate

The rack will also be home to the clamping assembly. As seen in the appendices, a

proposed clamping assembly will attach to the rear support shaft and swing downwards into the

rack allowing pressure to be applied to the stack of cardboard slivers. This design will have to be

prototyped once force analysis is done on the clamping system.

Finally, the sensor placement has yet to be determined. Because of the nature of sensors

and how they react to different reflections of materials, direct sensor placement will derive from

adequate testing and analysis allowing for the precise placement. This analysis will be mostly

based on where exactly the sensor will be most accurate. By finding a position along the frame in

which the sensor can function normally and without interference, we will be able to make the

overall system more accurate. Interference can be a result from many things (magnetic fields,

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reflective properties of the metals used, “noise”, etc.) so the placement will be determined during

our analysis and testing phases.

All subassemblies of the rack system will be attached with fasteners of 1/4” diameter and

varying lengths. Some will be direct carriage style bolts; some will be counter bored screws

allowing for flush design. The assembly will appear similar to the following:

Figure 9: Draft Assembly

Power Source

Power Source

Functioning power source

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Analysis of output power

The most important item to complete the electrical sub-system is the power source. The

microcontroller can be operated within a voltage range of six volts to twenty volts but operates

optimally between seven volts and twelve volts and uses a wall power adapter. The wall power

adapter chosen to power the selected microcontroller has an output of nine volts.

Control Circuit

2 to 4 demultiplexer
Breadboard
Power Supply

Working prototype
Stress tests for components

The individual inputs from the sensors will need to be processed in order for the correct

LED to light up. While we had originally planned to use an Arduino for this purpose, a physical

circuit will be cheaper to build and maintain. The physical circuit should also be more durable.

The circuit will follow a simple logic pattern (see appendix D).

Figure 10: Circuit Logic Diagram

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As the above figure shows, the circuit will have four states. State 00 (neither sensor

detects cardboard) will light up the green LED to tell the operator to fill the jig. State 01 (overfill

sensor off, fill sensor on) will light up the yellow LED to tell the operator that the jig is full. State

11 (overfill sensor on, fill sensor on) will light up the red LED to let the operator know the jig is

too full. State 10 (overfill sensor on, fill sensor off) will be used as a simple form of error

detection and will light up all three LEDs as red. Since we have 2 inputs and 4 outputs it is

necessary to use a 2-to-4 demultiplexer to handle the logic. A demultiplexer uses several AND

gates to take a small number of inputs and translate them into a greater number of outputs. The

pin assignment diagram for the demultiplexer is as follows (Also in appendix D):

Figure 11: Pin Assignment Diagram

Microcontroller

Microcontroller

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Working prototype
Documented C code structure

The individual inputs from the sensors will need to be processed in order for the correct

LED to light up. While this could be done using a physical circuit, the amount of data

transmitted by the sensors that would then need to be transmitted to the LEDs makes using a

physical circuit a poor option. Since power is required to operate the sensors and LEDs, it is a

small step to incorporate a microcontroller into the design. The microcontroller that fits our

design the based is part of the Arduino series of microcontrollers. These microcontrollers are

based on an open source platform that allows for easy development. The wiring diagram for the

sensors we plan to use is as follows (Also in appendix D):

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Figure 12: Microcontroller Wiring Diagram [11]

To connect the LEDs to the microcontroller, it will be necessary to use a 330 Ohm

resistor in series with each LED to prevent them from burning out. The microcontroller will need

to be programmed to handle the sensor inputs and convert them into the proper outputs for the

LED indicators. Arduino microcontrollers can be programmed in C, which is fortunately one of

the most wide-spread programming languages. The C language is very versatile, which is

fortunate since it allows the programmer to develop custom functions through which to run

inputs and outputs. This allows the code for the microcontroller to be minimal.

Sensors

IR Photosensors

Report of sensor placement on the jig
Report of sensor placement angles
Functional prototype
Analysis of sensor accuracy

30 | P a g e

Figure 13: Sensor Placement Diagram

Based on the project design, two sensors are needed. The term “sensor(s)” as used in this

subsection refers to both parts of the sensor unit, the emitter and the receiver. The first sensor

will be placed 4.25 inches above the base of the jig. This sensor will return a “low” value when it

detects under-fill and return a “high” value when the jig is full, indicating the correct number of

cardboard strips have been inserted. The second sensor will be placed .25 inches above the

under-fill sensor, and will be utilized to prevent over-fill of the jig, returning a “high” value

when the jig is not over-filled and a “low” value when the jig is over-filled. The over-fill

indicator is necessary in the event that an employee loads too many strips into the jig, going over

the specified amount of cardboard strips. This can easily happen due to the need for an increased

production rate of nearly four hundred percent as requested by the contract holder for the

cardboard bumper project(see appendix A). The biggest concern when selecting which sensor to

utilize is the range which the sensor produces accurate measurements. Another concern when

selecting the sensor is the level of background noise produced by ambient light. In order to

produce a final product that maximizes cost effectiveness and fits within size specifications,

photo sensors that work off the infrared spectrum of light will be implemented. The sensor works

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based on an LED that sends infrared light into the jig that will then be reflected into the photo

sensor when the cardboard strips reach the required height.

Indicator LEDs

Summary of Components:
Green LED (power on)
Yellow LED (capacity)
RedLED (over capacity)

List of Deliverables:
Analysis of viewing placement of LEDs
Analysis of LED placement on rack
Analysis LEDs colors and brightness
Functioning indicator system

Figure 14: Sample LED [12]

Once the photo sensors are inserted in the proper place, the use of red-green-blue light

emitting diodes (RGB LEDs) will be used to indicate the states of the cardboard strips placed in

the jig. A system of three LEDs will be used to specify if the jig has enough cardboard strips to

continue with the binding process. The first of the three LEDs will light up green and stay lit

most of the time to inform the employee operating the jig to keep inserting material. The second

LED will light up yellow once the jig is filled to correct height, which in this design is measure

at 4.25 inches. The third and final LED will light up red as fail safe to notify the operator that the

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machine is over-filled, which will be measured at 4.5 inches and strips must be removed until the

second LED displays yellow. Although one RGB LED is able to produce multiple colors, the

decision to go with three separate diodes was to take into account any employees that may have

problems distinguishing color. Therefore, the LEDs will be placed in an adjacent vertical

position so that the LEDs can mimic the fill process with the bottom light meaning fill, the

middle light meaning stop and the top light meaning over fill. This is shown below:

Figure 15

: LED Setup

Ventilation and Filter


Fan
Exhaust Vents
Housing

Diagram of electrical sub-system placement
Analysis of filters efficiency
Analysis of airflow and operating temperatures
Analysis of exhaust vent placement
Functioning cooling and protective layout

The other electrical sub-systems will need to be enclosed within a case to protect them

from any damage due to the working environment. The goal is to make this case rugged and

breathable with a light weight material. The design include two exhaust vents and a fan that will

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be used to give the parts better air flow and keep internal temperature at or slightly below room

temperature (approximately 72°F). One of the exhaust vents will be placed facing away from the

jig while the other facing the side as intake. A filter will be placed inside of the exhaust vent for

intake to prevent any dust entering the case and causing damage to the parts inside. The type of

fan, filter and even vent placement has not been completely determined until we have complete

analysis of airflow and the operating temperatures produced by the other electrical sub-systems.

Training Aids

Training media for employees
Training Manuals

Training media for employees
Documentation of all subsystems for START to use if maintenance is needed

In order for both current and future employees of the START facility to use the prototype,

training materials will need to be designed. The directors of the facility will need to be

interviewed to determine the most effective training materials currently in use at the facility so

that the materials provided for this product are as effective as possible. Possible training

mediums include training videos, training manuals, and posters with helpful reminders.

Regardless of the medium used, the training materials will provide a step-by-step walkthrough of

the operation of the jig. A manual will also be provided to the directors of the START facility in

order for them to have full documentation of the components used. Included in this manual will

be instructions for basic maintenance.

Material Selection

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Material type Yield Strength Density Cost Overall rating
(MPa) (lb/in^3) ($/ton)
ASTM A681 (Steel) 380 0.282 1000 8.6
AISI 1020 (Steel) 350 0.284 3000 5.5
Al 2024 (Aluminum) 324 0.1 2100 7.2
Al 5052 (Aluminum) 228 0.097 1000 8.5
Table 5: Material Selection Matrix

From this material selection matrix, it can be seen that a steel subsidiary is the best choice

for cost effectiveness in this application.The steel will be a common carbon steel, like ASTM

A81 and AISI 1020 as shown in the matrix, that can be bought at a local hardware store.

