ERC for Compact

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ERC for Compact Efficient Fluid Power

• Vision and Impact
• Strategic Research Plan
• Start-Up Site Visit Review
• 11 October 2006

Kim A. Stelson, Professor Center
Director Department of Mechanical
Engineering University of Minnesota
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Vision The vision of the Engineering Research
Center for Compact and Efficient Fluid Power
(CCEFP) is to transform fluid power so that it is
compact, efficient and effective. This will
benefit humanity by significantly reducing energy
consumption and spawning whole new industries. A
coordinated research and education program will
facilitate this transformation.
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ERC in Compact and Efficient Fluid Power Lead
University University of Minnesota Core
Universities University of Illinois
Urbana-Champaign, Georgia Institute of
Technology, Purdue University, Vanderbilt
University Outreach Universities Milwaukee
School of Engineering, North Carolina AT State
University (HBCU). Outreach Institutions
National Fluid Power Association, Project Lead
the Way, Science Museum of Minnesota.
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• Resources of the Center
• Best in fluid power in the country.
• Nationally Ranked in engineering, mechanical
  engineering and related disciplines.
• World-class research universities.
• Comprehensive universities with opportunities to
  tap into other expertise as the center evolves
  (medical schools, science departments,
  specialized facilities, business schools, etc.)

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What is fluid power?

• Advantages of fluid power
• Excellent power to weight/size ratio
• Capable of extremely large forces
• Flexible and relatively easy to control

• Current uses
• Heavy equipment
• Construction industry
• Off-road vehicles
• Manufacturing

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Fluid Power is Unique. It has unparalleled
torque, power and bandwidth for the same weight
or volume. Example Power/Weight (kW/kg)
Pneumatic Motor 0.3-0.4 Hydraulic
Motor 0.5-1.0 Electric Motor 0.03-0.1 Fluid
power weight advantage 101 Reference I. L.
Krivts and G. V. Krejnin, Pneumatic Actuating
Systems for Automatic Equipment, Taylor and
Francis, 2006.

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• But, Fluid Power has Challenges
• Efficiency improvements required
  Efficiency Thrust
• Further reductions in size and weight
  Compactness Thrust
• 3. Noisy, leaky, difficult to use
  Effectiveness Thrust

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Thrust Areas Efficiency Thrust is needed to
reduce our Nations dependence on imported fossil
fuels and benefit the environment. The energy
savings pay for the center many times over.
Compactness Thrust is needed to migrate fluid
power technology to human scale devices opening
up large opportunities for novel applications.
This will create entire new businesses and
increase the well-being of humanity. Effectiveness
Thrust is needed to realize the ultimate vision
of fluid power that is easy to use, clean and
safe. No one will use fluid power in the new
applications unless these problems are solved.
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Energy Importance

• Sector Energy cost/yr. Savings (10
  improve)
• Agriculture, Mining and Construction 28
  B 2.8 B
• Manufacturing (machine drives only) 42 B 4.2
  B
• Total 70 B 7.0 B
• Source U. S. Dept. of Energy, Annual Energy
  Review 2004, Report No. DOE/EIA 0384(2004)

Each 10 improvement in energy efficiency in
these sectors will result in a savings of 7
Billion/year.
Goal 1 Dramatic improvement in efficiency of
fluid power
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Energy Savings Transportation
Sector Energy cost/yr. Savings (10
improve) Transportation 240 B 24
B Sub-sector Energy cost/yr. Savings
(10 improve) garbage trucks 1.1 B 110
M buses 1.3 B 130 M passenger cars 100
B 10,000 M
Each 10 improvement in the efficiency of
passenger cars would save 10 Billion/year
GOAL 2 Develop fluid power hybrid vehicular
technologies that make passenger cars highly
efficient and have high performance.
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Current Technology

• Battery-electric motor combination is too heavy
• Fluid power has high intrinsic power density
• However, overall system is not portable or
  un-tethered.

Apply Fluid Power
GOAL 3 Fluid power that is portable wearable
untethered autonomous capable of operating for
long periods without external energy sources.
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Barriers to Acceptability

• Barriers to the more widespread acceptance of
  fluid power
• 1. Leaky
• 2. Noisy
• 3. Unsafe
• 4. Difficult to use (slow, imprecise or
  non-intuitive)
• This prevents the more widespread use of fluid
  power.

