1. Harvesting Waste Energy: Bicycle Power Generation RIT-MSD-I Detailed Design Review Winter/Spring 2011-2012 P12414

2. 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

3. 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 Concerns & Next Steps Team, All

4. 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.

5. Customer Requirements

6. Specifications UnitsIdealMarginal DC output voltagevolt3.7-4.23.6-4.2 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 accomodaecm40.6-71.160.6-71.1 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-10-15 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

7. 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.

8. Full Assembly

9. Motor Assembly

10. Electronics Box

11. Force Displacement 150lb Uniform Load

12. RPM/Angular Acceleration

13. Inputs for Shaft & Roller

14. Outputs for Shaft & Roller

15. Spring Calculations SPRING

16. Motor Selection Voltage Output Testing on the MIT device

17. Motor Selection Voltage Output Testing on the Red Light Dynamo

18. Motor Selection Voltage Output Testing on the White Light Dynamo

19. Motor Selection Summary Selected this motor because it provides DC output. Cheap, small & lightweight. 12V DC

20. 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.

21. 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

22. Circuits Overview The Bridge Rectifier

23. 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.

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

25. 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 to the voltage regulator. It is not necessary if the output of the motor is always lower than 25V.

26. Circuits Overview At the end, after we get the 5V constant output. The output pins will connect to a standard A-type USB connector. Pins 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, various USB to cellphone connectors can be made.

27. 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 that 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

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

29. 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.

30. BOM Mechanical Parts SKU #Item # Product Parts per SKU Number SKUs to Purchas e Price Per SKU ($) Price per Part($) Total Price ($) 130852 The Hillman Group 1/4" x 1" Black Phosphate Coarse-Thread Hex-Head Serrated Flange Bolt 6420.680.171.36 137162 The Hillman Group 4-Count 1/4"-20 Zinc-Plated Jam Nuts 6420.920.231.84 American 1" Copper Split Ring Hanger 2121.29 2.58 3/8" Threaded Rod - Steel City (10') 16015.970.15.97 Kolpin Replacement Straps for Rhino Grips, Model#87010 121424 M-D 17'L X 1/2"W Gray Closed- Cell Foam Window Weather Strip 13412.980.092.98 3" Powder Coated Metal Handrail Bracket 1110.9 PFP Crimp Connector (2mm) 1110.12 Size 6 Rubber Stopper 1110.67 Round Copper Tube 3mm OD x.36mm Wall (3) 11711.990.121.99 Westinghouse 77049 3 Stainless Steel Beaded Chain with Connector 111111 T205 13.7 oz Natural Rectangle Tub 1110.34 J035 2 oz Single-Wall White Jar 1110.22 L216NF 53-400 Natural Smooth Lid with F217 Liner 1110.17 41471 3M Marine Adhesive Sealant White 130 11.970.40 9271K652 Torsion Spring 1615.971 T225 White Lid for Rectangular Tubs 1110.31 Carlon 3 Gang Plastic New Work Electrical Box 0003.9900 Hickory Harware Self Closing Hinge 0001.6600 Optix 6'x3' Clear Acrylic Sheet 00054.9800 M-D 17'L X 7/8"W White PVC Foam Door Weather Strip 0003.9700 Size 7 Rubber Stopper 000100 Round Aluminum Tube 2mm OD X ).45 mm Wall (4) (k+s9801) K-S Hobby and Craft Metal Tubing 0002.9900 Stainless Steel 304 Seamless Round Metric Tubing OD 3mm ID 2mm (2in pcs) 00068.1100 TOTAL for 1 Final Product: $12.42

31. 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-E4/51 10.390.350.27 Voltage Regulator LT780-05 1//0.4 10u Capacitor NPR 10M63 20.62// 0.1u Capacitor CML 104M50 10.62// USB Port PRT-09011 11.251/ 7.5V Zener Diode 1N5343BG 1//0.2067 Prototype Bread Board 1-1/2" * 1-3/4" 10.620.48 Wire 10 cm 10.05// LED RED and Yellow 20.48/0.081 Unit Price 1Unit Price for 100 NOKIA charger0.60.3 BLACKBERRY charger0.550.4 With accessories TOTAL for 1: $4.94 or $5.04

32. Electrical Part Specs/Reasoning ItemPart #CountSelection Reason Bridge Rectifier2W04G-E4/511 Voltage RegulatorLT780-051 0V 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-090111 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(W120-1000-ND)1 A positive and negative output need to be delivered to the circuit board from the dynomal

33. 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 8520 3.Nokia C3 4.Nokia 1616 5.Blackberry Bold 6-10 Various Blackberry Cell Phones (use micro USB)

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

35. Risks

39. 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

40. Required Equipment for Testing Engr. Spec. # Instrumentation or equipment not available (description) ES1Oscilloscope and Computer in the Systems Lab ES2Oscilloscope and Computer in the Systems Lab ES3Oscilloscope and Computer in the Systems Lab ES4Fitness Lab with V02 sensors ES5Various Bikes to attach device to. ES6Various phones to plug into device ES7Calipers and Tape Measure ES8Volunteers to Attach device ES9Various Tools and Volunteers ES10Stop Watch, Volunteers ES11Volunteers ES12Thermocouples, DAQ ES13Thermocouples, DAQ ES14Thermocouples, DAQ ES15N/A ES16N/A ES17Spring Scale, Weights ES18Tape Measure ES19Small particulates (i.e. sand) ES20Spray nozzle, Water pump, Tub for Submersion ES21Aesthetics Survey

41. Engr. Spec. # Specification (description)Unit of MeasureMarginal ValueComments/Status ES1DC Output Voltagevolt3.6-4.2 ES2Output CurrentmA<230 ES3Maximum Charging Rate (depends on battery)mAh>800 ES4estimated biking time to generate power 1 w-hr if the device does not generate continuouslyhour<3 maximum increased effort for bicyclist% VO2 increase<10% ES5range of bike tire sizes the device will accommodatecm60.6-71.1 ES6uses standard connectors to interface with cell phone or battery charger % of top 10 selling Haitian phones the device can charge (when separate adapter purchased)60% ES7sizecm^328x21.6x14 ES8number of people required to install device# of people≤3 ES9number of tools required to install device# of tools≤3 ES10time required for set up (each use)min<15 ES11time to train operator to use devicemin<30 ES12min operating tempCelsius Degree-15 ES13max operating tempCelsius Degree40 ES14Increased temperature to bicycle parts (rim, gears?)Celsius Degree<10 ES15manufactured cost ($20, per unit when manufactured in lots of 100)$<40 ES16installation cost$<5 ES17wire strengthForce that it can afford(N)≤50 ES18resists damage from impacts/crashesIEC60529* Level 1-9>5 ES19dust proofIEC60529* digit 1 Level 0-6>5 ES20water proofIEC60529* digit 2 Level 0-8>4 ES21people rating the device at 4 or above on a scale of 1-5 for aesthetically appealing%>30

42. Example Test Sheet

43. 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.

44. 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.

45. We Welcome Your Questions & Feedback