Action Item List

# Activity Person Assigned Due Status Comments
1 Order Electrical Parts JH 11/16/11 11/22/11 50%
Purchase Mechanical
2 JJ 11/16/11 1/17/12 0%
Parts
Begin testing and analysis
3 LE 11/16/11 1/24/12 0%
of AC Power
Begin Racking System
4 JJ 11/16/11 1/24/12 0%
Base Build
Begin Programming
5 JH 11/16/11 1/24/12 0%
Infared Sensors
Begin Programming
6 JH 11/16/11 1/24/12 0%
Simple Logic Controller
Begin Programming
7 JH 11/16/11 1/31/12 0%
Arduino Microcontroller
Begin Sensor Placement
8 JH/LE 11/16/11 1/31/12 0%
Analysis
9 Finalize LED Placement LE 11/16/11 2/7/12 0%
Begin Clamping
10 BB 11/16/11 2/7/12 0%
Mechanism Design
Begin Ventilation and
11 LE 11/16/11 2/7/12 0%
Filter Analysis
Table 6: Action Item List

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Project #: F11-75-NISH 17-Jan-12 24-Jan-12 31-Jan-12 7-Feb-12 14-Feb-12 21-Feb-12 28-Feb-12 6-Mar-12 13-Mar-12 20-Mar-12 27-Mar-12 3-Apr-12 10-Apr-12 17-Apr-12 24-Apr-12 1-May-12
Activity Week 1 Week 2 Week 3 Week 4 Week 5 Week 6 Week 7 Week 8 Week 9 Week 10 Week 11 Week 12 Week 13 Week 14 Week 15 Week 16
Design/Assembly
Test AC Power Source For Safety

Finalize Base Design for Racking System

Program Infared Sensors

Program Simple Logic Controller

Program Arduino Microcontroller

Determine Infared Sensor Housing Placement

Finalize Indicator LED Placement

Finalize Clamping Mechanism

Finalize Ventilation and Filter Placement

Assembly/Testing
Prototype Build/Assembly
#
Prototype Test 1

Redesign/Rebuild
Proposed Spring 2012 Schedule

Prototype Test 2
#
Intruction Manual and Signage

Reports
Written Progress Report

NISH Ability One Report Drafting

Table 7: Proposed Schedule
NISH Ability One Report
#
Mechanical Subsystem Report Drafting

Electrical Subsystem Report Drafting

SEC Design Report
#
Poster
#
Final Presentations
#
Notebooks

Team Evals and Course Assessment

End of Project Memo

Legend Bid Worked Revised
Activity
Milestone # ! *

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Resources Needed
Item Description Quantity Individual Price Overall Price Subtotal (w/on hand) Subtotal (w/o on hand)
1 AutoDesk Inventor Software 1 $1,500.00 On Hand
2 MEEP Machine Shop Work 5 hours $25.00 On Hand
Misc. Costs $0.00 $1,625.00
3 Arduino Uno 1 $30.00 $30.00
4 AC Adapter 1 $7.00 $7.00
5 Optical Phototransistor (QRD1114) 5 $1.13 $5.65
6 T1-3/4 (5mm) Multicolor RGB LED with White Diffused Lens 10 $1.75 $17.50
7 CanaKit 1/4W Resistor Kit 1 $15.00 $15.00
8 Wire (6 colors) 60 foot $0.1-0 per foot $6.00
Electrical Costs $81.15 $81.15
9 Steel Plate (48"x48" 1/4"thickness) 1 $118.86 $118.86
10 Steel Rectangular Shaft (2"x2" 1/4"thickness) 50 $0.54 per inch $27.05
11 Pins for Clamp (1/2" diameter) 2 $1.00 $2.00
12 Steel Clamp arms 2 $2.00 $4.00
13 Neoprene Handle 1 $4.50 $4.50
14 Misc. Bolts 100 $0.10 $10.00
Mechanical Costs $166.41 $166.41

Total $247.56 $1,872.56
Table 8: Resources Needed

List of Analyses

General
Durability Analysis
o Will focus on estimated material life through life cycle analysis as well as
operating needs (proper temperature, proper power, etc.) that must be met for the
system to continue to function.
Reliability Analysis
o Will focus on the ability to perform accurately and precisely over the life of the
unit.
Prototype Implementation for Analysis
Employee Strength Test
o Will be tested using force gauges to find the optimal force range for the project.
Motion Capture for Production Rates
o Daily and weekly production analysis to ensure that the projected production rate
is met.

