Harvesting Waste Energy Bicycle Power Generation RITMSDI Detailed

Harvesting Waste Energy: Bicycle Power Generation RIT-MSD-I Detailed Design Review Winter/Spring 2011 -2012 P 12414

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 TIME TOPIC Attendees 1: 30 -1: 45 Background Information Team Introduction Project Summary Customer Requirements Engineering Specifications Team, All 1: 45 -2: 45 Mechanical Assembly & Calculations Motor Assembly Electronics Box Assembly Team, ME professionals 2: 45 -3: 15 Electrical Overview Motor Selection Benchmark Analysis Team, EE professionals 3: 15 -3: 30 Cost 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 DC output voltage output current maximum charging rate (depends on battery) estimated biking time to generate power 1 w-hr if the device does not generate continuously maximum increased effort for bicyclist range of bike tire sizes the device will accomodae uses standard connectors to interface with cell phone or battery charger size number of people required to install device number of tools required to install device time required for set up (each use) time to train operator to use device min operating temp max operating temp increased temperature to bicycle aprts (rim, gears, ? ) manufactured cost ($20, per unit when manufactured in lots of 100) installation cost wire strength resists damange from impacts/crashes dust proof water proof people rating the device at 4 or above on a scale of 1 -5 for aesthetically appealing Units volt m. Ah Ideal 3. 7 -4. 2 <200 >1000 Marginal 3. 6 -4. 2 <230 >800 hour % VO 2 increase cm % of top 10 selling Haitian phones the device can charge (when separate adapter purchased) cm^3 # of people # of tools min Celsius Degree <1. 5 <3% 40. 6 -71. 1 <3 <10% 60. 6 -71. 1 90% 60% 16 x 16 <1 <1 <10 -10 50 <5 28 x 21. 6 x 14 <3 <3 <20 <10 -15 40 <10 $ $ Force that it can afford(N) IEC 60529* Level 1 -9 IEC 60529* digit 1 Level 0 -6 IEC 60529* digit 2 Level 0 -8 <20 0 <90 >7 6 >7 <40 <5 <50 >5 >5 >4 % >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 150 lb Uniform Load

RPM/Angular Acceleration

Inputs for Shaft & Roller SHAFT ROLLER

Outputs for Shaft & Roller ROLLER SHAFT

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 6 V voltage regulator and a 470 u. F 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 6 V constant output.

Circuits Overview • The voltage supplied by a USB port is nominally 5 V. In practical, the output is between 4. 75 V and 5. 25 V. A constant DC output of 5 V is needed for the design. Non-linear oscillating voltage input Circuit Constant 5 V 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 5 V constant DC output using a voltage regulator. The circuit diagram and simulations are shown. Capacitor C 8 and C 9 are used to additionally stabilize the voltage.

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

Circuits Overview Additional Zener diode Circuit As shown in circuit above, a 10 V 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 25 V.

Circuits Overview • At the end, after we get the 5 V 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 5 V 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 12 V DC motor is used in our design. The output from the motor is approximately 5 V DC voltage with ripples. The design shown below is used to regulate the voltage output. Circuit diagram for 12 V DC motor

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

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

130852 137162 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 3/8" Threaded Rod - Steel City (10') Kolpin Replacement Straps for Rhino Grips, Model#87010 M-D 17'L X 1/2"W Gray Closed- Cell Foam Window Weather Strip 3" Powder Coated Metal Handrail Bracket PFP Crimp Connector (2 mm) Size 6 Rubber Stopper Round Copper Tube 3 mm OD x. 36 mm Wall (3) Westinghouse 77049 3 Stainless Steel Beaded Chain with Connector T 205 J 035 L 216 NF 41471 9271 K 652 T 225 13. 7 oz Natural Rectangle Tub 2 oz Single-Wall White Jar 53 -400 Natural Smooth Lid with F 217 Liner 3 M Marine Adhesive Sealant White Torsion Spring White Lid for Rectangular Tubs Carlon 3 Gang Plastic New Work Electrical Box Hickory Harware Self Closing Hinge Optix 6'x 3' Clear Acrylic Sheet M-D 17'L X 7/8"W White PVC Foam Door Weather Strip Size 7 Rubber Stopper Round Aluminum Tube 2 mm OD X ). 45 mm Wall (4) (k+s 9801) K-S Hobby and Craft Metal Tubing Stainless Steel 304 Seamless Round Metric Tubing OD 3 mm ID 2 mm (2 in pcs) Total Price ($) Price per Part($) Price Per SKU ($) Item Parts per SKU Number SKUs to Purchase SKU # # Parts Needed for 1 Final Product BOM Mechanical Parts 6 4 2 0. 68 0. 17 1. 36 6 2 1 4 1 60 2 2 1 0. 92 1. 29 5. 97 0. 23 1. 29 0. 1 1. 84 2. 58 5. 97 1 2 1 4 2 4 1 1 34 1 1 1 1 2. 98 0. 9 0. 12 0. 67 0. 09 0. 12 0. 67 2. 98 0. 9 0. 12 0. 67 1 1. 99 0. 12 1. 99 1 1 1 30 6 1 1 1 1 0. 34 0. 22 0. 17 11. 97 5. 97 0. 31 1 0. 34 0. 22 0. 17 0. 4 1 0. 31 1 0. 34 0. 22 0. 17 0 5. 97 0. 31 0 0 0 0 0 3. 99 1. 66 54. 98 0 0 0 3. 97 1 0 0 0 0 2. 99 0 0 0 68. 11 0 0 TOTAL for 1 Final Product: $12. 42

2 W 04 G-E 4/51 Bridge Rectifier LT 780 -05 Voltage Regulator NPR 10 M 63 10 u Capacitor CML 104 M 50 0. 1 u Capacitor PRT-09011 USB Port 1 N 5343 BG 7. 5 V Zener Diode Prototype Bread Board 1 -1/2" * 1 -3/4" 10 cm Wire RED and Yellow LED NOKIA charger BLACKBERRY charger 1 1 2 1 1 1 2 Unit Price 1 0. 6 0. 55 0. 39 / 0. 62 1. 25 / 0. 62 0. 05 0. 48 Unit Price for 100 0. 3 0. 4 Unit Price for 1000 Unit Price for 100 Item Unit Price for 1 Part # # Parts Needed BOM Electrical Parts 0. 35 / / / 1 / 0. 48 / / 0. 27 0. 4 / / / 0. 2067 0. 48 / 0. 081 TOTAL for 1 Final Product: $4. 64 With accessories TOTAL for 1: $4. 94 or $5. 04

Electrical Part Specs/Reasoning Item Bridge Rectifier Voltage Regulator 10 u Capacitor 0. 1 u Capacitor USB Port 7. 5 V Zener Diode Prototype Bread Board Single Conductor Wire Double Conductor wire Part # Count Selection Reason 2 W 04 G-E 4/51 1 LT 780 -05 1 0 V to 12 V voltage input. Current range 200 m. A to 250 m. A. 5 V DC output. NPR 10 M 63 2 Can afford at least 15 V voltage input CML 104 M 50 1 Can afford at least 15 V voltage input PRT-09011 1 Can afford at least 15 V voltage input 1 N 5343 BG 1 Minimun voltage needed to the voltage regulator is 7 V 1 -1/2" * 1 -3/4" 1 Right size for all components 10 cm(A 3049 R-1001 ND) Connections on circuit board 2 m(W 120 -1000 -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 8520 3. Nokia C 3 4. Nokia 1616 5. 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 ▫ 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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