GOAL4 Fluid power that is ubiquitous since it
is leak proof, quiet, safe and easy to use.
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To conduct fluid power research that will provide
the U.S. with a dominant position in the global
marketplace.
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Three level diagram
Environment specifications
Engineered

Reduced fuel consumption
TB
-
3
TB
-
4
Systems and
Testbeds

Regeneration in cyclic ops.
TB
-
5
Small urban
Rescue

Tether
-
less operation
Hand
Vehicle
Crawler

Intuitive human interface
Tools

Compact and light weight
TB
-
2

Quiet and leak free operation
Injection Molding
TB
-
6
TB
-
1
Machine
Orthosis
Excavator
System
H/W S/W
Control
integration
Energy
Compact
Compact/
Compact, efficient
Compact
-
Regeneration
light weight
pumps, motors,
power supply
energy storage
scheme
components
transformers
Cad/Cam
Throttle
-
less
Leakless
for fluid power
Enabling
Compact, high
controllable
seals
integration/
Displ
.
Human/
energy density
Technology
components
optimization
Control
Noise/
Vib
machine
storage
control
interface
Compact,
Light weight
Low loss, high
Alternate
efficient
pressure
components
efficient FP
Improved
power supply
components
configurations
filtering
Knowledge
Multi
-
scale
Engineered fluids
Chemofluidic
Functionally graded
simulation
base
actuation
materials
Dynamic
Noise
scaling
Nanotube additives
Human
Open or
cavitating flow
factors
Phase change
prediction
On/off valve
energy storage
Free
-
piston
drag
Seal design
engine comp.
Tribology
control configs
reduction
Compactness
Effectiveness thrust
thrust
Efficiency thrust
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ERC testbeds
TB1 Excavator
TB2 Injection molding machine
Existing FP applications
TB3 small Urban Vehicle (sUV)
TB5 FP assisted hand tools
FP enabled breakthroughs in transportation
TB4 Compact Rescue Crawler
TB6 FP assisted orthoses prostheses
Reduced or delayed funding
New industries applications
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Thrust area 1 Efficiency

• Efficient system configurations
• 1A. Throttle-less control and regeneration
• 1E. On/off valve concepts for energy
  transformation and control
• 1F. Biomimetic approach for distributed fluid
  pressure generation, energy storage and control
• Efficient components
• 1B. EHD effects for adaptive surfaces for pumps
  and motors
• 1C. Microactuators for active modification of
  surface topology in lubrication gaps
• 1D. Drag reduction via biomimetic nano-surface
  features
• 1G. Engineered Fluids
• Red Increased funding Blue Decreased or
  delayed funding

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Thrust area 2 Compactness

• Compact power source
• 2A. Chemo-fluidic hydraulic actuators
• 2B. Free-piston engine compressor
• Compact energy storage
• 2C. Compact energy storage
• Materials
• 2D. High pressure, light weight components using
  engineered materials
• Scaling and Integration
• 2E. Component integration for fluid power systems
• 2F. Dynamically scalable fluid power systems

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Thrust area 3 Effectiveness

• Human factors
• 3A. Human factors and haptic interfaces for fluid
  power systems
• Noise vibration and cavitation
• 3B. Noise reduction in fluid power systems
• 3C. CFD simulation of cavitating flows
• Tribology
• 3D. Leakage reduction in fluid power systems
• 3E. Prevention and management of contaminants
• Red Increased funding Blue Decreased or
  delayed funding

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Major Accomplishments of the first five years

• Knowledge Base
• Models of turbulence-cavitation interactions,
  cavitation noise and impact on performance
• Models of Elasto-Hydro Dynamic phenomena within
  high pressure thin films in nanoscale domain
• Biomimetic nano-surface features and carbon
  nanotube additives to reduce flow drag
• Models of flow phenomena in thin films with
  elastomeric-metallic interfaces to understand
  inter-asperity cavitation and asperity
  deformation
• Dimensionless dynamic design criteria
• High bandwidth control of catalytic chemical
  reactions
• Human performance models of multi-modal
  human-hydraulic interfaces
• New control theories for fluid power systems
• High-pressure behavior of fluids and components

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Major Accomplishments of the first five years

• Enabling Technologies
• Compact and efficient pumps and motors
• Throttle-less control (displacement control,
  on/off control)
• Energy regeneration
• Compact power supplies
• Compact energy storage
• Compact, light-weight, efficient, high-pressure
  components
• Engineered fluids
• High-speed on/off valves
• Noise and vibration control
• Human/machine interface
• Modeling, integration and optimization software
  for fluid power

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Major Accomplishments of the first five years

• Engineered Systems and Testbeds
• Excavator (TB1) Comprehensive system evaluation
  to demonstrate significantly improved efficiency
  through improved control (displacement control,
  on/off control, regeneration) and improved
  components (pumps, motors, fluids).
• Small Urban Vehicle (TB3) Comprehensive system
  evaluation to demonstrate significantly improved
  efficiency (as with TB1) and compactness. Compact
  energy storage is a critical enabling technology.
• Rescue Robot (TB4) and Orthosis (TB6)
  Comprehensive system evaluation to demonstrate
  compactness. Compact energy sources and component
  integration are critical enabling technologies.
• All test beds Demonstrate improved effectiveness
  so that they are easy to use, quiet and leak
  proof.

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Organization Chart Research Leadership
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Multi-disciplinary Teams acoustics (Cunefare,
Mongeau) biomedical engineering (Durfee,
Goldfarb, Hsiao-Wecksler)chemistry (Kaltchev,
Michael) computer-aided design (Ivantysynova,
Paredis) computer science (Paredis) education
(McCary-Henderson) engineering design (Barth,
Book, Durfee, Goldfarb, Ivantysynova) fluid
mechanics (Frankel, Loth) fluid power (everyone)
human factors (Book, Durfee, Jiang, Mountjoy,
Park) internal combustion engines (Kittleson)
materials (Gervasi, Mantell, Stelson)
manufacturing (Gervasi, Mantell, Stelson) MEMS
(Werely) system dynamics and control (Alleyne,
Barth, Book, Durfee, Goldfarb, Li, Lumkes,
Stelson)tribology (Bair, Ivantysynova,
Salant) New research initiatives will involve
collaborators from other fields available in the
participating universities.
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Faculty and Students
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Equipment and Infrastructure Primary (28,000
ft2) Fluid Power Control Laboratories (UM),
Fluid Power and Motion Control Lab (GT), MAHA
Fluid Power Lab (PU), Center for Intelligent
Mechatronics (VU), Caterpillar Electromechanical
Systems Lab (UIUC), Fluid Power Institute
(MSOE). Supporting Center for Diesel Research
(UM), Composites Laboratory (UM), Nanofabrication
Center (UM), Materials Research Science and
Engineering Center (UM), Center for
Transportation Studies (UM), Integrated Acoustics
Lab (GT), Rapid Prototyping and Manufacturing
Institute (GT), Tribology Lab (GT), Microfluidics
Lab (PU), Multi-scale Manufacturing Center (PU),
Human Dynamics and Control Lab (UIUC), Institute
for Human Machine Studies (NCAT), Rapid
Prototyping Center (MSOE), Nanotechnology Center
(MSOE)
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Management Overview
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Organization Chart Administrative Leadership
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Education and Outreach Executive Summary
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Education and Outreach Vision
Mission Develop research inspired, industry
practice directed education for pre-college,
university and practitioner students. Integrate
research findings into education. Educate the
general public. Through active recruiting and
retention, increase the diversity of students and
practitioners in fluid power research and
industry. Vision A general public that is aware
of the importance of fluid power and the impact
of fluid power on their lives, students of all
ages who are motivated to understand fluid power,
students who can create new knowledge and
innovate, industry that capitalizes on new
knowledge to lead the world in fluid power
innovation, and participants in all aspect of
fluid power who reflect the gender, racial and
ethnic composition of this country.
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K-100 Learning

• General Public Of All Ages
• Interactive exhibit
• Youth education program (K-12)

awareness
lifelong learning

• Undergraduate
• Research
• Lab courses
• Lab modules
• Internships
• Design

• Junior High
• Study unit
• Lab module

• Industry
• Short courses
• Labs
• Publications

• High School
• Pre-engineering courses
• Lab module
• RET

• Graduate
• Research Fellows
• Courses
• Internships
• International Exchange

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Diversity
Goal Substantially increase the number of
underrepresented minorities and women in fluid
power specifically and in mechanical engineering
in general.
How will we do this?

