College CMET (Civil and Mechanical Engineering Technology) group class project. Incorporates mechanical design and thermodynamics into a real world application.

1. Hydro Generator Project
ΣForces
Andrew Bosak, Christopher Dahlen, Gus Hart, Philip Heuberger
CMET 222, 223, 235, 237
Spring 2018

2. Introduction
● The project our group chose for this
term consisted of a water turbine in
order to incorporate the requirements
of both Thermodynamics and
mechanical Design classes.
● This project will demonstrate three
dimensional movement and transfer
of energy from kinetic to mechanical.
Credit: hydrover.co.uk

3. Outline
● Introduction
● Executive Summary
● Sketches
○ Gus
○ Andrew
○ Chris
○ Final
● Concept Process
● CAD
● Prototypes
● Final Product
● Motion Analysis
● Force Analysis
● Thermodynamics Analysis
Credit: directindustry.com

4. Executive Sum(of forces)mary
Moving water has the potential to do work. We will use that principle to take running water and turn
an impeller, which in turn will run an electric motor through a set of gears to power an LED. Our source of
water will be a pressurized water hose connection.
credit: Mapio.netcredit: Watter Buddy

5. Sketch / Concept: Gus
● Pros
○ Covered the concepts required for machine
design and thermo
○ Construction challenge
○ Basic materials availability
● Cons
○ Too large for transportation
○ Variable flow rate water source

6. Sketch / Concept: Andrew
● Pros
○ Easy to build given laser-cut and 3D-
printed parts
○ Uses gravity-fed water input
● Cons
○ Water flow rate would be inconsistent
○ Uses gravity-fed water input

7. Sketch / Concept: Chris
● Pros
○ It satisfies the project guidelines given to us.
○ It turns mechanical energy into electrical
energy, which is cool.
○ The design could be very compact.
● Cons
○ Need to find or design a shredder

8. Sketch / Concept FINAL
● Simplified combination of all ideas
● Availability of mechanisms
● Availability of materials
● Simplicity

9. Sketch / Concept FINAL
Challenges
● Pelton Wheel
● Shaft design / fabrication
● Gears
● Consistent water source
● 3D Material quality
● Friction

10. Sketch / Concept FINAL
Challenges
● Pelton Wheel
● Shaft design / fabrication
● Gears
● Consistent water source
● 3D Material quality
● Friction

11. Concept - Gears
Credit: trinityscsp
Gearless Transmission
● Pros
○ Neat design
● Cons
○ Complicated movement
○ Difficult to align
○ Inefficient to 3D Print
○ Difficult to assemble

12. Credit: unknown
Pinwheel Gear Design
● Pros
○ Simple
○ Nostalgic
● Cons
○ Rough movement
○ Difficult to align
○ Inefficient to 3D Print
Concept - Gears

13. Bevel Gears
● Pros
○ Smooth
○ Easy to 3D Print
○ Consistent
○ Modern fit to our Design
● Cons
○ Difficult to design
Credit: “dea” GrabCAD
Concept - Gears

14. CAD
Used: Solidworks 2017
Hours: many hours
Resources used:
Mcmaster - hardware

15. CAD
CAD Design Challenges
● Bevel gear sizing

16. CAD
CAD Design Challenges
● Pelton wheel modeling
○ Runner - easy
○ Buckets - not so much

17. First Prototype
Added:
● Base and foundation
● Initial size of gears “slightly” too large
● Right angle coupler
● Horizontal shaft
● Cut threaded rods to size

18. Second Prototype
Added:
● Reduced gear size
● Adjusted right angle coupler size
● Motor with LED

19. Third Prototype
Added:
● Gear size
● Adjusted horizontal gear shaft size
to achieve 2:1 ratio
● A-Frame shaft support
● Removed DELL logo

20. Final Product
Added:
● Belt Retention Device (washer)
● Reprint/Replace long gear and
shaft

21. Final Product

22. Final Product Demonstration

23. Force Analysis

24. Force Analysis

25. Force Analysis

26. Force Analysis

27. Motion Analysis

28. Thermodynamics Background
In Chapter 2 of the textbook, we learned about mechanical energy. Our micro
hydro generator will capture the energy of water to generate electricity. A turbine
converts the kinetic energy of water into mechanical energy. Then a generator
converts the mechanical energy from the turbine into electrical energy.
Equations:
Qin + Ẇin + ṁ (h + (𝓋2/2) + g*z) = Qout + Ẇout + ṁ (h + (𝓋2/2) +g*z)
Ẇin = ṁ (𝓋2/2)

29. Thermodynamic Analysis

30. Thermodynamic Analysis
Velocity
Mass Flow Rate
Mechanical Energy
Efficiency

31. Questions?

32. References
Energy Systems. “Watter Buddy.” Home, 15 June 2017, microhydropower.com/our-products/watter-buddy/.
OpenStax. “Physics.” Lumen, Open SUNY Textbooks, courses.lumenlearning.com/physics/chapter/6-1-rotation-angle-and-angular-
velocity/.
“Pump Theory - Eulers Turbomachine Equations.” Nuclear Power, www.nuclear-power.net/nuclear-engineering/fluid-
dynamics/centrifugal-pumps/eulers-turbomachine-equations/.