Harvesting Waste Energy: Bicycle Power Generation RIT-MSD-I Detailed Design Review Winter/Spring P12414

Team Members Daniel Tobin (ME) ▫Project Manager Aaron Sieczkarek (ME) ▫Chief Engineer Amina Purak (ISE) ▫Facilitator Brenda Lisitano (ME) Zheng (Flora) Li (EE) GUIDE: Professor Brownell

Time Breakdown of Review TIMETOPICAttendees 1:30-1:45Background Information Team Introduction Project Summary Customer Requirements Engineering Specifications Team, All 1:45-2:45Mechanical Assembly & Calculations Motor Assembly Electronics Box Assembly Team, ME professionals 2:45-3:15Electrical Overview Motor Selection Benchmark Analysis Team, EE professionals 3:15-3:30Cost Worth Analysis Test Plan & Sample Test Sheet Gantt Chart Concerns & Next Steps Team, All

One Page Project Summary 1.Project Background People in countries with inadequate infrastructure have an unmet need for electricity. A possible source for creating and storing power is a bicycle rotation energy harvesting system. This system could provide the energy required for light, communication or water treatment. 2.Problem Statement Our goal is to transform kinetic energy within a bicycle into an electric power source intended to charge a cell phone. Our device is expected to be cheap to build, easy to install, maintain and use.

Customer Requirements

Specifications UnitsIdealMarginal DC output voltagevolt output currentmA<200<230 maximum charging rate (depends on battery)mAh>1000>800 estimated biking time to generate power 1 w-hr if the device does not generate continuouslyhour<1.5<3 maximum increased effort for bicyclist% VO2 increase<3%<10% range of bike tire sizes the device will accomodaecm uses standard connectors to interface with cell phone or battery charger % of top 10 selling Haitian phones the device can charge (when separate adapter purchased) 90%60% sizecm^316x16x1628x21.6x14 number of people required to install device# of people<1<3 number of tools required to install device# of tools<1<3 time required for set up (each use)min<10<20 time to train operator to use devicemin<10 min operating tempCelsius Degree max operating tempCelsius Degree5040 increased temperature to bicycle aprts (rim, gears, ?)Celsius Degree<5<10 manufactured cost ($20, per unit when manufactured in lots of 100)$<20<40 installation cost$0<5 wire strengthForce that it can afford(N)<90<50 resists damange from impacts/crashesIEC60529* Level 1-9>7>5 dust proofIEC60529* digit 1 Level 0-66>5 water proofIEC60529* digit 2 Level 0-8>7>4 people rating the device at 4 or above on a scale of 1-5 for aesthetically appealing%>60>30

Location of Installation Analysis The device will be designed to be installed on the back of a standard bike. The back of the bike is much more standard with regard to angles of the bike frame. There tends to be one horizontal tube and a tube that extends radially from the rear axel. This choice will allow for a greater number of bikes to be used and have the roller turn linearly as the wheel rotates.

Full Assembly

Motor Assembly

Electronics Box

Force Displacement 150lb Uniform Load

RPM/Angular Acceleration

Inputs for Shaft & Roller SHAFT ROLLER

Outputs for Shaft & Roller SHAFT ROLLER

Spring Calculations SPRING

Motor Selection Voltage Output Testing on the MIT device

Motor Selection Voltage Output Testing on the Red Light Dynamo

Motor Selection Voltage Output Testing on the White Light Dynamo

Motor Selection Summary Selected this motor because it provides DC output. Cheap, small & lightweight.

Circuits Overview Circuit Diagram for the MIT Device The MIT device uses a 12 V DC motor, a 6V voltage regulator and a 470uF Capacitor. The circuit diagram is shown above. The function of this circuit is to stabilize the DC output from the DC motor and regulate it to a 6V constant output.

Circuits Overview The voltage supplied by a USB port is nominally 5V. In practical, the output is between 4.75V and 5.25V. A constant DC output of 5V is needed for the design. Circuit Non-linear oscillating voltage input Constant 5V DC output

Circuits Overview The Bridge Rectifier

Circuits Overview The second step is stabilize the voltage output in a smaller range then it is regulated to 5V constant DC output using a voltage regulator. The circuit diagram and simulations are shown. Capacitor C8 and C9 are used to additionally stabilize the voltage.

Circuits Overview Overall Waveform of the simulations 12V AC Positive Output Positive Output in Range 5V DC Cellphone AC motor

Circuits Overview Additional Zener diode Circuit As shown in circuit above, a 10V Zener diode is added. The Zener diode does not affect the function of the circuit. It is used to prevent high voltage input damage the voltage regulator. It is not necessary if the output of the motor is always lower than 25V.

Circuits Overview At the end, after we get the 5V constant output. The output pins will connect to a standard A-type USB connector. The pin 1 and 4 will be connected to the positive 5V pin and the ground of the circuit. The data transfer pins will also be grounded. Using the pin out below, all different kinds of USB to cellphone connectors can be made.

Circuits Overview In the design process, we decided to use a DC motor instead of an AC motor because of the price of the motors. The bridge rectifier is no longer necessary. Assume the 12V DC motor is used in our design. The output from the motor is approximately 5V DC voltage with ripples. The design shown below is used to regulate the voltage output. Circuit diagram for 12V DC motor

Circuits Overview Simulation of 12V DC motor with 12V motor output with ripples. Simulation of 12V DC motor with 8V motor output with ripples.

