Harvesting Waste Energy:Bicycle Power Generation

RIT-MSD-I Detailed Design Review

Winter/Spring 2011-2012P12414

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 ReviewTIME 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 AnalysisTest Plan & Sample Test SheetConcerns & 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 RequirementsObjective:

To power simple personal devices using energy stored in the momentum of a bicycle

Importance Weight

Need # Customer Needs 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 attaches to a wide variety of bicycle types 6

Need 3 The device adds only a minimal increase in effort for the operator pedaling the bicycle, ideally none at all

4

Need 4 The device uses standard connectors to personal electronic devices

8

Need 5 The device is light weight 4

Need 6 The device is inexpensive to purchase, install and maintain

7

Need 7 The device is easy to install 5

Need 8 The device is easy to operate 6 Need 9 The device is easy to maintain 6

Need 10 The device resists environmental damage from dust, water, etc. 8

Need 11 The device works well on rough roads 8 Need 12 The device protects user safety 8

Need 13 The device is a stylish accessory to the bicycle 3

SpecificationsSpecifications Units Ideal MarginalDC output voltage volt 3.7-4.2 3.6-4.2output current mA <200 <230maximum charging rate (depends on battery) mAh >1000 >800estimated biking time to generate power 1 w-hr if the device does not generate continuously hour <1.5 <3maximum increased effort for bicyclist % VO2 increase <3% <10%range of bike tire sizes the device will accomodae cm 40.6-71.1 60.6-71.1

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%

size cm^3 16x16x16 28x21.6x14number of people required to install device # of people <1 <3number of tools required to install device # of tools <1 <3time required for set up (each use) min <10 <20time to train operator to use device min <10 <10min operating temp Celsius Degree -10 -15max operating temp Celsius Degree 50 40increased temperature to bicycle aprts (rim, gears, ?) Celsius Degree <5 <10manufactured cost ($20, per unit when manufactured in lots of 100) $ <20 <40installation cost $ 0 <5wire strength Force that it can afford(N) <90 <50resists damange from impacts/crashes IEC60529* Level 1-9 >7 >5dust proof IEC60529* digit 1 Level 0-6 6 >5water proof IEC60529* digit 2 Level 0-8 >7 >4people rating the device at 4 or above on a scale of 1-5 for aesthetically appealing % >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 Displacement150lb Uniform Load

RPM/Angular Acceleration

Inputs for Shaft & Roller

Outputs for Shaft & Roller

Spring Calculations

SPRING

Motor SelectionVoltage Output Testing on the MIT device

Motor SelectionVoltage Output Testing on the Red Light Dynamo

Motor SelectionVoltage Output Testing on the White Light Dynamo

Motor Selection Summary

•Selected this motor because it provides DC output.

•Cheap, small & lightweight.

•12V DC

Circuits Overview

C 1 14 7 0 u

-

+

12V DC motorTo Cell Phone

+

-

6V VoltageRegulator

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.

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 inputConstant 5V DC

output

Circuits Overview• The testing on excising dynamos and products shows that the

output of an AC motor is similar to a sin wave. Assuming that the output from the motor is a sin wave with 12V amplitude, 100Hz frequency, and 0 V offset. The first step is to use a Bridge Rectifier to rectify the output voltage. The output from the rectifier is always positive. The circuit diagram and simulation are shown below. As we can see, there is a voltage drop of . is the diode voltage.

V 3

F R E Q = 1 0 0V A M P L = 1 2V O F F = 0

0

D 5

D 1 N 9 1 4

D 6

D 1 N 9 1 4

D 7

D 1 N 9 1 4

D 8

D 1 N 9 1 4

R 51 k

V

V-

V+

Time

0s 1ms 2ms 3ms 4ms 5ms 6ms 7ms 8ms 9ms 10ms 11ms 12ms 13ms 14ms 15ms 16ms 17ms 18ms 19ms 20msV(V3:+,V3:-) V(D8:2)

-12V

-8V

-4V

0V

4V

8V

12V

The Bridge Rectifier

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.

V 4

F R E Q = 1 0 0V A M P L = 1 2V O F F = 0

0

D 9

D 1 N 9 1 4

D 1 0

D 1 N 9 1 4

D 1 1

D 1 N 9 1 4

D 1 2

D 1 N 9 1 4

U 3L M 3 4 0 -5

I N1

O U T2

GN

D3

0

C 71 0 u

C 81 0 u

C 9. 1 u R 6

1 0 0 k

VV

Time

0s 1ms 2ms 3ms 4ms 5ms 6ms 7ms 8ms 9ms 10ms 11ms 12ms 13ms 14ms 15ms 16ms 17ms 18ms 19ms 20msV(D12:2) V(R6:2)

0V

2V

4V

6V

8V

10V

12V

Circuits Overview

Time

0s 1ms 2ms 3ms 4ms 5ms 6ms 7ms 8ms 9ms 10ms 11ms 12ms 13ms 14ms 15ms 16ms 17ms 18ms 19ms 20msV(V3:+,V3:-) V(D8:2) V(D12:2) V(R6:2)

-12V

-8V

-4V

0V

4V

8V

12V

Overall Waveform of the simulations

12V AC Positive Output

Positive Output in

Range5V DC

Cellphone

AC motor

Circuits Overview

V 4

F R E Q = 1 0 0V A M P L = 1 2V O F F = 0

0

D 9

D 1 N 9 1 4

D 1 0

D 1 N 9 1 4

D 1 1

D 1 N 9 1 4

D 1 2

D 1 N 9 1 4

U 3L M 3 4 0 -5

I N1

O U T2

GN

D3

0

C 71 0 u

C 81 0 u

C 9. 1 u R 6

1 0 0 k

D 1 4D 0 2 C Z 1 0

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.

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.

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.

C 81 0 u

12V DC motor C 9. 1 u

A-type USBConnector

4

1

U 4L M 3 4 0 -5

I N1

O U T2

GN

D3

0

C 71 0 u

Circuit diagram for 12V DC motor

Circuits Overview

Time

0s 1ms 2ms 3ms 4ms 5ms 6ms 7ms 8ms 9ms 10ms 11ms 12ms 13ms 14ms 15ms 16ms 17ms 18ms 19ms 20msV(V5:+,0) V(R9:2,0)

4V

5V

6V

7V

8V

9V

10V

11V

12V

13V

Time

0s 1ms 2ms 3ms 4ms 5ms 6ms 7ms 8ms 9ms 10ms 11ms 12ms 13ms 14ms 15ms 16ms 17ms 18ms 19ms 20msV(V5:+,0) V(R9:2,0)

4.8V

5.2V

5.6V

6.0V

6.4V

6.8V

7.2V

7.6V

8.0V

8.4V

Simulation of 12V DC motor with 12V motor output with ripples.

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

Circuits Overview• Assume the waveform below is generated by a person riding

for 20s with two stops.

Time

0s 1s 2s 3s 4s 5s 6s 7s 8s 9s 10s 11s 12s 13s 14s 15s 16s 17s 18s 19s 20sV(V5:+,0) V(R9:2)

0V

2V

4V

6V

8V

10V

12V

• According to the simulation, the output of the circuit maintain at 5V when the motor’s output is between 6V to 12V.

BOM Mechanical PartsSKU # Item #

Product Parts per SKU

Number SKUs to Purchas

ePrice Per SKU

($)Price per Part($)

Total Price ($)

130852The Hillman Group 1/4" x 1" Black Phosphate Coarse-Thread

Hex-Head Serrated Flange Bolt 6 4 2 0.68 0.17 1.36

137162 The Hillman Group 4-Count 1/4"-20 Zinc-Plated Jam Nuts 6 4 2 0.92 0.23 1.84

American 1" Copper Split Ring Hanger 2 1 2 1.29 1.29 2.58 3/8" Threaded Rod - Steel City (10') 1 60 1 5.97 0.1 5.97

Kolpin Replacement Straps for Rhino Grips, Model#87010 1 2 1 4 2 4

M-D 17'L X 1/2"W Gray Closed- Cell Foam Window Weather

Strip 1 34 1 2.98 0.09 2.98

3" Powder Coated Metal Handrail Bracket 1 1 1 0.9 0.9 0.9 PFP Crimp Connector (2mm) 1 1 1 0.12 0.12 0.12 Size 6 Rubber Stopper 1 1 1 0.67 0.67 0.67

Round Copper Tube 3mm OD x .36mm Wall (3) 1 17 1 1.99 0.12 1.99

Westinghouse 77049 3 Stainless Steel Beaded Chain with

Connector 1 1 1 1 1 1T205 13.7 oz Natural Rectangle Tub 1 1 1 0.34 0.34 0.34J035 2 oz Single-Wall White Jar 1 1 1 0.22 0.22 0.22

L216NF 53-400 Natural Smooth Lid with F217 Liner 1 1 1 0.17 0.17 0.1741471 3M Marine Adhesive Sealant White 1 30 11.97 0.4 0

9271K652 Torsion Spring 1 6 1 5.97 1 5.97T225 White Lid for Rectangular Tubs 1 1 1 0.31 0.31 0.31

Carlon 3 Gang Plastic New Work Electrical Box 0 0 0 3.99 0 0 Hickory Harware Self Closing Hinge 0 0 0 1.66 0 0 Optix 6'x3' Clear Acrylic Sheet 0 0 0 54.98 0 0

