1.

Manufacturing Documentation
This section contains the required documentation for manufacturing each model of the Personal
Power Supply. Each component has a thorough description of the part, including materials, required
tools, construction time, and an image of the part. Assembly drawings show how each component fits
into the final product. See Error! Reference source not found. for special notes on creating the more
complicated components.

1.1. Low-Cost Model Manufacturing Documentation

The following gives a description of each major component needed to be manufactured for the
low cost model. A detail drawing for each piece is also provided. At the end of the section, an overall
assembly drawing is shown which includes items that were both manufactured and purchased by the
team.

1.) Alternator Mounting Bracket and Base: The alternator mounting bracket and base is designed to
hold either the Delco-Remy or Wind Blue alternator. It contains the following items from the BOM: 12,
13 and 14

A. BOM Item 13 - 2”x2”x1/4” Angle Iron (x2)

Tools Required: Vertical axis mill and small hand drill

Material: AISI/SAE 1018 hot roll steel 2”x2”x1/4” Angle Iron

Estimated Construction Time: 30 minutes each

Detail Drawing: Figure 1

Figure 1: Angle Iron

B. BOM Item 14 – Delco-Remy Car Alternator Bracket

Tools Required: Vertical axis mill and small hand drill

Material: AISI/SAE 1045 hot roll 1/2" plate steel

Estimated Construction Time: 30 minutes

Detail Drawing: Figure 2

Figure 2: Alternator Bracket

C. BOM Item 12 – Base

Tools Required: Vertical axis mill

Material: AISI/SAE 1045 13”x3” channel iron

Estimated Construction Time: 45 minutes

Detail Drawing: Figure 3
 Figure 3: Base

D. Alternator Mounting Bracket and Base Assembly

Tools Required: MIG Welder and Wrench

Estimated Assembly Time: 20 minutes

Total Construction Time: 2.6 hours

Assembly Model: Figure 4 (Alternator and pinion gear also shown)
 7/16” Bolt,
Nut, and
Washer

Fillet Weld

7/16” Bolt,
Nut, and
Washer

Figure 4: Alternator mounting bracket and brace

2.) Intermediate Shaft and Mount: This is a mounting scheme that allows for an additional gearing
stage through an intermediate shaft. The intermediate shaft will transmit power delivered from the chain
and sprocket to the pinion and flywheel system. The intermediate shaft is supported by two 1” pillow
block bearings (BOM item 15) which are fastened to this mount. This mount contains the following
items from the BOM: 4, 8, 10, 11, and 12.

A. BOM Item 4 – Intermediate Shaft

Tools Required: Lathe

Material: AISI/SAE 1045 hot roll steel 1” bar stock

Estimated Construction Time: 20 minutes

Detail Drawing: Figure 5
 Figure 5: Intermediate shaft

B. BOM Item 10 – Mounting Plate

Tools Required: Hand drill

Material: AISI/SAE 1045 hot rolled 1/2” plate steel

Estimated Construction Time: 20 minutes

Detail Drawing: Figure 6
 Figure 6: Mounting plate

C. BOM Item 11 – Supporting Columns (x2)

Tools Required: Steel saw

Material: AISI/SAE 1045 hot rolled steel 2” square tube stock

Estimated Construction Time: 10 minutes each

Detail Drawing: Figure 7
 Figure 7: Supporting columns

D. BOM Item 12 – Base – see section 1

E. BOM Item 8 – 1” Self Aligning Pillow Block Bearing (x2)

Tools Required: Allen wrench

Material: Purchase

Estimated Construction Time: Purchase

Detail Drawing: Figure 8

Figure 8: Pillow block bearing

F. BOM Item 5 – Fly wheel and Hub

Tools Required: Lathe, mill, steel saw, hand drill, and wrench

Material: AISI/SAE 1045 hot rolled steel

Estimated Construction Time: 2 hours

*See Error! Reference source not found. for detailed instruction regarding this piece*

