
Mini Conveyor Design
Author: Shae Threlfall | Major: Mechanical Engineering | Semester: Spring 2025
Shae Threlfall, an honors mechanical engineering student, has been completing research in tribology, the study of friction, wear, and lubrication, in a nanomaterials lab dedicated to using nanoscience to solve everyday problems.
My name is Shae Threlfall, and I am an honors mechanical engineering student at the University of Arkansas. Under the mentorship of Dr. Min Zou in the Department of Mechanical Engineering, I have significantly contributed to a project dedicated to improving the efficiency of conveyor systems. Throughout Spring of 2025, I have created vital testing methods and machines to aid in this research. I first joined Dr. Zou’s lab in a Research Experience for Undergraduates (REU) program in the summer of 2023 where I designed and improved a mini conveyor tester to test low-friction coatings. After the REU ended, I was hired to see through the rest of the project allowing me to apply the machine design and analysis coursework I am studying to make advancements in environmental sustainability, a topic I am deeply committed to pursuing throughout my research career.
In industries that use large conveyor systems like supply chains, the costs due to friction are astoundingly high. Solid lubricants, or coatings, can mitigate these issues, reducing not just the monetary and environmental burdens associated with friction, but also cutting down repair costs so vital packages can be distributed smoothly. My research focuses on developing and optimizing graphite-based coatings to reduce the environmental and economic impacts of friction. These coatings provide a sustainable alternative to petroleum-based lubricants, enabling smoother operation of conveyors while cutting repair costs and waste. These coatings will be used on large-scale industrial sized conveyors, which cannot be replicated in the lab, which is where I come in. Working with Dr. Zou’s Nano Mechanics and Tribology Lab, I’ve spent the past semester building and improving devices like a small scale conveyor to test these coatings in industry-like conditions. The goal? To ensure these coatings are not just scientifically sound but practical and scalable for real-world use. Diving into this project has taught me more than just technical skills. On the research side, I’ve learned about the complexities of creating and applying graphite coatings and the importance of designing experiments that simulate real-world conditions.
This project wasn’t without hurdles, though. After designing and building a miniature conveyor tester to test the low friction coating, I implemented it with different sensors to quantify energy reduction (through motor torque, temperature, power, etc). Dr. Zou played a crucial role in guiding my research. Her weekly meetings kept me on track, and her suggestions for experiments and deadlines pushed me to think critically and stay organized. Collaborating with other researchers in the lab was also an enriching experience. Whether we were troubleshooting equipment or brainstorming new approaches, the teamwork makes challenges feel manageable and the successes even more rewarding.
Looking ahead, I plan to optimize the conveyor data collection process. I’m eager to apply my engineering skills at an internship at a conveyor company, where I hope to tackle more sustainability-focused challenges. This research experience has solidified my commitment to creating practical solutions that make a difference in the real world. I am deeply grateful for the support of the Honors College, Dr. Zou, and my lab team, who have paved the way for this experience. Research has taught me that the most meaningful work often comes from overcoming challenges and turning ideas into reality. If you’re a student considering research, my advice is simple: go for it. It’s an opportunity to not only learn about your field but also to discover what you’re capable of.