Publication Date

Spring 5-7-2026

Document Type

Student Project

First Advisor

Lin. Peter

Second Advisor

Tahernezhadi, Mansour

Degree Name

B.S. (Bachelor of Science)

Department

Department of Mechanical Engineering

Abstract

For aerospace companies like Collins, pressure switches are crucial for safety, precise control, and reliability. As such, thorough testing of these switches is an essential step in Collins’ manufacturing workflow. However, current testing regimes suffer from several critical drawbacks. Firstly, they require constant manual supervision, costing precious time and manpower. Existing systems are also only able to test one single switch at a time, which creates backlog and delays. Lastly, current testing equipment has poor integration with the Collins digital ecosystem, hindering the utility of these devices. To solve these design challenges, a new system is required that is self-operable, allows for simultaneous testing, and is better at data handling. The prototype needs to function on its own without constant operator presence. It must be more reliable, with smoother pressure control, and safer, with features like a drip pan to contain leaks, and clear work instructions with a troubleshooting guide. The upgrade is also geared towards affordability due to using the existing prototype. The addition of cost to the prototype would be practical parts like storage for tools and a barcode scanner. The improved prototype works through three main functional domains. First being the mechanical domain which deals with retrofit adapters, storage, a mount for the keyboard and mouse, and drip pan. Second, the control domain involves simultaneous testing, PID control, and full system integration. Finally, the software domain is for designing the code for data collection and display, involving GUI design and overall data management. By working together, these changes create a tester that is efficient, safter, and faster, meeting the high standards required for aerospace.

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