Bicycle Power – Alternative Energy and Fitness Solution Choluteca, Honduras Group Members: Brandon King, Nirupa Manohar, Elizabeth Schweizer, Stephanie Tsavaris 4/19/2012

Project Component – Roles All team members will contribute to construction and testing. Team Member Role Brandon King Historian Nirupa Manohar Team Recorder Elizabeth Schweizer Schedule Coordinator Stephanie Tsavaris Team Leader

Table of Contents Overview Sustainability and Feasibility Pre-Trip Project Components Project Implementation in Honduras Future Recommendations Acknowledgements

Overview Encourage exercise Form fitness program Enforce healthy lifestyles Form of alternative energy Electricity is very expensive Designed for use in villages with limited to no electricity Worked with Larry and Angie Overholt from the World Gospel Mission as well as vocational school staff.

Influences Readings “…potential projects at the school that would not only benefit OSU students, but also the vocational school students as well as the community” -Importance of Appropriate Collaboration with International Partners Team Discussion Decided on the most easily reproducible and beneficial design Decided on alternator option over permanent magnet motor.

How is it Sustainable? Plenty of Bicycles in Honduras Affordable, Replicable Design Human Powered No Reliance on Fossil Fuels Environmentally Friendly

Feasibility Analysis Maintainability Safety and Risk Educate Vocational School Staff on Operation Safety and Risk Closed off, Protected Electrical Components Secure Bike Stand for Stability

Project Components

Stand Prototype Top View Front View Side View

System Layout Bike Alternator 12V 20AH Battery 400W Inverter

𝐺𝑒𝑎𝑟 𝑅𝑎𝑡𝑖𝑜= 𝑟𝑒𝑣𝑜𝑙𝑢𝑡𝑖𝑜𝑛𝑠 𝑜𝑓 𝑜𝑢𝑡𝑝𝑢𝑡 𝑟𝑒𝑣𝑜𝑙𝑢𝑡𝑖𝑜𝑛𝑠 𝑜𝑓 𝑖𝑛𝑝𝑢𝑡 Power Analysis To determine battery size 𝐴𝑚𝑝𝐻𝑟=𝑇𝑖𝑚𝑒∗ 𝑃 𝑉 where Time = how long the wattage would be available P = total power (wattage) V =voltage of the battery Time to charge battery 𝐶ℎ𝑎𝑟𝑔𝑒 𝑇𝑖𝑚𝑒= 𝐴𝑚𝑝𝐻𝑟 𝑁𝑒𝑡 𝐶𝑢𝑟𝑟𝑒𝑛𝑡 where AmpHr is the battery rating Net Current is read from an Ammeter Determine Gear Ratio 𝐺𝑒𝑎𝑟 𝑅𝑎𝑡𝑖𝑜= 𝑟𝑒𝑣𝑜𝑙𝑢𝑡𝑖𝑜𝑛𝑠 𝑜𝑓 𝑜𝑢𝑡𝑝𝑢𝑡 𝑟𝑒𝑣𝑜𝑙𝑢𝑡𝑖𝑜𝑛𝑠 𝑜𝑓 𝑖𝑛𝑝𝑢𝑡

Project Bill Of Materials Pre-Trip Actual Expenses Actual Expenses in Choluteca Project Project Specific Shared Bicycle $161.38 $22.29 $0.00 $28.98 Item Alternator 1993 Honda Accord $23.45 Total 400w Inverter $26.70 $212.65 12v 20 AHBattery $60 Alternators (2) $30 5/8" x 4'-0" threaded rod (1x$6.57); 5/8" nuts (4x$0.35); 5/8" couplings (6x$1.43) $16.55 Miscellaneous items $4.68 Cylinder Rails Total: $212.65

Pre-Trip Timeline January 4th : Introduction and initial project discussion 11th : Project management and formed project teams 18th : Presented and edited project proposal drafts February 8th : Project design review - short team presentations  29th : Project presentations March 7th : Final project wrap up 17th : Departed Columbus and arrived in Choluteca

In-Country (Honduras) Timeline March 18th : Beach day 19th : Inspected pre-made bike stand and began assembly 20th-22nd : Worked on implementing 1st alternator 22nd-23rd : Worked on implementing 2nd alternator 24th : Returned home 18th also sorted materials

Implementation in Honduras

Stand Modifications Stand was pre-fabricated Almost ready upon arrival Modifications were needed Holes in vertical posts needed widening Vertical posts not parallel to crossbars Metal rails attached

Additions to Stand Added threaded rod Added end coupler and drilled out half the threads – used loctite and 2nd nut to hold in place Added locking mechanism -handles added so a tool wasn’t necessary to lock rod onto bike - rubber lining added to handle to account for diameter differences -nuts used to hold handle in place Rails added

Initial Build Tray made of scrap c-channel Vertical supports added to attach alternator 3rd supports added to support cylinder Thicken alternator shaft to fit cylinder snuggly Duct tape 2 Layers of copper wire 1 Layer of copper wire Vinyl tape

Modifications Holes drilled to attach tray to stand Hand drill Drill press Rubber from a spare inner tube used to increase friction Super glue Zip ties

Securing the Components Metal added to stabilize cylinder support Washers used as spacers

Assembly Attach alternator to tray Stabilize cylinder

1st Alternator Results First Alternator Stable tray built Initially working system -Ratio 22:1 -Net Current 0.5 A -Time to charge battery 40 hrs Short circuited alternator

Second Alternator Had to build new tray 2nd alternator was smaller than first Altered dimensions to fit between rails better Used 3 vertical supports

New tray built in timely fashion 2nd Alternator Results Second Alternator New tray built in timely fashion -More accurate design Faulty alternator

Project Deliverables Bike-electric system needing modifications Packet of Manuals Construction Operation Power Analysis

Future Recommendations

Recommendations Have vocational school students take ownership of project Acquire working alternator Consider belt design

Belt Design Advantages Simpler System Better Gear Ratio Disadvantages Requires a designated bike Belt needs to be purchased and adjusted to the appropriate tightness (Generator.com)

Belt Design Advantages Item Connected to Alternator Shaft Gear Ratio Rpms of Alternator Shaft (Given an input of 60 rpms) Percent Increase Cylinder (current) 22:1 1320 rpm -- 2.375” pulley diameter 27.8:1 1667 rpm 26.3% 2” pulley diameter 33:1 1980 rpm 50.0% 𝐺𝑒𝑎𝑟 𝑅𝑎𝑡𝑖 𝑜 𝑝𝑢𝑙𝑙𝑒𝑦 𝑠𝑦𝑠𝑡𝑒𝑚 = 66 𝑑 𝑝𝑢𝑙𝑙𝑒𝑦 = 66 2 =33:1 𝑅𝑝𝑚 𝑠 𝑎𝑙𝑡𝑒𝑟𝑛𝑎𝑡𝑜𝑟 𝑠ℎ𝑎𝑓𝑡 =𝑅𝑝𝑚 𝑠 𝑢𝑠𝑒𝑟 ∗𝐺𝑒𝑎𝑟 𝑅𝑎𝑡𝑖𝑜 =60 𝑟𝑝𝑚∗33=1980 𝑟𝑝𝑚

Choluteca Community Helped provide information for design process Helped fabricate stand prior to arrival Helped with additional materials such as wires and provided tools Helped with machining processes

Acknowledgements Roger Dzwonczyk, PE Miriam Simon Dr. John Merrill Larry and Angie Overholt & World Gospel Mission Vocational school staff OSU Office of International Affairs

Questions?

Manuals Operation Manual: Construction Manual: Power Calculations Manual: