Bike Cellphone Charger Chris Battaglia (ME) Ajeetesh Govrineni (EE) Kellen Warriner (IE)

Project Summary and Background Second generation project (see right) Design a bicycle cell phone charger for use in Haiti and other underdeveloped countries Includes generator, breadboard, and phone holder Total material cost should be <$15 and manufacturable on-site in Haiti No heavy machinery used (lathe, mill, etc) Time needed to charge a phone must be reasonable for the user Nokia and Blackberry phones. Primarily target is the former Design must be simple, robust, easily repaired/replaced, and adjustable Old Design Our Design

Design Summary Consists of two main sub-assemblies 1.Generator Housing Generator is enclosed in plastic cylindrical housing with shaft extending out Shaft is held against the tire of the bike, friction turns the shaft Held to bike frame via two rubber-lined clamps joined with a bolt and wing nut Consists of two main sub-assemblies 2.Phone Holder Contains breadboard and power connector Comfortably holds Nokia and Blackberry phones and adjoining cables Attached to handlebar of bike with two Velcro strips

Product Performance & Information Half-charged a Nokia phone in 25 minutes Takes approximately 6-8 hours of continuous use to deplete the battery Requires 1-4 hours (based on speed) to fully charge a phone Approximately 1:2 Work to Use Ratio on average CONTAINED IN KIT Bicycle Frame Attachment Connecting Power Cable Phone Holder + Breadboard Generator + Housing Phone USB Cable

Customer Needs and Results # DescriptionTarget ValueActual ValueResult 1 Voltage Output V V Achieves minimum value at 9.67 mph. 2 Current Output >250 mA mA Achieves target value at speeds >13.5 mph. Begins charging at 9.67 mph at 110 mA. 3 Material Cost <$15~$14.50 Meets target price, but only just. 4 # of Machines Used in Construction 00 Only hand/power tools used in construction. 5 Duration on Rough Road Conditions Before Misalignment >1 hour No misalignment after an hour on rough road conditions or repeat use on smooth conditions. Quantitative Objectives #DescriptionPass/FailResult 6 Charger fits standard phone connectorsFits any standard USB cable (typically shipped with phone) 7 Aesthetically pleasing; provides user feedbackReactions to the design have been positive 8 Easy to install, maintain, and useWhile it’s fundamentally easy to install, proper installation takes several fine adjustments, instruction, and trial and error to do correctly 9 Protects user safetyWhile a potentially minor issue, the breadboard is uncovered and may present a hazard. The generator shaft also becomes painfully hot to the touch after use. 10 Simple to manufactureCAD drawings have a high tolerance, process is very simple Qualitative Objectives ~ ~

Testing TestEngineering SpecTested SpecTestPass/Fail Electrical Testing Charge All Phones Universal ConnectionTested with USBBike Charge TestPass Output voltage 4.7 V -5.3 V4.8 V - 5 VBike Charge TestPass Max Current >750 mA>730 mABike Charge TestPass Current output at average biking speed >750 mA250mA< current < 800mABike Charge TestPass Mechanical Testing Rough Road Test NoneRough RoadRough Road TestPass Environmental Testing Water Test Resists Water IEC IP water test: Level 3 spraying water Water Test Pass Dust Test Resists Dust IEC IP dust test: Level 5 dust protected Dust TestPass Impact Test Generator Does not break when dropped/bike crash IEC IP impact test: Level 5 (500 grams dropped from 40 cm) Actual test was 1 meter drop height Drop TestPass Impact Test Phone Housing Does not break when dropped/bike crash IEC IP impact test: Level 5 (500 grams dropped from 40cm) Actual test was 1 meter drop height Drop TestFail General Testing Bike Tire Range cm26 inch bike wheel (66cm)MeasurementsPass Total Cost < $ 15 Pass Weight Less than currentLess than CurrentWeight TestFail Number of Machine ToolsLess than 0 Pass Number of People to Produce 1 person Pass Number of Tools to Install Less than 1 Zero (Hands free installation) Pass Cost to Install00 Pass Current/Voltage test Output at various speeds See above graph Rough road test Road bike on rough terrain, checked generator positioning Impact test Drop test Environmental Damage test Water and dust test

Suggestions for Future Work Better means of holding the nub of the generator shaft against the tire Optimize potential output Simplify installation Cheaper components / overall cost reduction Certain items are large contributors to the overall cost Powerjack Cable, etc Better generator? Remove breadboard?