Manufacturing Engineering
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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 9
15
2 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
8
9
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
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 9
15
2 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
8
9
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
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