Harvesting Waste Energy Bicycle Power Generation RITMSDII Design

Harvesting Waste Energy: Bicycle Power Generation RIT-MSD-II Design Review 5/18/12 2: 15 -2: 45 pm 09 -4425 Winter/Spring 2011 -2012 P 12414

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

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

Customer Needs Objective: To power simple personal devices using energy stored in the momentum of a bicycle Importance Weight 1 (Low) – 10 (High) Need # Customer Needs 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. 8 Need 4 The device works well on rough roads 8 Need 5 The device protects user safety 8 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 6 Need 9 The device attaches to a wide variety of bicycle types 6 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 4 Need 13 The device is a stylish accessory to the bicycle 3

Specifications DC output voltage Units volt Ideal 4. 8 -5. 2 Marginal 4. 7 -5. 3 output current m. A 250 -1000 200 - 1500 Estimated biking time to generate power 1 w-hr if the device does not generate continuously hour <1. 5 <3 % VO 2 increase <3% <10% Range of bike tire sizes the device will accommodate cm 40. 6 -71. 1 60. 6 -71. 1 Uses standard connectors to interface with cell phone or battery charger % of 90% 60% Size cm^3 16 x 16 28 x 21. 6 x 14 # of people <1 <3 # of tools <1 <3 Time required for set up (each use) min <10 <20 Time to train operator to use device min <10 Celsius Degree <5 <10 Manufactured cost ($20, per unit when manufactured in lots of 100) $ <20 <40 Installation cost $ 0 <5 IEC 60529* Level 1 -9 >7 >5 Dustproof IEC 60529* digit 1 Level 0 -6 6 >5 Waterproof IEC 60529* digit 2 Level 0 -8 >7 >4 % >70 >50 Maximum increased effort for bicyclist Number of people required to install device Number of tools required to install device Increased temperature to bicycle Parts (rim, gears, ? ) Resists damage from impacts/crashes People rating the device at 4 or above on a scale of 1 -5 for aesthetically appealing

Functional Architecture

Our Concept: Electrical Circuit Diagram

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

Our Concept: Mechanical Motor Housing Electronics Box

Final Product Motor Housing Electronics Box

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

Test Results Test Ideal Value Measured Value Ideal(I) Marginal (M) Fail (F) Cost Analysis Waterproof Dust Proof Range of Bikes Range of Phones <$20 7 6 60. 6 -71. 1 (cm) 90% $15. 02 4 6 60. 96 -68358 (cm) 90% I M I Rough Road Stays on and no Damage sustained No damage sustained M Motor Voltage >7 V Speed to Charge <20 km/hr First Install 1 person 1 tool <5 min setup <10 min train Each Use Operating Temperature <5 degrees C Change Impact Resistance 15 Lbs any angle Output Current 250 -1000 m. A Device Size 16 x 16 cm Aesthetics 75% 4 or better V 02 <10% Phone Charging Yes Main Usage >25% in 30 minutes Output Voltage with Input 5 V Greater than 6 V >7 V I <20 km/hr (17 km/hr I greatest) 1 person 0 tools I <5 min setup I <3 min train 4. 9 degrees C I 15 Lbs any angle 380 -892 m. A 16 x 10 x 12 cm 75% Statistically 0% Yes 25% 30 minutes I I 5 V I I I

