Potential Design Outreach (DO) Involvement Nov 14, 2014 + ? Big need – 90% of world’s designers currently work for 10% of world’s rich population. Design for the Other 90% is a movement to reverse this; and is close to EMI’s DNA. We recognized last year there is lots of room for EMI to grow in Appropriate Technology expertise, and then through Don and CJ, in AT product development. So this Wedge Project is EMI’s first ever Appropriate Technology Product Development project. Excited to partner with Don & CJ in this. Expecting to make a few mistakes as we figure this out together.

Agenda Design Outreach Intro – Greg (5 min) Need for Electrical Power – Craig (5 min) Brief History of Wedge 1.0 – Don (10 min) EMI Wedge 2.0 Efforts - Craig (10 min) EMI Wedge 1.1 Efforts – Don (5min) EMI Wedge 3.0 Efforts – Wil (10 min) Potential Benefits of DO Involvement (10min) Next Steps (10min)

Design Outreach (Greg) Greg’s Story Design Outreach Lifepump Invented by Don in Liberia – on EMI trip despondent over poverty of LIberia. Sitting on beach. Lord say “Harness this power for the people” Originally a Surf Model – ran into environmental hurdles trying to develop it on West Coast. River Model Adaptation – with CJ’s involvement, turned to River Model bc less environmental hurdles and still broad potential. EMI Involvement – Don came to EMI fall 2010 to share what he developed, then we hit on idea of EMI team to help develop further. Performance – peak performance of river model was 178W maximum at 60 RPM in Navigators Glen Eyrie Camp Creek.

Needs & Potential (Craig) Only 2-5% of rural Sub-Saharan Africa served by electric grids 1.6 billion people in developing countries currently live without electricity International Energy Agency (IEA) estimate that by 2020 developing countries will need to double their electrical power output Potential 4 million estimated micro-hydro locations worldwide 100,000 family size micro-hydro units in Vietnam Estimated 100,000 household sites In Philippines There is a huge need for Electrical Power worldwide, and a huge Potential as well.

History (Don) Invented by Don Sternitzke from Liberia Vision Originally a Surf Model River Model Adaptation Wedge 1.0 2010 Prototype Performance – 178W maximum at 60 RPM Invented by Don in Liberia – on EMI trip despondent over poverty of LIberia. Sitting on beach. Lord say “Harness this power for the people” Originally a Surf Model – ran into environmental hurdles trying to develop it on West Coast. River Model Adaptation – with CJ’s involvement, turned to River Model bc less environmental hurdles and still broad potential. EMI Involvement – Don came to EMI fall 2010 to share what he developed, then we hit on idea of EMI team to help develop further. Performance – peak performance of river model was 178W maximum at 60 RPM in Navigators Glen Eyrie Camp Creek.

Wedge 2.0 (Craig) EMI’s First(?) Ever Appropriate Technology Product Development Project Don Contacted EMI 2010 as EMI exploring new programs Wedge Intensive April 2011 – Purpose: Design, Build & Test next-generation prototype Approach: Similar to classic EMI Design Team approach

Wedge Intensive Team Wedge Team (from L to R): Don Sternitzke (Wedge Inventor), Andy Engebretson (Elec. Eng), Pat Godsell (fabricator), Darryl Byle (Mech Eng), Calla Suen (Envir. Eng), CJ Anderson (Wedge Co-Founder), Tim Godsell (Fabricator), Sam Loomis (Mech/Elec Eng), Phil Harshaw (Mech Eng), Steve DeLory (Elec.Eng), Craig Hoffman (Civil Eng), Steven Kwan (Hydrodynamic Eng), Chris (Fabricator). Not pictured: Mark Hopewell (Civil/Mech Tech) Front Row: Proposed Wedge 2.0 Culvert Housing, Existing Wedge Prototype

Ultimate Goals (Design Criteria) Ultimate User: Poor rural household in developing World Desired Characteristics Affordable – for rural farmer making $400/yr Reliable & Durable – 24 hours/day for up to 3 years. Debris protection Simple – easy to install, maintain and replace by poor rural developing world farmer Safe Secure – resistant to theft and vandalism Environmentally Friendly Modular – for scalability Technical Requirements: Stream Flow of 5-20 ft3/sec Power > 300 watts – enough for lights, cell phone, computer Ideal Cost < $100 (production model in developing world hopefully produce power for < $.08/watt Purchase Plans: 3 year loan payback. Business charging cell phone batteries, etc. Other Potential Models: Backpacker – smaller Villager – larger or linked household models Municipal – for North American municipalities: power or lighting for parks

Summer 2011 – Wedge 2.0 Refinement Goals More efficient prototype: > 300 watts Elegant design for future manufacturing simplicity Cost < $500 (parts only) Method: EMI Design Intensive –April 19-22, 2011 Wedge 2.0 Fabrication - till end of May Summer testing – throughout summer Colorado Springs Utilities (CSU) graciously interested CSU/FMDC requirements – Ultimate requirements, plus especially safe and environmentally safe Not interrupt flow, normal operations or cause erosion. Emergency removal capability.

Existing Wedge Dynamics Impeller tilted allows for greater diameter, which equals more power Converting velocity to head Hydraulic Jump Effect RPM Existing Wedge Prototype Peak Performance: 178 watts at 60 RPM (Glen Eyrie Camp Creek)

Hydrodynamic Modeling – Existing Wedge

Hydrodynamic Modeling – Housing Options Best: Option 4 “Open Arms/Hugging”: increases velocity 13% over straight tube  40% power increase

Ultimate Design – Custom PMG Improvements: Tube more efficient hydraulics Wings capture more flow Direct drive eliminates pulley losses More efficient turbine Better generator Goal: 300 watts (we hope)

Wedge 2.0 Fabrication Sam Loomis built adjustable propeller in Seattle garage Chris, Tim & Pat Fabricated Housing and tube in Colorado Springs EMI Team (Andy, Justin, Wil, Craig) assembled Majik Pie Generator and electrical testing equipment at Chris’ garage

Wedge 2.0 Testing Fall 2013 in COS Utilities Garden of Gods Wastewater Treatment outfall ‘creek’ Optimize Wedge 2.0; and Compare to 1.0

Wedge 2.0 Testing See video

Wedge 2.0 Test Results Wedge 2.0 generated 400% more power than Wedge 1.0 peak power output of the Wedge 2.0 was 126 watts.  peak power of Wedge 1.0 was 28 watts (attempt to optimize pulleys) Wedge 2.0 approx 200% more efficient Efficiency calculation very sensitive to water speed & cross-sectional area. peak Efficiency for the Wedge 2.0 occurred in trial 21 and was 79%.  peak efficiency for Wedge 1.0 was in trial 26 and was 40% Optimal Configuration of Wedge 2.0: Blade angle of 10 degrees Tube angle of 32 degrees

Wedge 1.1 Improvements (Don) Variable Speed Drive Other – see also Wedge 1.1 VSD ?

Wedge 3.0 Improvements (Wil) “Suitcase” Model Reuse 55 gal barrel drum – housing and split ‘catcher’ Car fan as turbine Direct drive on angle through tube housing

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Next Steps Independent Development or “Merge” 1.1 and 2.0 and 3.0? Short Term Test to Optimize Merge? Long term test to prove reliability over time Fine-tune for Developing World? Field test in Developing World – Haiti?