1. Harvesting Waste Energy: Bicycle Power Generation
RIT-MSD-II
Design Review 5/18/12
2:15-2:45pm
Winter/Spring
P12414
dan

2. Team Members Daniel Tobin (ME) Aaron Sieczkarek (ME) Amina Purak (ISE)
Brenda Lisitano (ME)
Zheng (Flora) Li (EE)
dan
GUIDE:
Professor Brownell

3. Agenda Needs/Specs Functional Architecture
Our Concept: Mechanical and Electrical
Final Product
Testing
Cost Worth Analysis
AMPL Program
Major Issues
Objective Evaluations
Future Considerations
dan

4. Customer Needs Objective:
To power simple personal devices using energy stored in the momentum of a bicycle
Need #
Customer Needs
Importance Weight
1 (Low) – 10 (High)
Need 1
The device provides power to charge a cell phone or a rechargeable battery to power LED lighting
 10
Need 2
The device uses standard connectors to personal electronic devices  8
Need 3
The device resists environmental damage from dust, water, etc.
Need 4
The device works well on rough roads
Need 5
The device protects user safety
Need 6
The device is inexpensive to purchase, install and maintain  7
Need 7
The device is easy to maintain  6
Need 8
The device is easy to operate
Need 9
The device attaches to a wide variety of bicycle types
Need 10
The device is easy to install  5
Need 11
The device is light weight  4
Need 12
The device adds only a minimal increase in effort for the operator pedaling the bicycle, ideally none at all
Need 13
The device is a stylish accessory to the bicycle 3
dan

5. Specifications Specifications Units Ideal Marginal DC output voltage
output current mA
Estimated biking time to generate power 1 w-hr if the device does not generate continuously
hour
<1.5
<3
Maximum increased effort for bicyclist
% VO2 increase
<3%
<10%
Range of bike tire sizes the device will accommodate cm
Uses standard connectors to interface with cell phone or battery charger
% of
90%
60%
Size
cm^3
16x16x16
28x21.6x14
Number of people required to install device
# of people
<1
Number of tools required to install device
# of tools
Time required for set up (each use)
min
<10
<20
Time to train operator to use device
Increased temperature to bicycle Parts (rim, gears, ?)
Celsius Degree
<5
Manufactured cost ($20, per unit when manufactured in lots of 100) $
<40
Installation cost
Resists damage from impacts/crashes
IEC60529* Level 1-9
>7
>5
Dustproof
IEC60529* digit 1 Level 0-6 6
Waterproof
IEC60529* digit 2 Level 0-8
>4
People rating the device at 4 or above on a scale of 1-5 for aesthetically appealing %
>70
>50
dan

6. Functional Architecture
Flora

7. Our Concept: Electrical
Flora
Circuit Diagram

8. Our Concept: Electrical
Voltage(V)
Time (s)
Non-linear input test

9. Our Concept: Mechanical
Motor Housing
Aaron
Electronics Box

10. Final Product
Motor Housing
BRENDA :D
Electronics Box

11. Testing All specifications tested Either passed ideally or marginally
No tests failed
Examples of successes
Waterproof
Dustproof
Impact Test
Voltage Test
Aesthetic Survey
Dan

12. Test Results Test Ideal Value Measured Value
Ideal(I) Marginal (M) Fail (F)
Cost Analysis
<$20
$15.02 I
Waterproof 7 4 M
Dust Proof 6
Range of Bikes
(cm)
(cm)
Range of Phones
90%
Rough Road
Stays on and no Damage sustained
No damage sustained
Motor Voltage
>7V
Speed to Charge
<20 km/hr
<20 km/hr (17 km/hr greatest)
First Install
1 person 1 tool
1 person 0 tools
Each Use
<5min setup
<10 min train
<3 min train
Operating Temperature Change
<5 degrees C
4.9 degrees C
Impact Resistance
15 Lbs any angle
Output Current mA mA
Device Size
16x16x16 cm
16x10x12cm
Aesthetics
75% 4 or better
75%
V02
<10%
Statistically 0%
Phone Charging
Yes
Main Usage
>25% in 30 minutes
25% 30 minutes
Output Voltage with Input Greater than 6V
5 V
Dan

