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

2. 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

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

4. 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.

5. 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.

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

7. 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

8. Project Components

9. Stand Prototype
Top View
Front View
Side View

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

11. 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

12. 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); /8" nuts (4x$0.35); 5/8" couplings (6x$1.43)
$16.55
Miscellaneous items
$4.68
Cylinder
Rails
Total: $212.65

13. 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

14. 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

15. Implementation in Honduras

16. 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

17. 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

18. 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

19. 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

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

21. Assembly
Attach alternator to tray
Stabilize cylinder

22. 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

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

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

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

26. Future Recommendations

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

28. 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)

29. 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

30. 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

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

32. Questions?

33. Manuals Operation Manual: Construction Manual:
Power Calculations Manual: