The University of Connecticut Department of Mechanical Engineering has developed an industry recognized Senior Design Capstone course. The course provides fourth-year students the opportunity for a “major design experience in which they apply the principles of engineering, basic sciences, and mathematics to model, analyze, design, and realize physical systems, components or processes, and it prepares students to work professionally” [1]. The course is taught by a class instructor and is supported by the faculty of the Mechanical Engineering department at UConn. In the 2013–2014 academic year there were over 40 projects in the course. This paper presents the issues and challenges that students faced when working on a project for Koffee Karousel’s coin-operated K-Cup vending machine. Work on the project began with the problem statement, and was followed by the generation of possible solutions (accepting the most promising ones) and finally, choosing the ideal solution. The subsequent steps involved preliminary and detailed design, structural analysis, creating a 3D CAD representation, generating drawings, and producing a prototype. The prototype was then tested to verify its capabilities. The example of switching from a coin-operated design, with its limited potential use, to an electronically operated solution is described in this paper. The objective of this senior design project was to implement a credit card reader onto the original Koffee Karousel design. To accomplish this goal, a redesign of the Koffee-Karousel’s coin mechanism was required. An electrical engineering team of four students worked independently on the credit card and display setup, while a mechanical team worked on a lever mechanism and gears activated by the validation of a credit card. The implementation of this new mechanism included designing a replacement face, a couple of brackets for electrical hardware, and several new parts, including an actuator and a mini-stepper motor. In addition, students designed the new cam that would interface with stepper motor. Some parts were accepted from the current design of the lever and ejector. The new design still allows the customer to choose which K-Cup flavor they want by hand by operating a rotating knob at the top of the carousel, but no longer requires the user to trigger the ejector mechanism manually. Students tested the new mechanism to ensure it was not only efficient, but also worked properly. The stresses on each individual part were calculated for the first design iteration to ensure the new design would not yield or fail over time due to fatigue.
The project and its challenges are described in this paper, as well as the students’ contributions to the design of the Karousel mechanisms, switching it from a purely mechanical to a mechatronik solution.