Report Design ( human generater device)

8/14/2019 Report Design ( human generater device)

1/39

KJM 553 MECHANICAL ENGINEERING DESIGN I

INTRODUCTI

ON

1


2/39


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 dynamoat 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 fingerand second fingermutually atright 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
http://wiki/Thumbhttp://wiki/First_fingerhttp://wiki/Second_fingerhttp://wiki/Second_fingerhttp://wiki/Right_angleshttp://wiki/Right_angleshttp://wiki/First_fingerhttp://wiki/Second_fingerhttp://wiki/Right_angleshttp://wiki/Thumb


3/39


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.

3


4/39


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 well-

written 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

4


5/39


COLLECTION

INFO

RMATION

5


6/39


2.0 COLLECTING INFORMATION

2.1Identify 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.

6


7/39


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 tothe 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

7


8/39


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


9/39


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


10/39


Application

Green energy - a sustainable solution thats 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 youll 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

10


11/39


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

11


12/39


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 lets 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.

12


13/39


CONCEPTUAL

DESIGN

3.0 CONCEPT GENERATION

13


14/39


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 alteringthat 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

14


15/39


3.2 Morphological chart

Morphological chart

Design

Criteria1 2 3 4 5

Casing

Load

Connection

15


16/39


Transmit

Material

Steel

Wood

Magnet/solenoid

Stainless steel

Magnet/solenoid

Stainless steel

Plastic part

Magnet/solenoid

Stainless steel

Plastic part

Magnet/solenoid

Stainless steel

Plastic part

Magnet/solenoit

Table 2.0 : Morphological chart

16


17/39


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

Less energy since use body to move

the chair

Disadvantages High cost

complicated

high tolerance

big and weight

17


18/39


Table: Specifications of major machine parts

No. Name of component Major dimensions (mm) Material

18


19/39


1 Piston

2 Connecting rod

3 Flywheel shaft Length = 740, max.

diam = 72

SAE 1030 mild steel

4 Flywheel Outer diam=1000, rim

Width=1000, no. of

arms=6

Hub diam=100,

wgt=50kg

Cast iron

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 thisdesign as the following:

19


20/39



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

Disadvantages Required continuous force/motion of

rotating wheels to progress the magnetic

plate.

Low production rate

20


21/39


Design 3

Future:

21


22/39


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.


Function

Generate small amout of electricity

Only for small voltage mentol

Part Used plastic

Gear

Pedal

Small magnet

Coil

Material Stainless steel

Plastic part

Cover with rubber

Advantages Low cost

Portable

Available according to weight

Easy to use

Required small force

High production

Disadvantages Small amount of electricity

Suitable for small voltage mentol

Can not store energy

22


23/39


Design 4

23


24/39


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.


Function Transmitted motion/force between two gear togenerate power

Generate high voltage current

Restore some energy

Part Simple gear motion

Pedal Chain

Seat

Material Steel

Advantages Low cost

Variety in load are used

Portable and lightDisadvantages Required large space

Noisy operation

Low safety method

24


25/39


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.


Function Using rotational motion as the way

to produce energy.

Rotated shaft drive the magnet to

cut the magnetic field around the

25


26/39


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 Too much human power require.

We cant do others thing at the same

time.

big and weight

26


27/39


27


28/39


Components of the concept.

28


29/39


29

1.a ) (S

SHAPE) ROD

Copper rod Stainless steel Mild steel Carbon fiber.

b) shape

2.a) type of

bearing.

Tapered roller bearing Ducati sprag bearing Muff Bearing Four_Point_Contact_B

all_Bearing

max Torque Tmax=2.5xTkn

3.a) copper

disc.

4.a) gear Trans Spur gear 36T Opt gear-worm Vertical axis gear

b)shape


30/39


Table: Specifications of major machine parts

No. Name of component Major dimensions (mm) Material

1 S shape bar. SAE 1030 mild steel

2 Bearing.

3 Magnetic gear. Outer diam=500, rim

Width=400, no. of

part=1

Hub diam=10, wgt=5kg

Magnet

4 Copper disk. Outer diam=600, rim

Width=300, no.part=1

Hub diam=10, wgt=3kg

Copper

5 Connecting rod Length= 600, dia=50 SAE 1030 mild steel

6 Magnetic bar. Length= 350, width= Magnet

7 Socket. Length = 740, max.

diam = 72

Copper

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 Sshape 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.

30


31/39


31


32/39


EVALUATATION

OF

C

ONCEPT

32


33/39


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


34/39


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 partssimplicity of design

Ease of operation (accessibility, emergency response)

Ease of integration into the automobile subsystems

Lightweight

34


35/39


4.2.1 Evaluation Pughs concept 1

* s = the concept is similar to the datum

35

Bil Weight Criteria Design

1

Design

2

Design

3

Design

4

Design

5

Datum

1 7 Ease of achieving + - + - s

2 8 Resistance to corrosion

(water, pollutants)

s s s + +

3 9 Resistance to vibration,

shock, acceleration/

deceleration, wear & tear

s + + + +

4 7 Resistance to temperature

cycling & extremes

+ - + s -

5 10 Low power consumption + + s s s

6 6 Small size + s + + -

7 8 Long service life s - - + s

8 7 Low manufacturing cost - + s s +

9 8 Ease of installation - + - + s

10 7 Long shelf life s + + s +

11 5 Quick response time - s - - -

12 6 Small number of parts-

simplicity of design

+ + s - s

13 8 Ease of operation

(accessibility, emergency

response)

+ s s + +

14 5 Low weight s - + - +

Total better than datum (+) 44 48 41 46 44

Total worse than datum (-) 20 26 21 21 18

Overall total [ better(+) worse (-)] 24 22 20 25 26


36/39


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 its 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 Pughs concept analysis

above we summaries that design 5 is better than the other design. The weighted score for

design 5 is 26. its followed by design 4 and design 1 with score 25 and 24 respectively.

36


37/39

Pughs concept

Bil weight Design

1

Design

2

Design

3

Design

4

Design

5

Datum

1 Assembly

2 8 Easy to assemble - + + s +

3 8 Easy to disassemble - + + s +

4 6 Moderate assembly time s s + + -

5 4 Interesting to build - + s + s

6 7 Not too many parts - - s s -

7 Safety

8 7 Low pollution + + + + +

9 8 No sharp edges + s s s s10 Costs

11 6 Retails for less than thecompetition

+ - s s +

12 4 Low replacement parts

cost

s - - s -

13 Requirements

14 9 Portable - + + s s

15 6 Strong material + s - + -

16 7 Corrosion proof + - - - s

17 6 Lightweight - + + s +

18 5 Visually appealing + + + s +

Total positive (+) 6 7 7 4 6

Total negative (-) 6 4 3 1 4

Overall total [positive negative] 0 3 4 3 2

Weighted total -3 23 32 16 17


4.2.2 Evaluation Pughs concept 2

Discussion 2

37


38/39


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 Pughs 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:

38


39/39


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.

Date post:	30-May-2018
Category:	Documents
Upload:	dadin85
View:	213 times
Download:	0 times

Report Design ( human generater device)

Documents