Report Design ( Human Generater Device)

KJM 553 MECHANICAL ENGINEERING DESIGN I

INTRODUCTI ON

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KJM 553 MECHANICAL ENGINEERING DESIGN I

1.0 INTRODUCTION 1.1 Background Electricity is the main source of energy. The alternative way to produce it is through the mechanical system. For instance, the motion of the water flowing through the river in the dam that link to the turbine to generate the current to produce the electricity. Since our world today lack of the energy sources, we should have to find the alternative way or another solution to produce it. In this project, we are required to produce the electricity by using the Fleming Hand Rules concept through a magnetic field. As a concept of dynamo at the bicycle, these magnets will connect to the wire to supply the electricity. The rotating magnet will create the magnetic field that cut by the solenoids. The rotating magnet will generate the current supply to the solenoids .In this project, there are constraints required such as portable, suitable sizes to be carrying out, easy to use and reasonable range of price. •

How to produce electric by using basic Flemming Hand Rules (either right or left).

The right hand is held with the thumb, first finger and second finger mutually at right angles, as shown in the diagram . •

The Thumb represents the direction of Motion of the conductor.

•

The First finger represents the direction of the Field.

•

The Second finger represents the direction of the induced or generated Current (in the classical direction, from positive to negative). 2

KJM 553 MECHANICAL ENGINEERING DESIGN I

1.2 Project Title: Human powered generator. 1.3 Problem Scenario Electricity is possible to produce by undrestanding basic Fleming Hand Rules (either left or right). Fleming hand rules are the principle for generators. By consindering the human power (i.e mechanical movement) it able to generate electricity that can be use for home lighting. Constraint: •

Portable

•

Suitable size to be carry out

•

Easy to use

•

Reasonable range of price

1.4 Objective: The main objective of our project is to make a simple device by consudering the human power (i.e. mechanical movement) it able to generate electricity that can be use for home lighting. •

Designing mechanism device that use human power such as hand or foots to generate electricity.

•

Using basic Fleming Hand Rules (either left or right) to produce electricity.

After completed of this course, students should be able to explain basic concepts of mechanical engineering design process, design machine elements, and systems. Besides taht, student also can apply acquired knowledge to design and analysis of mechanical elements for specific small engineering design project. For example in gear,bolt and welding.

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KJM 553 MECHANICAL ENGINEERING DESIGN I

1.5 Product Design Specification The Product Design Specification (P.D.S) is a comprehensive document which establishes guidelines to be followed through the rest of teh design and manufacturing processes. In this document, customer needs are distinguished froms and prioritized to form a baiss for evaluating design ideas. The P.D.S must guide the design process without over-constraining it. Though it is sunjected to minor adjustments, a wellwritten and robust P.D.S will successfully capture the design intent and lead to the creation of a succcesful product. 1.6 Quality and Realibility •

Quality for Mechanism Device for Generate Electricity should not generally fail with a period of five years and only 1 in 50 should fail within the first year.

•

Manual Operated Mechanism Device for Generate Electricity should success in the factor of produce an amount electricity.

1.7 Scope of the project: In order to determine whether mechanism device for generate electricity by human powered bound the concept of Flemming Hand Rules, this report takes into consideration the following factor: •

The report was only carried out in 4 mechanism device by using human power especially using hand or foot

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KJM 553 MECHANICAL ENGINEERING DESIGN I

COLLECTION INFO RMATION

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KJM 553 MECHANICAL ENGINEERING DESIGN I

2.0 COLLECTING INFORMATION 2.1 Identify the need.

A design task may emerge as a perceived need for an existing product. Conversely the task may be totally innovative and with greater visual requirements. Design is costly and time consuming. As a new product, is conceived or and existing one improved, the primary objectives to present a commodity that will meet a need or render a service in a manner superior to that of any former or similar product.

2.2 Method of Investigation. The information of this report has been obtained from internet source on the mechanism device which use human power to generate electricity. Beside that, we also ask for Dato Prof Ir Dr Ow Chee Seng how to produce electric by using mechanism device.

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KJM 553 MECHANICAL ENGINEERING DESIGN I

2.3 Device in marketing 2.3.1 Human Power Generator

Figure 1 : Human Power Generator Use pedal power to generate electricity. The Human Power Generator is user friendly, portable and available when have the need for it. The power output is directly proportional to the effort put into it. The Human Power Generator can be a valuable tool in teaching an appreciation of the physical energy required to produce the electricity we tend to take for granted. Features: The Human Power Generator is primarily designed: To charge a 12Volt, deep cycle battery or to contribute to a 12Volt system. Can also provide DC direct power. AC appliances can be used with the Human Power Generator by using a DC-AC inverter connected to a battery for stability

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KJM 553 MECHANICAL ENGINEERING DESIGN I

Figure 2 : Component in the Human Power Generator Specifications: The Human Power Generator consists of a heavy, powdercoated steel frame holding a bicycle-like crank, with a step-up chain drive Applications: •

Emergency power generation and battery charging.

•

Exercise systems that do useful work generating power while exercising.

•

Measurement of human power and endurance.

•

Remote or off-grid power for 12-volt water pumps and small appliances.

•

Independent radio or radiotelephone systems; emergency communications.

•

Classroom projects and educational exhibits to demonstrate the physical effort required to generate electrical power.

2.3.2 Sherpaxray-blue-small 8

KJM 553 MECHANICAL ENGINEERING DESIGN I

Figure 3 : Sperpaxray-blue-small

The Free play self-charge system is built around a custom designed, highly efficient alternator. The architecture of this patented system has been developed to maximize the ability of the user to convert human mechanical energy into stored electricity quickly and efficiently. While the basis of Freeplay's superiority lies in the performance of this system, Freeplay has extended the engineering excellence to every aspect of the Sherpa LED. The winder handle is made from tough glass reinforced Nylon and is designed, along with the grip of the flashlight, for comfort and ease of use. Features: The transmission (gear train) is constructed to high manufacturing tolerances from glass reinforced Nylon and Acetyl – dissimilar engineering plastics that dramatically increase the life of the gear train. The transmission has undergone accelerated lifetime testing in excess of 500 000 cycles. Under self-charge conditions the batteries receive a conditioning charge that negates the memory effect common to rechargeable batteries and similarly increases their useful life. Accelerated lifetime tests on the batteries in the Freeplay self-charge system have reflected no significant capacity loss after 10 000 crank charge cycles. The light source is a cluster of 7 ultra bright white 5 mm LED's. These offer bright white light but with significantly higher efficiency and lifetime than incandescent lamps, and are rated at up to 100 000 hours. 9

KJM 553 MECHANICAL ENGINEERING DESIGN I

Application •

Green energy - a sustainable solution that’s built to last. The power mechanism is tested to 500 000 input cycles, and the LEDs are rated up to 100 000 hours or 11 years of continuous use (24 hours a day).

•

The Xray LED offers a real alternative to grid electricity or fossil fuels, so the more you use your flashlight, the fewer batteries you’ll be throwing away.

•

When your batteries run out and you need to wind for power, the Freeplay self-charge mechanism converts over 74% of your kinetic energy into stored electricity.

•

Compact and rugged, it will fit into your drawer, your glove box, toolkit or backpack.

•

A constant brightness means dependable beam quality that does not fade away as the batteries get flatter.

•

The plastic molding and rubberized lens enclosure and body panels make it easy to carry and use when it is cold.

•

A great lighting solution to teach your kids about the value of green energy – and show them how their own energy can provide them with all of their lighting needs.

•

Lasts virtually forever.

2.3.3 Recumbent

Generator

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KJM 553 MECHANICAL ENGINEERING DESIGN I

Figure4: Recumbent Generator

The recumbent generator is a devise that used to generate power by mean of human power. The device is generating electric power by pedaling as it transmission sources. It does can produce the 3 phase electricity power which can used to supply power for 1 house. Features: •

Includes 2 pedals that cycle by a human to generate power.

•

Able to generate high voltage power.

•

The modified solenoid is useful to generate high voltage current by little power used.

•

It really helpful device for generating free electricity sources while encourage people to do some exercise.

Specifications: •

Adjustable and easy to used.

•

Low energy used to generate high voltage current.

•

Installation – 16 pole 3phase solenoid as it power sources, pedal mounted as load to transmit human power trough chain.

2.3.4 DIY car jumper

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KJM 553 MECHANICAL ENGINEERING DESIGN I

Figure 5: DIY car jumper The DIY car jumper is a foot powered generator with an internal 12-volt battery that with the right cabling can then be used to power emergency lighting, recharge electronics or even jump start a car. However, nowhere does it state exactly how much pumping is needed to charge the battery, but let’s hope when you are done there is enough energy to run the defibrillator you will need. Features: •

Using a foot step as human powered sources to generate electric power.

•

Able to generate high voltage power.

•

There are cables provided to supply the power generated from the source to the load.

•

It really helpful device for generating free electricity sources when no electricity.

Specifications: •

Adjustable and easy to used.

•

Low energy used to generate high voltage current.

•

Compact size and easy to bring any where.

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KJM 553 MECHANICAL ENGINEERING DESIGN I

CONCEPTUAL DESIGN

3.0 CONCEPT GENERATION 13

KJM 553 MECHANICAL ENGINEERING DESIGN I

All of us have to create any own two ideas or concepts of the mechanism device to generate electricity at the firts stage in order to do a project for Mechannical Engineering Design (KJM 553). The main requirements of the concept are manually operated and operate by one person only. Then we formed a group ang have discussed to complete our project that mechanical device to generate electricity using human power which the project by our lecture. We combined all of our ideas together before we selected of the best five ideas. After that, we ahve decided a final idea from the best five for our project. The main purpose of the mechanism device is to generate electricity base on the concept Fleming Hand Rules. After we decided the final concept, we have studied on the selected concept. Many altering that we ahvee been doing on teh concept.

3.1 Generate idea •

The ideas are generated by base on the title of the project about Mechanism device for generate electric using basic concept of Fleming Hand Rules. In addition the product also can be use for normal people too.

•

From by identify what customer need by survey, we are try to concentrated the main point of the design using magnetic and coil.

•

In fact we produce 5 and more ideas are relevant and have the constraints the mechanism device for produce electricity

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KJM 553 MECHANICAL ENGINEERING DESIGN I

3.2 Morphological chart Morphological chart Design 1

2

3

Criteria

Casing

Load

Connection

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4

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KJM 553 MECHANICAL ENGINEERING DESIGN I

Transmit

Material

• • •

Steel Wood Magnet/solenoid

• •

Stainless steel Magnet/solenoid

• • •

Stainless steel Plastic part Magnet/solenoid

Table 2.0 : Morphological chart

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• • •

Stainless steel Plastic part Magnet/solenoid

• • •

Stainless steel Plastic part Magnet/solenoit

KJM 553 MECHANICAL ENGINEERING DESIGN I

Design 1 Features: Based on principle for generator (Fleming hand rules) to produce electric, we need rotation mechanism to rotate whether magnet or coil. Therefore we design a slider-crank as a mechanism to rotate the magnet. Criteria

Specification •

Function

•

Transmitted motion from linear to rotational. Rotated shaft drive the magnet

Part

• • • • •

Chair (kerusi malas) Piston Connecting rod Crank shaft

Material

• • •

Wood aluminum SAE 1030 mild steel

Advantages

•

Seat and simultaneously generate electric

Disadvantages

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•

Less energy since use body to move

•

the chair High cost

•

complicated

•

high tolerance

•

big and weight

KJM 553 MECHANICAL ENGINEERING DESIGN I

Table: Specifications of major machine parts No.

Name of component

Major dimensions (mm) 18

Material

KJM 553 MECHANICAL ENGINEERING DESIGN I

1

Piston

2

Connecting rod

3

Flywheel shaft

Length = 740, max.

SAE 1030 mild steel

diam = 72 4

Flywheel

Outer diam=1000, rim

Cast iron

Width=1000, no. of arms=6 Hub diam=100, wgt=50kg

Manufacturing Process The complete process of manufacturing this machine has three stages: (1) manufacture of chair, and (2) connection of slider-crank to chair and shaft, and (3) generator to produce electric.

Design 2 Fiture: This design used the flywheel to generate the motion of the magnetic plate. The criteria in this design as the following: 19

KJM 553 MECHANICAL ENGINEERING DESIGN I

Criteria

Specification

Function

•

Transmitted motion/force between two gear by using belt.

Part

• • • • • •

Gear Timing Belt Solenoids Metal magnet plate (cylindrical shape) Metal plate (cylindrical shape) to locate he solenoids Wheel

Material

•

Steel (for Metal plate (cylindrical shape))

Advantages

•

Low cost

•

Variety in load

•

Portable and light

• •

Safe Required continuous force/motion of

Disadvantages

rotating wheels to progress the magnetic plate. •

Low production rate

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KJM 553 MECHANICAL ENGINEERING DESIGN I

Design 3 Future: 21

KJM 553 MECHANICAL ENGINEERING DESIGN I

In our third idea, the design is more smaller than other design. This mechanism device use a small force to generate electricity but it siutable for a small voltage mentol exact arm and shoulder motions needed for easy propulsion and provides hand exercise which is essential to a healthy lifestyle and any training program. Criteria

Specification

Function

Part

Material

Advantages

Disadvantages

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• •

Generate small amout of electricity Only for small voltage mentol

•

Used plastic

•

Gear

•

Pedal

•

Small magnet

•

Coil

•

Stainless steel

•

Plastic part

•

Cover with rubber

•

Low cost

•

Portable

•

Available according to weight

•

Easy to use

•

Required small force

•

High production

•

Small amount of electricity

•

Suitable for small voltage mentol

•

Can not store energy

KJM 553 MECHANICAL ENGINEERING DESIGN I

Design 4 23

KJM 553 MECHANICAL ENGINEERING DESIGN I

Future: In our first idea, the design is basically similar to the common one in the market. The recumbent generator with high voltage current sources provided. This kind of device can give high voltage current with less energy use.

Criteria Function

Specification • • • • • • •

Transmitted motion/force between two gear to generate power Generate high voltage current Restore some energy Simple gear motion Pedal Chain Seat

Material

•

Steel

Advantages

•

Low cost

•

Variety in load are used

• •

Portable and light Required large space

•

Noisy operation

•

Low safety method

Part

Disadvantages

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KJM 553 MECHANICAL ENGINEERING DESIGN I

Design 5 Features: Based on principle for generator (Fleming hand rules) to produce electric, we need rotation mechanism to rotate whether magnet or coil. Therefore we design a slider-crank as a mechanism to rotate the magnet. Criteria

Specification •

Function

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Using rotational motion as the way to produce energy. Rotated shaft drive the magnet to cut the magnetic field around the

KJM 553 MECHANICAL ENGINEERING DESIGN I

outside pole Part

• • • • • • • • •

S shape bar. Connecting rod. Copper disk. Magnetic bar. Magnetic gear. Wire (pole). Battery. Bearing. Socket.

Material

• • • • • •

Copper. Aluminum. Handle wood. Magnet. Insulator (rubber). SAE 1030 mild steel

Advantages

•

Cycling and simultaneously generate electric Easy to operating since free hand movement. Less space require to make it work.

• • • •

Disadvantages

•

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Too much human power require. We can’t do others thing at the same time. big and weight

KJM 553 MECHANICAL ENGINEERING DESIGN I

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KJM 553 MECHANICAL ENGINEERING DESIGN I

Components of the concept.

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1.a ) (S SHAPE) ROD

Copper rod

Stainless steel

Mild steel

Carbon fiber.

b) shape KJM 553 MECHANICAL ENGINEERING DESIGN I

2.a) type of Tapered roller bearing bearing.

Ducati sprag bearing

Muff Bearing

Four_Point_Contact_B all_Bearing

max Torque Tmax=2.5xTkn

3.a) copper disc.

4.a) gear b)shape

Trans Spur gear 36T Opt

gear-worm

Vertical axis gear 29

KJM 553 MECHANICAL ENGINEERING DESIGN I

Table: Specifications of major machine parts No.

Name of component

1

S shape bar.

2

Bearing.

3

Magnetic gear.

Major dimensions (mm)

Material SAE 1030 mild steel

Outer diam=500, rim

Magnet

Width=400, no. of part=1 Hub diam=10, wgt=5kg 4

Copper disk.

Outer diam=600, rim

Copper

Width=300, no.part=1 Hub diam=10, wgt=3kg 5

Connecting rod

Length= 600, dia=50

SAE 1030 mild steel

6

Magnetic bar.

Length= 350, width=

Magnet

7

Socket.

Length = 740, max.

Copper

diam = 72 8

Pole wire.

About=20000.

Copper

9

Chasing

Mild steel/ stainless steel

10

Copper brush

Copper.

Manufacturing Process The complete process of manufacturing this machine has three stages: (1) manufacture of S shape bar, magnetic gear, copper disk, wire pole and chasing. For the stage (2) connection of all component each other as well as drafting picture. Lastly is the stage number (3) is, an negative charges will produce an electric power and supplied to menthols and battery.

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KJM 553 MECHANICAL ENGINEERING DESIGN I

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KJM 553 MECHANICAL ENGINEERING DESIGN I

EVALUATATION OF C ONCEPT 32

KJM 553 MECHANICAL ENGINEERING DESIGN I

4.0 EVALUATION OF CONCEPT 4.1 Selection Design To design is either to formulate a plan for the satisfaction of a specified need or to solve a problem. The result in the creation of our product having a physical reality, then the product must be functional, safe, reliable, competitive, usable, manufacturability and marketable. These are define as follows: •

Functional: The product

perform to fill its intended need and customer

expectation. •

Safe: The product is not hazardous to the user, bystander, or surrounding property.

•

Reliable: Reliability is the conditional probability at a given confidence level, that the product will perform its intended function satisfactorily or without failure at a given age.

•

Competitive: The product is a contender in its market.

•

Usable: The product is a “user friendly”, accommodating to human size, strength, posture, reach, force, power and control. 33

•

KJM 553 MECHANICAL ENGINEERING DESIGN I

Manufacturability: The product has been reduced to a “minimum”

number of parts,

suited to mass production, with dimension, distortion and strength under control. •

Marketable: The product can be bought and service (repair) is available.

4.2 Criteria Original List of Criteria •

Resistance to corrosion (water, pollutants)

•

Resistance to vibration, shock, acceleration/deceleration, wear-and-tear

•

Resistance to temperature cycling and extremes

•

Low power consumption

•

Ease of maintenance

•

Small size

•

Long service life

•

Low manufacturing cost

•

Ease of installation

•

Long shelf life

•

Quick response time

•

Small number of parts—simplicity of design

•

Ease of operation (accessibility, emergency response)

•

Ease of integration into the automobile subsystems

•

Lightweight

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KJM 553 MECHANICAL ENGINEERING DESIGN I

4.2.1 Evaluation Pugh’s concept 1 Bil Weight

Criteria

Design Design Design Design Design Datum

7 8

Ease of achieving Resistance to corrosion

1 + s

2 s

3 + s

4 +

5 s +

9

(water, pollutants) Resistance to vibration,

s

+

+

+

+

7

deceleration, wear & tear Resistance to temperature +

-

+

s

-

5 6 7 8 9 10 11 12

10 6 8 7 8 7 5 6

cycling & extremes Low power consumption Small size Long service life Low manufacturing cost Ease of installation Long shelf life Quick response time Small number of parts-

+ + s s +

+ s + + + s +

s + s + s

s + + s + s -

s s + s + s

13

8

simplicity of design Ease of operation

+

s

s

+

+

s

-

+

-

+

44 20 24

48 26 22

41 21 20

46 21 25

44 18 26

1 2 3

shock, acceleration/ 4

(accessibility, emergency 14

5

response) Low weight

Total – better than datum (+) Total – worse than datum (-) Overall total [ better(+) – worse (-)] * s = the concept is similar to the datum

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KJM 553 MECHANICAL ENGINEERING DESIGN I

Discussion 1 From each completed design, we can take a look at the result to judge the validity of the criteria. For example, we notice that not one of the new concepts was resistance to temperature changes; none was able to achieve smaller size or longer shelf life. These sample criterions are importance for consumer requirement. A consensus may emerge about which criteria are the most important and should be given more weight than other. For example, low power consumption, resistance to vibration, shock, acceleration/ deceleration, wear & tear, resistance to corrosion ,long service life, ease of installation and ease of operation are the most important criteria so that it be given the higher weight. The other criteria are also important but it’s be given lower weight due to its function. Than, the total scores for each design are obtained. The positives and negatives are added separately since positives cannot cancel out negatives. The overall total score are obtained by minus the total positives score and negatives score. From the result of Pugh’s concept analysis above we summaries that design 5 is better than the other design. The weighted score for design 5 is 26. it’s followed by design 4 and design 1 with score 25 and 24 respectively.

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KJM 553 MECHANICAL ENGINEERING DESIGN I

4.2.2 Evaluation Pugh’s concept 2 Pugh’s concept

Bil

weight

1 2 3 4 5 6 7 8 9 10 11

Assembly 8 Easy to assemble 8 Easy to disassemble 6 Moderate assembly time 4 Interesting to build 7 Not too many parts Safety 7 Low pollution 8 No sharp edges Costs 6 Retails for less than the competition 12 4 Low replacement parts cost 13 Requirements 14 9 Portable 15 6 Strong material 16 7 Corrosion proof 17 6 Lightweight 18 5 Visually appealing Total – positive (+) Total – negative (-) Overall total [positive – negative] Weighted total

Design 1

Design 2

Design 3

Design 4

Design 5

s -

+ + s + -

+ + + s s

s s + + s

+ + s -

+ +

+ s

+ s

+ s

+ s

+

-

s

s

+

s

-

-

s

-

+ + + 6 6 0 -3

+ s + + 7 4 3 23

+ + + 7 3 4 32

s + s s 4 1 3 16

s s + + 6 4 2 17

Discussion 2 37

Datum

KJM 553 MECHANICAL ENGINEERING DESIGN I

From each design, we can take a look at the result to judge the validity of the criteria. These criterions are importance for consumer requirement. Now we consider 4 major criteria that are assembly, safety, costs and requirements. For assembly, we consider on how ease the design to be assembles, disassemble and number of part to be installed. The safety factor is the most important aspect in designing product. As a result to reduce the injuries during the exercises, these two criteria are give high weighted. The cost of the product is also an important thing that affects that design. Although the cost of the product is high but as a designer we have to minimize the cost of part compare to other competitors. After calculate the entire positive and negative score and multiply it with the weight, the design that gets the highest score is design 3 and followed by design 2.

Conclusion From both two Pugh’s concepts before, we can conclude that the design 3 is the most chosen once. The total score for design 3 is 52, followed by design 2 and design 5 with score 45 and 43 respectively. Design 3 is almost followed all the criteria that customer need. The criteria that involved in design 3 are lightweight. Ease to install and remove, high safety factor and portable. These factors are important because the customer normally will choose a product that comfortable and suit with them. For the exercise equipment, the safety factors are the most important thing since it can avoid user from injured during exercise

REFERENCES:

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KJM 553 MECHANICAL ENGINEERING DESIGN I

A. Search by Internet: 1. http://en.wikipedia.org/w/index.php?title=Right_hand_rule&redirect=no 2. http://science.howstuffworks.com/generators.htm 3. http://www.windstreampower.com/Human_Power_Generator_Series.php 4. http://en.wikipedia.org/wiki/Ergonomics.

B. Search by Journal: 1. J.T.Pattiwar & J. P. Modak, “Design, Development & Analysis of Torsionally Flexible Clutch for Onload Starting of Human Powered Process Machine”, Accepted for publication in HUMAN POWER, Journal of International Human Powered Vehicle Association (IHEVA), USA.

2. S.D.Moghe & J. P. Modak, “Formulation of Generalized Experimental Model for Determination of Optimum Cranking Arrangement for the Cycle Rickshaw”, Accepted for publication in HUMAN POWER, Journal of International Human Powered Vehicle Association (IHEVA), USA.

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