Cost Analysis MOTOR ASSEMBLY 1/4"20 x 3/4" 20 x 1/2" machine 3/16 X. 049" screws with ALUMI TUBE HOME nuts HOME DEPOT 1. 5"diamete 60 A 1/2" Rubber Spring grip 2 mm 53 -400 r, . 5" thick mcmaster diameter Dipping Clear broom aluminum mcmaster rubber , 2 oz Single- Natural extrusion material- Voltage Wall White Smooth Lid Aquarium bracket, billet, 6' car steel 1/4" Regulator rubber Plasti Dip EVERBILT length rod, 3 ft diameter Jar with F 217 Seal roller 60 A from SEARS mcmaster length need 1/2 Liner 6" length Menards carr length 10μ Capacitor . 1μ Capacitor USB Port Bread Board DC output Voltage 3. 7 9 1 1 DC output Current 3. 7 1 1 1 Output Power 3. 7 Energy Conversion Efficiency 3. 4 Charging Rate 3. 4 Weight 5. 2 1 1 Size 4. 1 1 1 Min Environmnt Temp 2. 8 1 1 Max Environment Temp 2. 8 1 1 3 3 Increased temperature through use 1 1 1 9 9 1 3 1 3 1 1 1 3 1 9 1 3 9 1 1 1 3. 9 Dust proof level 4. 2 Impats/crashes resist level 5. 7 Wire strength 4. 4 Increased opperator effort 5. 5 Device Connector 5. 7 Installation Cost 4. 2 1 1 1 Installation Time 5. 4 1 1 1 Installation People 4. 7 1 Instalation Tools 4. 7 1 Trainning Time(opparating) 4. 4 1 1 1 Appearence 4. 1 3 1 1 Manufactoring cost 3 3 9 1 1 1 6 9 1 1 1 25 9 1 1 9 1 40 9 1 1 3 1 26 9 1 1 3 1 1 21 4 4 1 8 9 9 9 51 9 9 9 52 9 9 46 9 1 1 11 1 7 3 1 4 9 20 1 9 1 2 1 1 9 1 3 23 10 9 1 3 1 1 1 9 1 3 1 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 Relative WORTH 3. 40% 1. 68% 1. 00% 2. 01% 3. 88% 13. 15% 1. 45% ACTUAL COST 2 0. 9 0. 2 1. 12 3. 136 RELATIVE COST 10. 53% 4. 74% 1. 05% 5. 89% 16. 51% 6. 3 1 Standoffs 9 9 Water proof level 3 9 3 1 1 4 3 3 9 Quick Connect Wire TOTALS WEIGHT BOX ASSEMBLY M-D 17'L X 1" 1/4"Kolpin Westinghouse 1/2"W Gray 3" Powder diameter, 20 x 1/2" Clear Plastic PFP Crimp Closed- Cell Replacement 77049 3 Stainless Coated Metal 1/4" hole machine Box 24 oz Zip Ties Connector Foam Straps for Rhino Steel Beaded Handrail OD Washers screws with lid Grips, Chain with (2 mm) Window Bracket (dan nuts HOME Ollie's Model#87010 Connector Weather purchased) DEPOT Strip 1 6 1 26 1 1 3 1 1 1 1 48 0. 665 2. 293 1. 346 0. 918 0. 834 0. 171 1. 341 0. 242 0. 678 0. 471 0. 242 20. 092 100. 00% 1. 16% 2. 95% 1. 00% 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% 1. 20% 1 0. 48 0. 087647 0. 196 0. 448333 0. 976 0. 99 0. 688 0. 456286 0. 198 0. 402556 0. 22 0. 17 0. 087647 0. 4 0. 62 1 0. 48 0. 05 1. 495 0. 01 $19. 01 1. 99% 5. 26% 2. 53% 0. 46% 1. 03% 2. 36% 5. 14% 5. 21% 3. 62% 2. 40% 1. 04% 2. 12% 1. 16% 0. 89% 0. 46% 2. 11% 3. 26% 5. 26% 2. 53% 0. 26% 7. 87% 0. 05% 100. 03% 0. 378

BOX ASSEMBLY WEIGHT 1/4"-20 x 1/2" Westinghouse 1" diameter, Clear Plastic Kolpin Replacement 3" Powder machine 77049 3 Stainless 1/4" hole OD Box 24 oz Straps for Rhino Coated Metal Zip Ties screws with Steel Beaded Chain Washers (dan with lid Grips, Model#87010 Handrail Bracket nuts HOME with Connector purchased) Ollie's DEPOT DC output Voltage 3. 7 DC output Current 3. 7 Output Power 3. 7 Energy Conversion Efficiency 3. 4 Charging Rate 3. 4 Weight 5. 2 Size 4. 1 Min Environmnt Temp 2. 8 Max Environment Temp 2. 8 Increased temperature through use 4 Water proof level 3. 9 Dust proof level 4. 2 Impats/crashes resist level 5. 7 Wire strength 4. 4 Increased opperator effort 5. 5 Device Connector 5. 7 Installation Cost 4. 2 Installation Time 5. 4 Installation People 4. 7 Instalation Tools 4. 7 Trainning Time(opparating) 4. 4 Appearence 4. 1 Manufactoring cost 6. 3 RAW SCORE Relative WORTH ACTUAL COST RELATIVE COST 1 1 3 1 1 1 3 1 0. 684 3. 40% 2 10. 53% 1 1 1 0. 337 1. 68% 0. 9 4. 74% 1 1 1 1 0. 2 1. 00% 0. 2 1. 05% 3 3 1 1 1 0. 404 2. 01% 1. 12 5. 89% 1 1 3 9 1 1 0. 779 3. 88% 3. 136 16. 51% 1 9 9 9 9 1 9 9 2. 643 13. 15% 0. 378 1. 99% 3 1 1 0. 291 1. 45% 1 5. 26%

Cost Analysis Relative Cost 1/4"-20 x 1/2" machine screws with nuts HOME DEPOT Kolpin Replacement Straps for Rhino Grips, Model#87010 Clear Plastic Box 24 oz with lid Ollie's 2 oz Single-Wall White Jar Relative Worth

Line Balancing Program #SETS set T; #tasks set N; #stations set Pre. T{T}; #subset of precedence #PARAMETERS param c; #Cycle time in hours (p=10, s=7. 5; c=1. 5 hrs) 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 Task. Assignment {j in T}: sum{k in N} X[j, k] = 1; subject to Completion. Time {k in N}: sum{j in T} d[j]*X[j, k] <= c; subject to Precedence {j in T, k in N, i in Pre. T[j]: i>0}: X[j, k] <= sum{f in 1. . k}X[i, f];

Line Balancing Results 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. Finished Product Electronics Housing Motor Housing Mechanical BOX Electrical Motor Electrical CB Mechanical Motor

Life Cycle Assessment

LCA Graphs – ENERGY & CO 2 Summary

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

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

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.

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