13. Cost Analysis Amina  BOX ASSEMBLY MOTOR ASSEMBLY WEIGHT
WEIGHT
Kolpin Replacement Straps for Rhino Grips, Model#87010
3" Powder Coated Metal Handrail Bracket
Westinghouse Stainless Steel Beaded Chain with Connector
1" diameter, 1/4" hole OD Washers (dan purchased)
1/4"-20x1/2" machine screws with nuts HOME DEPOT
Clear Plastic Box 24 oz with lid Ollie's
Zip Ties
PFP Crimp Connector (2mm)
M-D 17'L X 1/2"W Gray Closed- Cell Foam Window Weather Strip
1/4"-20x3/4" machine screws HOME DEPOT
3/16 X .049" ALUMI TUBE
1/2" diameter extrusion rubber roller 60A 6" length
Spring grip broom bracket, EVERBILT from SEARS
Rubber Dipping material- Plasti Dip from Menards
1.5"diameter, .5" thick aluminum billet, 6' length mcmaster carr
2mm mcmaster car steel rod, 3 ft length
60A mcmaster rubber , 1/4" diameter need 1/2 length
2 oz Single-Wall White Jar
Natural Smooth Lid with F217 Liner
Clear Aquarium Seal
Voltage Regulator
10μ Capacitor
.1μ Capacitor
USB Port
Bread Board
Wire
Quick Connect
Standoffs
TOTALS
DC output Voltage
3.7 9 1 23
DC output Current 6
Output Power 3 25
Energy Conversion Efficiency
3.4 40
Charging Rate 26
Weight
5.2 10
Size
4.1 21
Min Environmnt Temp
2.8 4
Max Environment Temp
Increased temperature through use 8
Water proof level
3.9 51
Dust proof level
4.2 52
Impats/crashes resist level
5.7 46
Wire strength
4.4
Increased opperator effort
5.5 11
Device Connector 7
Installation Cost
Installation Time
5.4
Installation People
4.7 2
Instalation Tools 20
Trainning Time(opparating)
Appearence
Manufactoring cost
6.3 48
RAW SCORE
0.684
0.337
0.2
0.404
0.779
2.643
0.291
0.234
0.592
0.201
0.287
0.119
1.392
1.028
0.569
0.759
0.665
2.293
1.346
0.918
0.834
0.171
1.341
0.242
0.678
0.471
20.092
Relative WORTH
3.40%
1.68%
1.00%
2.01%
3.88%
13.15%
1.45%
1.16%
2.95%
1.43%
0.59%
6.93%
5.12%
2.83%
3.78%
3.31%
11.41%
6.70%
4.57%
4.15%
0.85%
6.67%
1.20%
3.37%
2.34%
100.00%
ACTUAL COST
0.9
1.12
3.136
0.378
0.48
0.196
0.976
0.99
0.688
0.198
0.22
0.17
0.4
0.62
0.05
1.495
0.01
$19.01
RELATIVE COST
10.53%
4.74%
1.05%
5.89%
16.51%
1.99%
5.26%
2.53%
0.46%
1.03%
2.36%
5.14%
5.21%
3.62%
2.40%
1.04%
2.12%
0.89%
2.11%
3.26%
0.26%
7.87%
0.05%
100.03%
Amina 

14. BOX ASSEMBLY
WEIGHT
Kolpin Replacement Straps for Rhino Grips, Model#87010
3" Powder Coated Metal Handrail Bracket
Westinghouse Stainless Steel Beaded Chain with Connector
1" diameter, 1/4" hole OD Washers (dan purchased)
1/4"-20x1/2" machine screws with nuts HOME DEPOT
Clear Plastic Box 24 oz with lid Ollie's
Zip Ties
DC output Voltage
3.7
DC output Current
Output Power
Energy Conversion Efficiency
3.4
Charging Rate
Weight
5.2 1
Size
4.1 9
Min Environmnt Temp
2.8
Max Environment Temp
Increased temperature through use 4
Water proof level
3.9 3
Dust proof level
4.2
Impats/crashes resist level
5.7
Wire strength
4.4
Increased opperator effort
5.5
Device Connector
Installation Cost
Installation Time
5.4
Installation People
4.7
Instalation Tools
Trainning Time(opparating)
Appearence
Manufactoring cost
6.3
RAW SCORE
0.684
0.337
0.2
0.404
0.779
2.643
0.291
Relative WORTH
3.40%
1.68%
1.00%
2.01%
3.88%
13.15%
1.45%
ACTUAL COST 2
0.9
1.12
3.136
0.378
RELATIVE COST
10.53%
4.74%
1.05%
5.89%
16.51%
1.99%
5.26%
Amina 

15. Cost Analysis
Amina 

16. Line Balancing Program
#SETS set T; #tasks set N; #stations set PreT{T}; #subset of precedence #PARAMETERS param c; #Cycle time in hours (p=10, s=7.5; c=1.5hrs) param d{j in T}; #task duration param b{j in T, k in N}; #cost of doing task "j" in station "k" #VARIABLES var X {j in T, k in N} binary; #1, if task "j" is assigned to station "k", 0, otherwise #OBJECTIVE FUNCTION minimize Stations: sum{j in T, k in N} b[j,k]*X[j,k]; #CONSTRAINTS subject to TaskAssignment {j in T}: sum{k in N} X[j,k] = 1; subject to CompletionTime {k in N}: sum{j in T} d[j]*X[j,k] <= c; subject to Precedence {j in T, k in N, i in PreT[j]:i>0}: X[j,k] <= sum{f in 1..k}X[i,f];
Amina 

17. Line Balancing Results
Finished Product
Electronics Housing
Mechanical BOX
Electrical CB
Motor Housing
Electrical Motor
Mechanical Motor
Cycle Time 10 30 60
Stations Needed 8 3 2
Feasible results will be attained for Cycle Times 9 minutes or greater.
Shorter Cycle Times will require a further break down of manufacturing processing times.

18. Life Cycle Assessment
Amina 

19. LCA Graphs – ENERGY & CO2 Summary
Amina 

20. Major Issues Concept Choice in MSD I
Initially ordering parts at a low cost
Material selection
Aaron

21. Objective Evaluation
Final product meets customer requirements as a proven, robust, functional prototype. Project is on time and under budget.
Several improvements could be made:
Reduced number of parts
Decreased complexity of design
Increased grip of spring clip design
Aesthetic appeal
Brenda

22. Future Considerations
A better phone container could be utilized that is completely waterproof.
Decrease number of tools required to build device as to be easily constructed in Haiti
Utilize a specialized motor
Contact Industrial Design Department to find out if any students wish to work on the project as well.
Systems modeling of the motor output and circuitry with a dynamic model.
Brenda

23. We’re Out!