• Leverage partner institutions existing strengths
  in education
  and outreach programs.
• Formal collaborative partnership with LSAMP
  program headquartered at NCAT, Purdue, and
  Tennessee State
• AGEP at Georgia Tech
• Four tribal colleges in Minnesota and Wisconsin

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Graduate Student Recruiting

• REU Programs
• Industrial Intern Program

Faculty Recruiting

• 12 new faculty to be recruited for the center
  (two from UIUC, Purdue, Vanderbilt, NCAT, Georgia
  Tech and U of MN).
• We are making every effort in our advertising
  and networking to reach the broadest, most
  diverse audience possible.

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Faculty Recruiting

• 12 committed
• U of M search underway, interviews begin in
  December
• Purdue posted ad this month
• Vanderbilt in process of interviewing
  candidates
• MSOE hired Paul Michael, Fluids Expert
• UIUC one in place by year 3, another by year 5

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Student Diversity Strategy
North Carolina AT State University (LSAMP)
Georgia Tech (AGEP)

• 2nd in nation, engineering Ph.D.s to African
  Americans
• 8th in nation, engineering Ph.D.s to Hispanic
  Americans
• 3rd in nation, engineering Ph.D.s to
  underrepresented minorities
• Participating in research side of ERC, Thrusts
  1-3
• AGEP with Emory, Spelman, Morehouse

• Public land grant university
• Historically Black College and University (HBCU),
  located in Greensboro, North Carolina
• Leading producer of African-American engineers in
  the nation. (B.S., Ph.D.)
• Leading producer of female engineers in the
  nation (B.S.)
• Participating in research side of ERC, Thrust 3

Other Partners

• LSAMP (Vanderbilt, Purdue)
• AGEP (NCAT, Purdue)
• Tribal Colleges (4 TCUPs in WI and MN)

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Industry Affiliate Program
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Industry Partnerships

• Center Stakeholder
• Industrial Advisory Board to lead research
• Project Champions
• Technology Transition
• Hiring Students
• Student Intern Program
• Industrial Contributions (first five years)
• 3.1 Million cash
• 0.5 Million in-kind

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Industry Sponsors AAA Products
International   Air Logic Bimba Manufacturing
Company Bosch Rexroth Corp. Caterpillar Inc. John
Deere CompanyDelta Computer Systems Deltrol
Fluid Products Eaton Corporation Enfield
Technologies Festo Corporation Fluid Power
Educational Foundation Gates Corporation Häglunds
Drives Inc. Haldex Hydraulics Corporation HECO
Gear, Inc. Hedland Flow Meters High Country
Tek HUSCO International, Inc. HYDACHydraquipINA
USA Corp. Schaeffler Group Kepner
Products LatchTool Linde Hydraulics Corp.G.W.
Lisk Co., Inc. Master Pneumatic-Detroit, Inc.
Mead Fluid Dynamics MICO, Inc. Moog
Inc. National Fluid Power AssociationNational
InstrumentsNational Tube Supply
Co. NORGREN Parker Hannifin Corporation PHD,
Inc.PIAB Vacuum Products Poclain Hydraulics,
Inc. Prince Manufacturing Corporation Quality
Control Corporation R.T. Dygert
International Ralph Rivera RB Royal Industries,
Inc. RohMax USA, Inc. ROSS Controls Sauer-Danfoss
Schroeder Industries Simmetrix Sterling
Hydraulics, Inc. Sun Hydraulics
Corporation SunSource Tennant Company The Toro
Company Veljan Hydrair Private Limited
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Project Management Process
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Management Oversight System
SAB
IAB
EOAB
Evaluate 1. Strategic Plan 2. Next years
projects

• Executive Committee
• Director Kim Stelson
• Deputy Director Perry Li
• Thrust Area Leaders Monika Ivantysnova, Andrew
  Alleyne, Wayne Book
• Other Core University Michael Goldfarb
  (Vanderbilt)
• Two IAB Members
• One SLC member

Project Proposals New and Renewal
Next Years Projects
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Project Assessment / Selection Methodology

• Evaluation Criteria
• Accomplishments relative to Centers mission
• Integration with Centers Plans and Teams
• Scientific/Engineering Contributions
• Industrial/Manufacturing Relevance
• Contribution to Broader Mission of Center

• Metrics
• Deliverables as promised and new ideas
• Mapping to defined Centers goals, collaboration
  with other research teams
• Publications, Conf., Invited Presentations
• Patents, Industry sponsored research, IAB
  evaluation
• Diversity, Students, REU, Short courses

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END Success
Strategic Plan Goals, Intermediate and Final
Milestones, Resources
Yes
Final Milestones
No
Invite Project Proposals
Continue Funding?
No
Continue Execution
Not Funded Documented Feedback
Yes
Align with Goals?
No
Yes
Yes
Milestones meet Criteria
Intermediate
Project Execution
Selected for Funding
No
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Center Finances
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Financial Support 5 Year Cost Sharing
University match 2,994,000
Industry in-kind donations 522,000
Industry 3,115,000
NSF 14,970,000
Total funding 21.6 M
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Research Funding (Y1, NSF only) Thrust 1
0.726 M Thrust 2 0.650 M Thrust 3 0.747
M Testbeds 0.388 M TOTAL 2.511 M
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Impact of Budget Reductions

• Delayed or Reduced Funding (2.78 million from
  five-year NSF budget)
• 1. 1C. Microactuators for active modification of
  surface topology in lubrication gaps
• 2. 1F. Biomimetic approach for distributed fluid
  pressure generation, energy storage and control
• 3. 3A. Human factors and haptic interfaces for
  fluid power systems
• 4. 3E. Prevention and management of contaminants
• 5. TB2. Injection molding machine
• 6. TB5. Fluid power assisted hand tools.

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New Opportunity Engineered Fluids

• Recent advances in long-chain polymer additives
  have created hydraulic fluids with a much higher
  viscosity index (less variation of viscosity with
  temperature).
• Test under realistic conditions show double digit
  improvements in efficiency.
• Research goals
• 1. Explore new additives (carbon nanotubes).
• 2. Tailor the fluid to the application (viscosity
  (pressure, temperature)).
• 3. Optimize fluid power components (including
  fluids) and systems.

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New Opportunity Increased Pressure

• Compactness requires increased power density
• Power Pressure x Flow
• Increased Flow required Increased Rotation Rate
  for Pumps and Motors leading to
• 1. cavitation and noise
• 2. decreased efficiency
• 3. reduced equipment life
• Solid material performance is well-known at high
  pressure, but fluid and fluid power component
  performance is less well-known.
• High Pressure Operation New Sub-thrust under
  compactness

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Request for Supplemental Funds

• New Opportunities Engineered Fluids and High
  Pressure Operation
• Supplemental Funding Request 300,152
• 1. Sealing and Liquid Property Investigation
  Applied to Hydraulics at High Pressure (expansion
  of 3.D Seal Modeling and Design) Scott Bair and
  Richard Salant (Georgia Tech)
• 2. Nanotube Additives for High-Pressure Fluid
  Power Systems (expansion of 1.G Optimized
  Engineered Fluids) Paul Michael (MSOE) and Eric
  Loth (UIUC)
• 3. High Pressure High Speed PWM Valve Operation
  (expansion of 1.E On/Off Based Control) John
  Lumkes (Purdue) and Perry Li (Minnesota)

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Todays Agenda

• Wednesday, October 11
• Johnson Room, McNamara Alumni Center, University
  of Minnesota
• 810 Center Overview Kim A. Stelson
• 910 Strategic Research Plan Perry Y. Li
• 1040 Break
• 1100 Center Administration Stephanie
  Bettermann
• 1130 SVT Executive Session (in Gold Room)
• Break for Attendees
• 1215 p.m. Lunch (in Ski U Mah)
• 100 Education Outreach William K. Durfee
• 130 Closed Meeting SVT with SLC (in Minnesota
  Room)
• Break for Attendees
• 200 Walk to Mechanical Engineering or CCEFP
  Center
• 215 Rotating Lab / Poster Tours
• ME 212 Classroom, Mechanical Engineering,
  University of Minnesota
• 330 Industrial Collaboration Michael J. Gust

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Tomorrows Agenda

• Thursday, October 12
• ME 1130 Seminar Room, Mechanical Engineering,
  University of Minnesota
• 730 a.m. Continental Breakfast
• 800 Clarification of Issues ERC Team
• ME 4125B Conference Room, Mechanical Engineering,
  University of Minnesota
• 1000 SVT Executive Session
• 400 p.m. SVT Departure