Mechanical

Analysis of maximum force needed on handle
Analysis of mechanical advantage
Analysis of minimum pressure needed for plate clamping
Analysis of proper sensor placement
Analysis of maximum force applied on supports
Analysis of tolerance through system

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Analysis of clamping attachment placement
Wear and fatigue testing

Electrical
Analysis of output power
Coding revision and testing
Analysis of proper housing placement on jig
Analysis of sensor accuracy
Analysis of viewing placement of LEDs
Analysis of LED placement on rack
Analysis LEDs colors and brightness
Analysis of filters efficiency
Analysis of airflow and operating temperatures
Analysis of exhaust vent placement

38 | P a g e

Works Cited

1. Dictionary.com, "handicap," in The American Heritage® Stedman's Medical Dictionary.

Source location: Houghton Mifflin Company.

http://dictionary.reference.com/browse/handicap. [Oct 5, 2011]

2. American Fact Finder, U.S. Census Bureau, [Oct 2, 2011]

http://factfinder2.census.gov/faces/tableservices/jsf/pages/productview.xhtml?fpt=table

3. “About NISH.” Internet: http://www.nish.org/NISH/ [Oct 5, 2011]

4. AbilityOne Network Fact Sheet [Oct 4, 2011]

http://www.nish.org/NISH/Rooms/DisplayPages/LayoutInitial?Container=com.webridge.enti

ty.Entity%5BOID%5B3A204683BB46664D9DEFF5408A4A0613%5D%5D

5. “Judging Criteria.” [Oct 5, 2011] http://www.instituteforempowerment.org/design-

challenge/judging-criteria

6. Specialized Training for Adult Rehabilitation. [Oct 3, 2011]

http://www.startinc.org/AboutUs.php

7. Better Packages, Inc. “Better Pack® 333 Plus water-activated paper tape dispenser.” 2008.

[Oct 5, 2011]http://www.betterpackages.com/products/dispensers/manual/bp333plus.shtml,

8. Seattle Robotics Society [Oct 4, 2011] http://www.seattlerobotics.org/guide/infrared.html

9. R.A. McIntosh, R. G. Bernier, D. A. Estabrooks. “Stacking System for Fanfold Paper and

The Like,” U.S Patent 4,226,410, Oct. 7, 1980.

10. Powerpress, Inc. “15 X15 Digital High Press Sublimation Clamp Shell

T Shirt Heat Press Transfer Screen Printing Machine.” 2010 [Nov 4 2011]

11. Bildr.org. “Are we getting close? Proximity Sensors + Arduino” [Nov 7, 2011]

http://bildr.org/2011/03/various-proximity-sensors-arduino/

39 | P a g e

12. Acronum.com. “Sample LED” [Dec 6, 2011]

http://acronum.com/nz-

en/components/com_virtuemart/shop_image/product/RGB_LED_5mm_4_00_4c47d58584e7

8.jpg

40 | P a g e

Appendix A

From: Carl Hartmann<carlhartmann1@gmail.com>
Date: Tue, Oct 18, 2011 at 12:25 PM
Subject: Re: NISH
To: John Hughey <jcwh129@siu.edu>

Good Morning,

We have recently purchased two new tape machines, which brings our total to 4. In full
production, if we have the cardboard cut, we can utilize two people per tape machine. We
currently have trouble getting the cardboard cut, so we are utilizing only three or four
clients per day. ( We have a large crate building operation which is utilizing our saws in
the woodshop for another 4 weeks. After that we should be able to cut enough cardboard
to utilize all of the tape machines.)

Presently per client, they are producing 80 - 90 bundles per day, per client. Presently we
are producing an average of 250 per day, or about 1200 per week. We are being told, that
the ideal production, per our customer , is 4,000 per week.

Hope this is helpful, please ask if you have other questions.

Carl

On Tue, Oct 18, 2011 at 11:15 AM, John Hughey <jcwh129@siu.edu> wrote:

Hi Carl,

This is John Hughey, the project manager from the NISH design team. For the purpose of our design we were
hoping you could provide us with the production figures for the carboard bumpers. When we first toured the
facility Kathy mentioned that the Aluminum Company had recently increased demands so we need to know
how many units they need per month and how many you are currently producing.

Thanks,

John Hughey

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Senior Engineering Design Center
College of Engineering – Mailcode 6603
Carbondale IL 62901-6603
618-453-7837, -7031, -7025

Appendix B

Request for Proposals (RFP)

9 September 2011

Subject: AbilityOne Network Design Challenge

Client: Institute for Economic Empowerment

Project Number: F11-75-NISH

Since the passage of the Americans with Disabilities Act of 1990 employers have been required to make
adjustments in the work environment to make reasonable accommodation those with disabilities. The purpose
of NISH goes beyond reasonable accommodation to a mission to create employment opportunities for people
with severe disabilities by securing federal contracts through the AbilityOne Program for its network of
community-based, nonprofit agencies. In keeping with this mission, the AbilityOne Network Design Challenge
was founded to encourage the development of creative technological solutions for barriers that prevent people
with disabilities from entering or advancing in the workplace.

Saluki Engineering Company, hereinafter SEC, has been appointed Architect-Engineer Coordinator for the
referenced study on behalf of Institute for Economic Empowerment,hereafter Client, to make an engineering
study of the referenced project.

SEC has divided the work into packages by engineering team capability and will coordinate the overall work.
SEC has sent this bid package to three competitive engineering teams, hereinafter Engineer, of equal capability
including your team. SEC is hereby requesting a proposal from Engineer for Client’s approval to do the
defined work. The timeline for this project will be as follows:

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Senior Engineering Design Center
618-453-7837, -7031, -7025

8 November 2011 Proposal FINAL draft due posted on website by 11AM. This proposal will be
evaluated for compensation (grade in the course).
8 November – 17 November 2011 First Design Reviews teams 70-77
29 Nov – 8 Dec 2011 Oral presentations of proposals 11:00-11:50 am in EGR A111
8 December 2011 Spiral bound hardcopy AND proposal posted to website with required
modifications, if any
17 January 2012 Phase II work begins.
23 February 2012 Progress Reports posted to web space by 1PM
19 April 2012 Design Reports (6 copies: 3-ring binder + 4CDs + Website) due at 1PM
24-26 April 2012 Demonstrations of projects E215 1PM
24-26 April 2012 Presentations of posters E215 1PM (may be required on an earlier date)
1-3 May 2012 Design oral presentations

Your proposal will receive conditional acceptance on 12 Dec 2011; you may have to make additional changes
in January after Management and Client review it and new data become available.

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Saluki Engineering Company 9 September 2011 Project # F11-75-NISH
SEC Request For Proposal Letter Page 44

Engineer will present the drawings, specifications, and explanatory text in a final Design Report together with
the capital cost estimate and schedule to construct, install, or manufacture the product.

One written and one oral progress report will be required during the design as indicated above. In addition, one to three
design review meetings will be required.

The proposal, which you will submit by noon according to the attached schedule, must include:
1. A cover and title page
2. A transmittal letter
3. An abstract or executive summary of 300 to 500 words
4. A non-disclosure statement
5. A table of contents
6. An introduction that indicates that you understand the study and why it is being undertaken.
7. A literature survey that lays out the following:
a. An introduction that outlines the content of the literature review
b. what is already known about projects of this type, including similar existing systems
c. what the required design procedures are
d. the relevant content of the applicable codes and standards
e. the relevant materials and components available on the market
f. a summary of how the reviewed literature relates to this project
8. An over all project description that indicates the subsystems and their relationships to each other, including
a site plan or block diagram to visually show how the subsystems are related, and how this system will be
different from existing systems
9. The design basis
10. For each subsystem,
a. a description of what each subsystem will be or do
b. a description of how each subsystem relates to the other subsystems, including references to the site
plan or block diagram to show the relationships,
c. a list of the elements which will define the subsystem design,
d. a list of deliverables, including all drawings, tables, lists, write-ups and other elements, that you can
now identify as probable parts of the Design Report you will submit at the completion of the project
e. a list of design activities required to produce the deliverables listed
11. A project organization chart indicating project manager and showing for each nominee: name, principal
area of responsibility, and discipline (ME, EE, or CpE);
12. An action item list that shows detailed action items for the first two weeks and significant action items for
weeks thereafter
13. Team timeline indicating major design activities and significant milestones in either
a. Excel or Word table,
b. Microsoft Project, or
c. other project tracking software package.
[Note that there is a lot of redundancy between 10e, 11, and 12. Be aware that self-consistency is one
item on which your proposal will be evaluated.]
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14. A list of all resources you will need including space, computers and specialized software required, and
including – for design and build projects – a list of all components that you can now anticipate needing and
their actual costs, or current location if they are to be borrowed
15. List of data analyses, experiments, and simulations to be performed
16. Description of what is to be built and demonstrated or software to be written and demonstrated
17. An appendix that includes
a. the resumes for all candidates for the team
b. copies of any communications your team has with Client, other companies, or individuals.