Detail Drawing: Figure 9

Figure 9: Hub

G. Intermediate Shaft and Mount Assembly

Tools Required: MIG welder and wrench

Estimated Assembly Time: 45 minutes

Total Construction time: 2.33 hours

Assembly Model: Figure 10 (Fly wheel and small sprocket are also shown)
 7/16” Bolts,
Nuts, and
Washers

Fillet Weld

Figure 10: Intermediate shaft and mount assembly

3.) Alternator Connecting Shaft/Coupling: This piece allows for the connection between the car
pinion gear and the Delco-Remy alternator. This could have been a purchased component, but the team
elected to manufacture it ourselves.
A. BOM Item 7 – Alternator Connecting Shaft/Coupling

Tools Required: Lathe, hand drill, and Allen wrench

Material: AISI/SAE 1045 hot rolled steel 1” bar stock

Estimated Construction Time: 1 hour

Detail Drawing: Figure 11
 Figure 11: Alternator coupling

4.) Purchased and Assembled Components: The following details the tools required and assembly
times for the low cost model’s purchased components.

A. Chain and Sprockets Assembly (BOM Items 2, 3, and 15)

Tools Required: Chain tensioner, Allen wrench, and screw driver

Estimated Assembly Time: 50 minutes
B. Flywheel, Pinion, and Alternator Assembly (BOM Items 5, 6, 7, 8, and 9)

Tools Required: MIG welder, wrench, and Allen wrench

Estimated Assembly Time: 2 hours

5.) Overall System Assembly: Figure 12 shows an exploded assembly drawing for the low cost model.
The overall manufacturing and assembly time follows.
 1 4
14
3 5 7

15

6
8
10 13

12
11

Figure 12: System assembly of the Low-Cost model

Overall Manufacturing and Assembly Time: 10.75 hours

6.) Electrical Wiring: See Figure 13 for wiring diagram. All connections must be secure, and wires
must be insulated from other wires. Where marked, wires must be 12 AWG or larger. Other wires must
be 22 AWG or larger.

Figure 13: Wiring Diagram for the Low-Cost model

 1.2. High-Performance Model Manufacturing Documentation
The following gives a description of each major component needed to be manufactured for the
high performance model. The specific manufacturing details are identical to those presented in the
low cost model section, so they are not shown again here. At the end of the section, an overall
assembly drawing is shown which includes items that were both manufactured and purchased by the
team.

1.) Alternator Mounting Bracket and Base: The alternator mounting bracket and base is designed to
hold either the Delco-Remy or WindBlue alternator. It contains the following items from the BOM: 7, 8
and 9.

2.) Alternator Connecting Shaft/Coupling: This piece allows for the connection between the car
pinion gear and the WindBlue alternator. This could have been a purchased component, but the team
elected to manufacture it ourselves. It is BOM item 4.

3.) Purchased and Assembled Components: The following details the tools required and assembly
times for the low cost model’s purchased components.
A. Charge Controller Wiring Connections (BOM Item 10 and 11)

Tools Required: Screwdriver and wire cutters

Estimated Assembly Time: 1.5 hours
C. Flywheel, Pinion, and Alternator Assembly (BOM Items 2, 3, 4, and 6)

Tools Required: MIG welder, wrench, and Allen wrench

Estimated Assembly Time: 2 hours

*See Error! Reference source not found. for detailed instruction regarding the flywheel
coupling and hub*

4.) Overall System Assembly: Figure 14 shows an exploded assembly drawing for the high
performance model. The overall manufacturing and assembly time follows.
 7

Figure 14: System assembly of the High-Performance model

Overall Manufacturing and Assembly Time: 9.1 hours

5.) Electrical Wiring: See Figure 15 for wiring diagram. All connections must be secure, and wires
must be insulated from other wires. Where marked, wires must be 12 AWG or larger. Other wires must
be 22 AWG or larger.

Figure 15: Wiring Diagram for the High-Performance model