Bader Dashti Bill Dunlap Chris Hansen. Mechanical Mechatronic Mechanical Ahmed Kamfar Alexander Kendrick

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1 Bader Dashti Bill Dunlap Chris Hansen Mechanical Mechatronic Mechanical Ahmed Kamfar Alexander Kendrick Mechanical Mechanical Sponsor: One Media Player per Teacher Faculty Advisor: Professor Gregory Kallio

2 75 million children do not have access to primary school 776 million adults lack basic literacy skills. One Media Player per Teacher (OMPT) Mini-projectors and digital audio devices

3 Projector issues with battery recharging Solar panels Existing hand crank generators Problems with existing models

4 To research, design, build and test a prototype of a multifunctional human powered generator that is more ergonomically efficient than currently available models.

5 Requirement Metric Method / Device Weigh no more than 14 lbs lb Scale Max size 2 wide x 1.5 tall x 3 long feet Measuring tape Fully charge a 3.7 V, 1700 mahlithium-ion battery in 2 hours Protect batteries from over voltage and over current Integrate small solar panel Indicator that battery is fully charged Be capableof connecting to different sized batteries Portable easy to transport by single individual Have an onboard battery Easy to operate Voltage/ Current Multimeter

6 Requirement Metric Method / Device Inexpensive around $70 U.S. Dollars Total price of unit Protect from weather durability Stress tests Water resistant seal Depth test Dust resistant seal Sun resistant UV resistance Material Analysis Primarily plastic construction

7 Requirement Metric Method / Device Durable last at least 5 years durability Stress tests Onboard storage of battery that is being charged Readily Available Parts for Field Repair

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10 Voltage Current Power 12V 125 mah Max 1.5 W Dimensions x 4.75 x.5 Weight 1.6 lb

11 Rated Rotating Speed : 2800 rev/min Total Gear Ratio of 28:1 Outer gear at 1.66 rev/sec Rated Current : 1000mA Generates 3-phase AC output Rectified DC Output: Lifetime: 18.2V DC 3000h

12 Made of mAh cylindrical cells with PCB and polyswitch for full protection Built-in IC chip will prevent battery pack from over charge and over discharge Capacity: 2200mAh Voltage: 7.4V Dimensions: 2.63 x 1.45 x 0.7 inch Weight: 3.5 oz Max. Charge Current: 1C (2.0A) Max. Discharge Current: 2.5C (5A) Cut off voltage: 6V Manufacturer's Part Number: 31003

13 Frame-Addition of an aluminum frame Case-Redesigned as a thin plastic case Pedal-Plastic surface with aluminum struts Flywheel- Custom aluminum casting Driveshaft-Formed using a steel rod

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17 Flywheel Drive Shaft

18 Analysis of drive shaft with 4x rated loading of generator. Even under extreme circumstances, the shaft experiences stress well below it s yield point.

19 Case side with load incident on drive shaft mount section. Load is 2 x the maximum human loading on the device

20 Bridge Rectifier Circuit V + Dynamo V A D D D Diodes: 1N4001 Capacitors: 10 uf V B V C C Resistor 1: 82k Ohm Resistor 2 : 56k Ohm D D D Voltage Regulator: 7805 V - USB Port Circuit V + Regulator 5V R1 R1 Internal V - C C R2 R2 USB Port Vcc D1 D2 Gnd Data Lines at 2 V

21 Battery Voltage Reduction Circuit Adjustable Voltage Regulator V + LM V V + Capacitors: 10 uf 240 Ohm C C LM 317 Regulator Formula: V Ohm V ( /240) Volts = 8.4 Volts V + Charging Source V - Battery Charging Indicator Circuit 1M Ohm k Ohm 10k Ohm 1 Ohm 8 4 V + Battery 1k Ohm LM 393A D2 V - 1 LED LM 393: Voltage Comparator 1N5819

22 Solar Panel V + V - V + LM 317 Regulator 5V V + Dynamo V A V B V C D D D C 240 Ohm 1370 Ohm1 C C R1 R2 R1 R2 USB Port D D D Data Lines at 2 V V - Internal Vcc D1 D2 Gnd V + 1M Ohm LM k Ohm 2.2k Ohm 10k Ohm LED 7.4 V Battery V - Diodes: 1N4001 Capacitors: 10 uf 1 Ohm Resistor 1: 82k Ohm 1N5819 Resistor 2 : 56k Ohm Voltage Regulator: 7805

23 Multimeter attached to leads from projector battery. Monitors voltage at ten minute intervals over the course of the charge cycle.

24 Part Fasteners (Screws, Nuts Bolts, Washers) Projected Cost $33.20 Table 9.3- Funding Sources Source Amount One Media Player per Teacher $1, Electrical Components $24.61 Solar Panels $16.08 Plastic Components $31.95 Batteries $21.95 Mechanical Components $ Misc. $65.97 Associated Students Sustainability Fund $3, Total Funding for Project $5, Total Cost (per prototype) $305.27

25 Table 9.2 Hours Name Total Hours Total Cost Per Person Bill $14, Chris $13, Bader $11, Ahmed $12, Alex 111 $12, Total Cost $64,534.95

26 Problems include The weight requirement of the project. Alignment of the dynamo to the flywheel Material selection Recommendations Single frame PCB Larger onboard battery Custom solar panel

27 The current design prototype fulfills most of the requested specifications given by the sponsor, One Media Player per Teacher. With this in mind, our sponsor can proceed with implementation of the generator in the field where it is most needed.

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