M-D 17'L X 7/8"W White PVC Foam Door Weather Strip 0 0 0 3.97 0 0 Size 7 Rubber Stopper 0 0 0 1 0 0

Round Aluminum Tube 2mm OD X ).45 mm Wall (4) (k+s9801)

K-S Hobby and Craft Metal Tubing 0 0 0 2.99 0 0

Stainless Steel 304 Seamless Round Metric Tubing OD 3mm ID

2mm (2in pcs) 0 0 0 68.11 0 0

TOTAL for 1 Final Product: $12.42

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 1 0.39 0.35 0.27Voltage Regulator LT780-05 1 / / 0.4

10u Capacitor NPR 10M63 2 0.62 / /0.1u Capacitor CML 104M50 1 0.62 / /

USB Port PRT-09011 1 1.25 1 /7.5V Zener Diode 1N5343BG 1 / / 0.2067

Prototype Bread Board 1-1/2" * 1-3/4" 1 0.62 0.48 0.48Wire 10 cm 1 0.05 / /LED RED and Yellow 2 0.48 / 0.081

Unit Price 1 Unit Price for 100NOKIA charger 0.6 0.3

BLACKBERRY charger 0.55 0.4

With accessories TOTAL for 1: $4.94 or $5.04

Electrical Part Specs/Reasoning

Item Part #Coun

t Selection Reason

Bridge Rectifier 2W04G-E4/51 1Voltage Regulator LT780-05 1 0V to 12V voltage input. Current range 200mA to 250mA. 5V DC output.

10u Capacitor NPR 10M63 2 Can afford at least 15V voltage input0.1u Capacitor CML 104M50 1 Can afford at least 15V voltage input

USB Port PRT-09011 1 Can afford at least 15V voltage input7.5V Zener Diode 1N5343BG 1 Minimun voltage needed to the voltage regulator is 7VPrototype Bread

Board 1-1/2" * 1-3/4" 1Right size for all components

Single Conductor Wire

10 cm(A3049R-100-ND) 1

Connections on circuit boardDouble Conductor

wire 2m(W120-1000-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 Phones1. Blackberry Curve2. Blackberry 85203. Nokia C34. Nokia 16165. Blackberry Bold6-10 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

Risks

Risks

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 TestingEngr. Spec.

# Instrumentation or equipment not available (description)

ES1 Oscilloscope and Computer in the Systems Lab

ES2 Oscilloscope and Computer in the Systems Lab

ES3 Oscilloscope and Computer in the Systems Lab

ES4 Fitness Lab with V02 sensors

ES5 Various Bikes to attach device to.

ES6 Various phones to plug into device

ES7 Calipers and Tape Measure

ES8 Volunteers to Attach device

ES9 Various Tools and Volunteers

ES10 Stop Watch, Volunteers

ES11 Volunteers

ES12 Thermocouples, DAQ

ES13 Thermocouples, DAQ

ES14 Thermocouples, DAQ

ES15 N/A

ES16 N/A

ES17 Spring Scale, Weights

ES18 Tape Measure

ES19 Small particulates (i.e. sand)

ES20 Spray nozzle, Water pump, Tub for Submersion

ES21 Aesthetics Survey

Engr. Spec. # Specification (description) Unit of Measure Marginal Value Comments/Status

ES1 DC Output Voltage volt 3.6-4.2  

ES2 Output Current mA <230  

ES3 Maximum Charging Rate (depends on battery) mAh >800  

ES4 estimated biking time to generate power 1 w-hr if the device does not generate continuously hour <3  

maximum increased effort for bicyclist % VO2 increase <10%

ES5 range of bike tire sizes the device will accommodate cm 60.6-71.1

ES6 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) 60%

ES7 size cm^3 28x21.6x14

ES8 number of people required to install device # of people ≤3

ES9 number of tools required to install device # of tools ≤3

ES10 time required for set up (each use) min <15

ES11 time to train operator to use device min <30

ES12 min operating temp Celsius Degree -15

ES13 max operating temp Celsius Degree 40

ES14 Increased temperature to bicycle parts (rim, gears?) Celsius Degree <10

ES15 manufactured cost ($20, per unit when manufactured in lots of 100) $ <40

ES16 installation cost $ <5

ES17 wire strength Force that it can afford(N) ≤50

ES18 resists damage from impacts/crashes IEC60529* Level 1-9 >5

ES19 dust proof IEC60529* digit 1 Level 0-6 >5

ES20 water proof IEC60529* digit 2 Level 0-8 >4

ES21 people rating the device at 4 or above on a scale of 1-5 for aesthetically appealing % >30

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.

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.

We Welcome Your

Questions & Feedback