Any literature that your team requests that vendors send to the College of Engineering during the course of the
writing of this proposal will be addressed as follows:

A. Weston, F. Harackiewicz, or K. Purcell
Southern Illinois University
In addition, any information you request to be faxed should be sent to

A. Weston, F. Harackiewicz, or K. Purcell
FAX: 618-453-7455
Voice: 618-453-7837 (Weston), -7031 (Harackiewicz)
618-559-6190 (Purcell)
Please note: If any material that arrives is sent to YOUR name at the college, you will never see the material
because students are not known by name to the mailroom staff. Be sure to give SEC management a memo
indicating (1) what and from whom you ordered and (2) the SEC Reference Number of the team that is
to get it. This is to alert management to watch for your material and recognize it when it comes in.

Engineer will adjust the Scope of Work so that it is suitable for each of the engineers who will be working on the project.
If significant design components of the project must be omitted because of time or staff limitations, clearly identify them
in your proposal. Your final cost analysis must, in any event, account for them.

The attachments to this letter are listed below:
1. Client’s project definition
2. Design Report deliverables checklist
3. Spring 2012 tentative schedule

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SEC management looks forward to receiving your proposal. Engineer shall deliver the proposal tothe SIU
Engineering College complex in Carbondale, Illinois, addressed to the attention of Dr. F. Harackiewicz and
Mrs. Purcell, SEC's Managers of ECE Projects or Dr. A. Weston, SEC’s Manager of ME Projects.

Sincerely,

F J Harackiewicz
Manager of ECE Projects
<fran@engr.siu.edu>

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Attachment 1 - Project Definition

Client wants a device or a system that will solve a real workplace problem for at least one group of
severely handicapped workers.

The winning proposal for the device or system will have verifiable, quantified goals. The proposal will
describe technologies that have been used in the past as well as those currently being used to overcome
the problem. The functional description of the proposed device or system will include a statement of
how it is different from, and better than, what currently exists. The proposed schedule will allow for at
least three design-build-test-modify iterations. The proposal will incorporate all of the requirements for
a winning design.

The device or system itself will have complete documentation so that it may be reproduced for use with
others of similar handicap. The documentation will contain a thorough failure analysis and data from
validation and revalidation of the design with members of the group it will serve.

More information on the design challenge for 2011-2012 can be found here:
http://www.instituteforempowerment.org/design-challenge

Challenge requirements can be found here:
http://www.instituteforempowerment.org/design-challenge/submission-specifications

For online registration go to:
http://www.instituteforempowerment.org/design-challenge/registration/college-entrants

For Judging criteria:
http://www.instituteforempowerment.org/design-challenge/judging-criteria

In case of a conflict between this RFP and Client's design requests, Client's design requests control. As
new data become available, Client may give Engineer additional data and criteria that Engineer will
incorporate into the design.

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Attachment 2 - Design Report Deliverables Checklist

The proposal Engineer submits will indicate that these items will be included in the Design Report (not the
Proposal!):

1. A literature review relevant to the design submitted (not a copy of the literature review in this
proposal)
2. A complete technical description and the results of all work done for all solution options studied
3. Equipment, component, materials take-off lists and costs for each solution studied
4. Engineering drawings defining the solutions
5. A recommended solution and a detailed justification for the choice recommended or implemented,
including a Pugh chart or some similar matrix comparison chart that is discussed in the text
6. A complete technical description of the recommended system and how it works
7. Incorporate into descriptions a summary and the significance of any laboratory work, computer
simulations, or mathematical analysis performed.
8. A complete engineering specification for the system including all engineering drawings necessary
for construction, manufacture, or installation and maintenance and repair
9. A complete list of the components and signals in the process, and a list of the ones that are included
in the model, if any, with the corresponding part of the model identified
10. Tables of performance data – individual subsystem and overall – expected and, for the part that was
built, achieved
11. Identification of the important technical problems and limitations encountered during design,
construction and debugging, e.g., time, accuracy of results, reproducibility of results, limitations on
input
12. An analysis of electromagnetic compatibility issues and changes necessary in the design to meet EMC
code specifications
13. A fault analysis of the recommended system, including identification of all faults that could
occur, a technical solution to eliminate their consequences, and the cost for incorporating the
improvement
14. For the working model, Technical Manual that includes a technical description of both the
hardware and the software, together with, but not limited to: appropriate hardware engineering
drawings and component lists; software flowcharts, listings, and disks; and instructions for
construction, maintenance, trouble shooting, and modification
15. If a prototype of the device was built, User's Guide for the individual using the prototype, including
both instructions on how to connect and use the hardware, how to set up and use the software, what
performance can be expected, and what limitations the prototype has
16. A conclusion and recommendations section that
a. summarizes the performance,
b. includes recommendations for improvement, enhancement, and manufacture, and
c. discusses the economic, societal, environmental, manufacturability, health, and safety issues
related to this project if it is implemented
17. An estimate of the amount of capital required to construct, build, manufacture, or install the
designed system, whichever is appropriate
18. A timeline schedule to construct, build, manufacture, or install the designed system, whichever is
appropriate

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Attachment 2 - Design Report Deliverables Checklist
19. In an appendix:
a. the actual itemized cost to construct the prototype, including costs of ruined components and
components for options not included in the prototype
b. any calculations, spreadsheets, computer simulation results, or other data that should be a part of
the report but is too numerous or too bulky to be included in the report itself, this material will
be be referenced and summarized in tables in the report,
c. formal laboratory reports for all laboratory work performed with the results referenced and
summarized in the report, and
d. for projects NOT having a working prototype with a Technical Manual, a listing of any software
developed as a part of the project.

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Appendix C

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Appendix D

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Benjamin W. Blair

13536 Mary’s Creek Rd. (618) 317-1926
Sparta, IL 62286 bwblair10@gmail.com

OBJECTIVE Seeking full time employment in the mechanical engineering field.

EDUCATION Southern Illinois University Carbondale, IL
Bachelor of Science in Mechanical GPA: 3.58/4.00
Engineering, May 2012

Related Coursework:
Thermodynamics Fluid Mechanics
Mechanical Design Internal Combustion Engines
Heat Transfer Computer-Aided Drawing
Engineering Economics Material Selection

EXPERIENCE Farmhand, Blair Farms Inc. 2006-Present
Operated and maintained mechanical equipment, obtaining
understanding of how different machines work.

Assistant, Sparta Animal Clinic
Performed office duties, building skills filing paperwork and
improving my customer interaction.

SKILLS Computer Skills:Microsoft Office, AutoCAD, C++, MATLAB

LEADERSHIP AND Academic Scholarship, SIUC, 2008-2010
AWARDS Volunteer Track and Field Coach, Sparta High School, 2010-2011
Volunteer Math Team Coach, Sparta High School, 2010

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Contact info
lindeneason@gmail.com
905 East Park Street Apt D5
LINDEN EASON, A.A. Carbondale, IL 62901
(815) 519-3741
Objective: To seek an internship position with a company requiring me to utilize my
technical abilities and further develop my engineering knowledge.
Education: Southern Illinois University Carbondale
Major: Electrical And Computer Engineering
Cumulative GPA: 3.0/4.0 Major GPA: 3.3/4.0
Expected Graduate Graduation: Fall 2012
Minor: Mathematics

Rock Valley College A.A.
Cumulative GPA: 3.0/4.0

Experience: Southern Illinois University Carbondale - Teacher’s Assistant Fall 2011-present
Provided students with diverse ways to approach technical
assignments
Graded all of the class assignments
Foot Locker Inc. – Champs Sports Sales Representative March 2006 –
Worked to provide customers with the best customer care September 2007
Helped organize and monitor inventory
The Kroger Co. – Hilander Foods Gas Clerk & Deli Worker May 2005 –
2. Managed the gas clerk area December 2005
3. Managed deli area

