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Table of Contents
Introduction ...................................................................................................................................2
1.1 Problem Statement ......................................................................................................2
1.2 Background Information .............................................................................................2
1.3 Project Planning ..........................................................................................................2
Customer Needs and Specifications ..............................................................................................2
2.1 Identification of Customer Needs ...............................................................................2
2.2 Design Specifications..................................................................................................2
Concept Development ...................................................................................................................3
3.1 External Search ...........................................................................................................3
3.2 Problem Decomposition..............................................................................................3
3.3 Concept Generation ....................................................................................................4
3.4 Concept Selection .......................................................................................................4
Detailed Design .............................................................................................................................4
4.1 Modifications to Proposal ...........................................................................................4
4.2 Overall Description .....................................................................................................5
4.3 Detailed Drawings ......................................................................................................6
4.4 Final Theoretical Analysis ..........................................................................................8
4.5 Component and material Selection Process for Mass Production ..............................8
4.6 Fabrication Processes for Mass Production ................................................................8
4.7 Industrial Design .........................................................................................................9
4.8 Safety ..........................................................................................................................9
Testing.........................................................................................................................................10
5.1 Test Procedure and Plan............................................................................................10
Conclusion ..................................................................................................................................10
Appendix A: Project Management ..............................................................................................11
Appendix B: Customer Survey and Results ................................................................................13
Appendix C: Analytical Hierarchy Process (AHP) Charts .........................................................15
Appendix D: Theoretical Analysis ..............................................................................................16
Appendix E: Detailed Drawings .................................................................................................17
Appendix F: Bill of Materials .....................................................................................................24
Appendix G: Safety Standards ....................................................................................................25
Appendix H: References .............................................................................................................26
Appendix I: Attestation of Work ................................................................................................27
Introduction
1.1 Problem Statement
We will develop a device which can be placed in line with a home faucet or shower head
to generate power from the water flow without disruption. The product will be designed around
household constraints such as average water flow and energy requirements for small appliances.
There is a potential market for 100,000 units per year over the next four years.
1.2 Background Information
Pennsylvania adheres to the International Plumbing Code 1993 which states a max water
temperature of 120F [1]. The average flow rate and pressure from a faucet is approximately 1.5
gallons/minute and 60 pounds per square inch [1].
1.3 Project Planning
The Gantt chart shows the timeline for completion of each stage of the project. The Gantt
chart and a table of team members, their qualifications, roles, and responsibilities can be found in
Appendix A.
Customer Needs and Specifications
2.1 Identification of Customer Needs
Ten homeowners and farmers over the age of 30 in York, Pa were surveyed. They were
also chosen because they expressed interest in the product and were available to be surveyed via
email. Larger sample sizes are ideal, however, a smaller sample size was chosen due to time
restrictions.
According to the survey, the customers are most concerned with the usefulness and low
cost of the product. The customer was asked to rank seven things that they wish they had in their
shower. Their top choices were music, clock, and decorative
lights. The survey and detailed survey results can be found in
Appendix B.
Six design criteria were used to rate each system. The
design criteria were weighted by how highly they were ranked
in the survey. The results can be found in Appendix B.
The analytical hierarchy process (AHP) was used to
determine the weights of the design specifications from the
companys product requirements. These results can be found in
Appendix C. The design criteria weights are based on the
customer needs and the companys product requirements. The
combined results are shown in Figure 1.
Combined Weighting Results
Cost 0.22
Ease of use 0.08
Waterproof/No Leaks 0.19
Aesthetics 0.08
Ease of Manufacturing 0.20
Usefulness 0.23
Figure 1-Weighting
other parts are comprised of aluminum, steel, and acrylic. See the Bill of Materials in Appendix
F for identification of all parts in the exploded view.
4.3 Detailed Drawings
Detailed drawings to be used for manufacturing and fabrication can be found in
Appendix E. These include specifications for the injection molded parts, turbine, gear, and
pinion. Off-the-shelf parts are referenced in the Bill of Materials in Appendix E. These parts
include the ball bearings, motor, end adapters, and epoxy. Specifications for these components
can be found through their respective company. The shaft, cover, and circuit board have basic
geometries that are specified in the Bill of Materials.
Figure 12: Isometric Motor Assembly View
Figure 11: Isometric Assembled View
Figure 13: Isometric Assembled View
Figure 14: Isometric View of Gear Assembly
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The motor produces the most power at one half of the no load speed. The angular speed
of the turbine will not achieve the optimal motor speed, so the design incorporates gears to
increase the rotation speed of the motor from the turbine. Due to design constraints and
geometry we were limited in selection of a gear ratio. The calculation above shows that the
motor angular velocity will be 1.8 times the angular velocity of the turbine.
The Alpha prototype was unable to produce power, so data was not available for analysis.
The Beta prototype was designed and fabricated. Testing of the prototype will provide data that
will be used to calculate the actual rotational velocity of the motor shaft. Once this data is
collected the design may be changed to accommodate a different gearing ratio to optimize the
performance of the motor.
4.5 Component and Material Selection Process for Mass Production
A majority of the components in the design need to be manufactured using plastic
injection molding since their geometry is vital. The housings, turbine, and gears are to be
injection molded with ABS Plastic. This type of plastic is commonly used for similar purposes
and has a strength and resistance to deformation that makes it a good work piece.
The components of this design will not be under high loads and therefore failure is
unlikely. There is minimal need for a high strength material such as steel. The shaft, ball
bearings, motor, cover, and end adapters are all off-the-shelf items. These components were
selected primarily to fit the design. The motor was selected because it was predicted to provide
the most power with respect to the capabilities of the input. Manufacturing these materials
requires extensive resources that would require too large of an investment.
4.6 Fabrication Processes for Mass Production
The fabrication process begins by plastic injection molding the four housings, gear and
pinion along with acquiring the parts from vendors. The following steps illustrate how the parts
are used to manufacture the final product.
Step 1: Turbine Housing
Begin by inserting one ball bearing into the bore of the Injection Molding # 1. Secure the
bearing using a small amount of epoxy. Then secure the shaft within the inner rings in the same
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way. Then slide the turbine onto the shaft and correctly position it while securing it with epoxy.
Place Injection Molding #2 and fit the bearing within the hole and around the shaft. Epoxy the
end adapters onto the top and bottom surfaces of the Injection Molding #1.
Step 2: Motor Housing
Insert the cover and circuit board into the appropriate slots of the Injection Molding #3
and secure with epoxy. Secure the correct electronic connections between the circuit board and
motor. Slide the motor into the housing and secure it with epoxy. Finally, fix the motor
assembly onto the front side of the turbine assembly using epoxy.
Step 3: Gear Housing
Epoxy the gear onto the turbine shaft and the pinion onto the motor shaft making sure
they mesh appropriately. Complete the full assembly by epoxying the Injection Mold #4 onto the
turbine and motor housing.
4.7 Industrial Design
The faucet-powered generator is easy to use and can attach in line to the 3/8 NPT thread
specification. The size and geometry allows for it to be twisted into place with small risk of
being inhibited by a structure. The PSU design on the front makes it an interesting product that
is visually pleasing to a consumer. The product requires less than four inches from the inlet to
outlet making the design usable in tight areas. The cover and motor housing creates a waterproof
seal that keeps the electrical area dry and makes the product safe. The lightweight design also
reduces the likelihood of component failure or a falling object injuring a consumer.
The premise of a faucet-powered generator is environmentally conscious because it
provides electrical power without the direct impact of burning fossil fuels. This clean form of
energy utilizes injection molding. The process of plastic injected molding is efficient in that
there is low amount of waste product after manufacturing.
Environmental downfalls of the design are found in the end life of the product. Since the
product is made of different materials, it cannot be easily recycled and will most likely be
disposed of in a landfill. Also, the ABS plastic requires raw materials and fabrication processes
that are harmful to the environment.
4.8 Safety
Having a product evaluated by UL for safety can provide product integrity. The UL mark
is known around the world as the standard of approved safety products [8].
The generator design will be submitted online using the Request for Quote form found at
http://www.ul.com/global/eng/pages/corporate/contactus/rfq/. The next step is to accept the
quote and discuss the product and the steps to being approved with an UL engineer. Samples will
be sent to UL and evaluated to determine if the safety standards are met. The engineer will
inform us if the product passes inspection and a formal report will follow. If it does not pass
inspection, we will receive a letter and work to redesign the product to ensure safety standards
are met. [8]
Typically, a new product is evaluated against UL standards which have already been
created. UL does not have any standards for water powered generators; however, there are
several standards which could be applicable. A list of these can be found in Appendix G.
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Because none of these stands are specific to water powered generators for the home, UL may
take this opportunity to create a new standard. [8]
Testing
5.1 Test Procedure and Plan
Testing was done with the Alpha prototype on April 8
th
. The
prototype failed to produce power and called for a complete redesign. The
redesigned product is the Beta prototype and will be tested April 29
th
. The
Beta prototype and the mass production unit have the same general design.
Testing will reveal how much power is generated in the mass production
unit and determine how many LED lights can be incorporated into the
circuit board.
Beta Prototype Testing
Purpose
Test Beta prototype to confirm mass production design
Confirm design is waterproof and produces sufficient power
Level of Approximation
Correct material, motor, bearings, gears, and water flow
Experiment Plan
Build mass production unit without parts 6, 7, 10, and 11 (see BOM)
Attach part 12 to faucet
Attach motor to multimeter
Set multimeter to measure volts
Turn on Maximum water flow
Measure and record voltage
Schedule
April 27 - Deadline for assembly of test Beta Prototype
April 29 - Testing completed
April 29 - Analysis Completed
Conclusion
The Beta prototype is a complete redesign of the Alpha prototype. The Beta prototype
should experience less energy loss and therefore be more efficient. Testing will determine how
many LED lights can be powered. This product is different from others on the market because it
can be customized. The panel which reads PSU as well as the color of the translucent plastic
behind the panel can be changed.
Testing
Equipment
Beta Prototype
Hose
Bucket
10 Ohm Resistor
Multimeter
Figure 15: Testing Equipment
Figure 16: Testing Procedure
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Appendix H: References
[1] Guide to Scalding Hot Water Temperatures, Laws, Regulations, Anti-Scald Equipment.
InspectAPedia. n.p. n.d. Web. 6 March 2014.
[2] Google. Patents. Web. 6 Feb. 2014. https://www.google.com/?tbm=pts
[3] Ecofriend. Eco Gadgets: Mini Hydro Turbine. 17 March 2009. Web. 20 Feb. 2014
http://www.ecofriend.com/eco-gadgets-mini-hydro-turbine-a-long-shower-for-a-
recharged-cellphone-battery.html
[4] McMaster-Carr. Single-Event Digital Timer. Web. 25 Feb. 2014
http://www.mcmaster.com/#alarm-timers/=qz9kyd
[5] Jameco. LEB Bi Color Green/Red 565nm/697nm 3-pin. Web. 25 Feb. 2014.
http://www.jameco.com/webapp/wcs/stores/servlet/Product_10001_10001_34673_-1
[6] Jameco. Single Pole Speaker Round Ferrite. Web. 25 Feb. 2014.
http://www.jameco.com/webapp/wcs/stores/servlet/Product_10001_10001_2081254_-1
[7] McMaster-Carr. McMaster-Carr Fastening and Joining. Web 1 March 2014.
http://www.mcmaster.com/#
[8] UL. Standards. Web. 2014.
http://www.ul.com/global/eng/pages/?utm_source=google&utm_medium=cpc&utm_ter
m=ul%20laboratory&utm_campaign=UL+Corp+-+Brand+-+Broad+-
+G&mkwid=sm7ilwG5U&pcrid=15225311913&kw=ul%20laboratory&placement=&pm
t=b&gclid=CL-nr_S29L0CFaN9OgodT20AGQ
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