Circuits Overview Assume the waveform below is generated by a person riding for 20s with two stops. According to the simulation, the output of the circuit maintain at 5V when the motor’s output is between 6V to 12V.

BOM Mechanical Parts SKU #Item # Parts Needed for 1 Final Product Parts per SKU Number SKUs to Purchase Price Per SKU ($) Price per Part($) Total Price ($) The Hillman Group 1/4" x 1" Black Phosphate Coarse-Thread Hex-Head Serrated Flange Bolt The Hillman Group 4-Count 1/4"-20 Zinc-Plated Jam Nuts American 1" Copper Split Ring Hanger /8" Threaded Rod - Steel City (10') Kolpin Replacement Straps for Rhino Grips, Model# M-D 17'L X 1/2"W Gray Closed- Cell Foam Window Weather Strip " Powder Coated Metal Handrail Bracket PFP Crimp Connector (2mm) Size 6 Rubber Stopper Round Copper Tube 3mm OD x.36mm Wall (3) Westinghouse Stainless Steel Beaded Chain with Connector T oz Natural Rectangle Tub J035 2 oz Single-Wall White Jar L216NF Natural Smooth Lid with F217 Liner M Marine Adhesive Sealant White K652 Torsion Spring T225 White Lid for Rectangular Tubs Carlon 3 Gang Plastic New Work Electrical Box Hickory Harware Self Closing Hinge Optix 6'x3' Clear Acrylic Sheet M-D 17'L X 7/8"W White PVC Foam Door Weather Strip Size 7 Rubber Stopper Round Aluminum Tube 2mm OD X ).45 mm Wall (4) (k+s9801) K-S Hobby and Craft Metal Tubing Stainless Steel 304 Seamless Round Metric Tubing OD 3mm ID 2mm (2in pcs) TOTAL for 1 Final Product: $12.42

BOM Electrical Parts TOTAL for 1 Final Product: $4.64 Item Part # # Parts Needed Unit Price for 1 Unit Price for 100 Unit Price for 1000 Bridge Rectifier 2W04G-E4/ Voltage Regulator LT //0.4 10u Capacitor NPR 10M // 0.1u Capacitor CML 104M // USB Port PRT / 7.5V Zener Diode 1N5343BG 1// Prototype Bread Board 1-1/2" * 1-3/4" Wire 10 cm 10.05// LED RED and Yellow 20.48/0.081 Unit Price 1Unit Price for 100 NOKIA charger BLACKBERRY charger With accessories TOTAL for 1: $4.94 or $5.04

Electrical Part Specs/Reasoning ItemPart #CountSelection Reason Bridge Rectifier2W04G-E4/511 Voltage RegulatorLT V to 12V voltage input. Current range 200mA to 250mA. 5V DC output. 10u CapacitorNPR 10M632 Can afford at least 15V voltage input 0.1u CapacitorCML 104M501 Can afford at least 15V voltage input USB PortPRT Can afford at least 15V voltage input 7.5V Zener Diode1N5343BG1 Minimun voltage needed to the voltage regulator is 7V Prototype Bread Board1-1/2" * 1-3/4"1 Right size for all components Single Conductor Wire 10 cm(A3049R-100- ND) 1 Connections on circuit board Double Conductor wire2m(W ND)1 A positive and negative output need to be delivered to the circuit board from the dynomal

Haiti Top 10 Phones To determine the best choice for USB to phone adaptors we contacted Digicel, the largest cell phone provider in Haiti (Our main country of interest). Most Popular Cell Phones 1.Blackberry Curve 2.Blackberry Nokia C3 4.Nokia Blackberry Bold 6-10 Various Blackberry Cell Phones (use micro USB)

Cost/Worth Analysis Mechanical SHOULD$15.15 Estimate$12.42 Electrical SHOULD $4.85 Estimate $ 4.64 NET $ 2.94

Risks

Test Plan Major Sub-Systems/ Features/ Function 1 Generator Efficiency 2 Enclosure Impact 3 Voltage 4 Water Proofing 5 Dust Proofing 6 Extra Energy 7 Charges Cell Phone 8 Road Conditions 9 Vibration Test 10 Time to Charge Battery 11 Temperature Change 12 Operating Temperature 13 Wire Strength Test 14 Entire Device Size, Weight Overall Fit 15 Aesthetics Survey 16 Power Requirements Meet

Required Equipment for Testing

Example Test Sheet

Ergonomics Highly visible and intuitive design with feedback that reflects the current knowledge in the world Simple, universal instruction manual on how to install and use. Should not use language, but rather effectively communicate with symbols/diagrams. Placed Cell Phone on handlebars to allow for maximum visibility of phone and immidiete charging feedback via cellphone screen.

Gantt Chart for MSDII

Concerns and Next Steps Next Steps ▫We will be taking all of the information gathered from the detailed design review and utilize it to make improvements to the project. ▫After we obtain permission we will order all of the required components before the break. Concerns ▫Additional calculations and simulations may be necessary based on feedback from the review. ▫Multiple prototypes may be required for testing. ▫Testing may take more time than initially allotted for.

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