Skills: MATLAB simulink
Visual Studio, C++
Microsoft Office Suite
Xilinx
Volunteer ACT preparation program Fall 2006-present
Work: -Helped to develop students test taking skills
Engineering Day SIUC
-Hovercraft demonstration
Erma Hayes Center
-Served as a mentor for children at the Erma Hayes Center
Adopt a Spot NSBE
-Helped to clean excess garbage off a stretch of road
Honors and Dean’s List Fall 2008
Activities: Awarded Smart Grant Fall 09-Spring 11
Awarded Minority Engineering Program Scholarship Fall 2011-Spring
2012
Extracurricular National Society of Black Engineers member SIUC Fall 2011-present
Activities: -Helped in the organization of volunteer work, fundraising and
events.
- Serve as one of the chapter’s senators

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John C. Hughey
jcwh129@siu.edu
Permanent Address: College Address:

102 DLK Drive 221 Bailey Hall

Anna, IL 62906 1225 Point Drive

618-833-3772 Carbondale, IL 62901

618-536-7979

Objective: A career in computer engineering.

Education

Southern Illinois University Carbondale (SIUC), Carbondale, Illinois August 2007 - Present

Course work toward Bachelors of Science in Computer Engineering with a Minor in Management

GPA: 3.0/4.0

Relevant Coursework

Digital Circuit Design
Intro to Software Engineering
Verilog and VHDL Synthesis
Experience

Resident Assistant, Southern Illinois University Carbondale August 2009-Present

Help Residents with both academic and personal issues.

Provide programming and other services to help improve the college experience.

Help achieve the mission and vision of SIUC University Housing.

Cook/Delivery Driver, Pizza Hut Inc. August 2006 – August 2008

Help satisfy customer complaints.

Skills

Microsoft Office Suite: Word, Excel, PowerPoint

Awards & Honors

College of Engineering Scholarship Fall 2008 – Spring 2010

Dean’s List, SIUC Spring 2007 – Fall 2008

Activities

Residence Halls of Horror – Director, Room Coordinator Fall 2009 – Fall 2011

Thompson Point Executive Council (TPEC) – Vice President Fall 2008 – Spring 2009

SIUC Leadership Council Fall 2007 – Spring 2008

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Jordan John
Permanent Address Cell: 618-303-0975 School Address (Until 5/15/2012)
13132 Fenwick Street Email: jjohn89@siu.edu 900 S. Elizabeth Street
Fishers, IN 46037 Apartment #3
Carbondale, IL 62901

Objective An entry level position in Mechanical Engineering beginning May 2012.

Skills Excellent written and oral communication skills
Numerous leadership experiences
Works well in a team or an independent setting

Education Southern IllinoisUniversity; Carbondale, Illinois
Carbondale, Illinois 62901
Pursuing Bachelor’s in Mechanical Engineering
Pursuing Minor in Mathematics
Projected Graduation Date: Spring 2012
GPA: 3.19/4.00

Specialized  CAD/CAM  Material Science
Course  Energy in Society  Material Selection for Design
Work  Energy Systems and Management  Pneumatic/Hydraulic Design

Relevant Boeing Integrated Defense Systems Externship - Joint Helmet Mounted Cueing System
Work (JHMCS) integration for F-15’s and F/A 18’s; St. Louis, MO (March 2011)
Experience SIUC Resident Assistant; SIUC University Housing (August 2009-May 2010)
SIUC College of Engineering Peer Mentor; SIUC University Housing (August 2008-May
2009)
Relevant Vacuum Flask Drinking Apparatus (Spring 2011)
Projects Individualized design of flask with in depth material selection based on
Thermos® technology
“A Renewable Home”: A Project on Sustainability and Renewable Energy Sources
for the Modern Home (Spring 2009)
Project Manager
Research and development of a completely self-sustained living unit complete
with energy flow analysis and renewable energy systems design

Awards SIUC Dean’s List and College of Engineering Honor Roll (Fall 2007, Summer 2009)
Two time recipient of the Highway District #9 Engineering Scholarship (Fall 2008, Fall 2009)
Phi Sigma Kappa Fraternity 2008-2009 “Brother of the Year”

Activities Order of Omega Honor Society (April 2010-Present)
Golden Key Honor Society (October 2008-Present)
Alpha Lambda Delta Honor Society (May 2008-Present)
Phi Sigma Kappa Fraternity (May 2008-Present)
 President (November 2009-November 2010)
 Vice-President (November 2010-April 2010)

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