This document provides a final status report for a senior design team's mechanical engineering project. The project aimed to address lack of access to water and electricity in developing countries by designing a portable system that can pump water and generate electricity through pedal power on a standard bicycle. The system attaches to any bike and allows it to still be ridden while powering a water pump and generator. The report describes the overall design, testing results, cost, and how the design meets the goals of providing potable water and phone charging capabilities through a low-cost and easy to use system.

1. MECHANICAL
ENGINEERING
DESIGN
PROJECTS
FINAL
STATUS
REPORT
1
|
P a g e
SUBMITTED
BY
Senior
Design
Team
4
Alyssa
Eng,
Cesar
Gutierrez,
Annie
Mroz
May
6,
2013

2. MECHANICAL
ENGINEERING
DESIGN
PROJECTS
FINAL
STATUS
REPORT
2
|
P a g e
TABLE
OF
CONTENTS
PROJECT
OVERVIEW
...............................................................................................................................................................
3
OVERALL
DESIGN
....................................................................................................................................................................
3
TESTING/PROTOTYPING
RESULTS
..........................................................................................................................................
3
PROPOSED
IMPROVEMENTS/LESSONS
LEARNED
..................................................................................................................
3
REQUIREMENTS
COMPLIANCE
...............................................................................................................................................
3
COST
.......................................................................................................................................................................................
4

3. MECHANICAL
ENGINEERING
DESIGN
PROJECTS
FINAL
STATUS
REPORT
3
|
P a g e
PROJECT
OVERVIEW
PROBLEM STATEMENT
Lack
of
access
to
water
presents
significant
barriers
to
growth
and
opportunity
in
developing
countries.
People
who
live
in
rural
areas
often
have
to
spend
several
hours
each
day
collecting
water,
due
to
the
fact
that
their
water
source
is
very
far
from
where
they
live
and
they
are
limited
to
what
they
can
physically
carry.
These
hours
spent
collecting
water
take
away
time
from
work,
leisure,
and
study.
Current
solutions
to
the
problem
such
as
hand
pumps
or
boreholes
are
typically
expensive,
complex,
and
fragile.
Water
access
without
electric
power
or
expensive
water
infrastructure
could
be
an
optimal
solution
to
this
problem.
HIGH LEVEL CONCEPT
To
address
these
issues,
our
project
simultaneously
solves
the
problem
of
lack
of
water
and
of
electrical
infrastructure
by
providing
both
the
ability
to
move
water
and
charge
small
devices.
This
is
accomplished
with
a
self-­‐contained
bike
system
in
which
the
user
provides
manual
power
to
both
applications
by
pedaling.
To
charge
devices,
the
user
pedals
and
the
back
wheel
of
the
bicycle
turns
a
roller
via
friction
contact.
This
roller
is
connected
to
a
generator
that
provides
electric
power
to
charge
a
battery
or
power
small
USB
devices.
To
move
water,
the
bike
transmits
pedal
power
to
an
external
gear
via
an
extra
bike
chain,
and
this
extra
gear
powers
a
pump.
REVISED PROJECT METRICS
Flow Rate 3 GPM
Pump Head 15 m
Generator Charge 12 Volt Battery
Charge cell phone or small appliances via
USB
Cost $20 - $100
Materials Incorporate recycled materials where
possible. Use as many recycled bike parts as
possible.
Additional Goals Portability, usability, ability to use any bike,
ease of set up
NOVELTY
After
much
research,
we
realized
that
bike-­‐water
projects
abound,
and
that
several
others
have
already
attempted
this.
However,
our
product
is
different
than
existing
bike-­‐water
projects
in
several
ways.
The
main
differentiation
between
our
project
and
others
is
that
the
bike
can
still
be
ridden
and
as
such,
the
entire
system
is
portable.
Any
bike
can
easily
be
dropped
into
our
system
without
any
significant
modifications
and
that
bike
can
be
as
easily
removed.
In
addition,
the
entire
product
is
inexpensive
and
made
primarily
from
recycled
bicycle
components.

4. MECHANICAL
ENGINEERING
DESIGN
PROJECTS
FINAL
STATUS
REPORT
4
|
P a g e
OVERALL
DESIGN
As
mentioned
before,
the
goal
we
pursued
with
our
project
is
solving
the
problem
of
lack
of
access
to
water
in
developing
countries,
as
well
as
providing
a
inexpensive
and
reliable
source
of
electrical
power
for
small
electronic
devices
such
as
cellphones
or
LED
lights.
The
ultimate
purpose
being
to
improve
the
quality
of
life
of
people
(specifically
kids)
in
developing
countries,
by
allowing
them
to
save
time
doing
chores
for
study
or
play.
To
accomplish
this,
we
designed
a
universal,
portable
power
providing
system
consisting
of
a
bike
stand
in
which
you
can
drop
any
multi-­‐gear
bike.
This
stand
can
easily
be
attached
to
any
bike,
and
the
bike
does
not
require
any
complex
modification.
The
only
modification
to
the
bike
consists
of
adding
a
second
chain
to
the
rear
gear.
This
is
required
to
implement
the
double
chain
system
which
powers
the
water
pump.
This
task
can
be
done
in
less
than
10
minutes
and
without
the
need
of
any
specialized
or
expensive
tools.
Once
the
stand
is
attached
to
the
bike,
the
bike
can
be
ridden
as
usual
(so
the
entire
system
is
portable)
but
at
the
same
time
has
the
capacity
of
pumping
water
and
generating
electricity.
The
setup
of
the
generator
system
takes
no
longer
than
10
seconds,
and
the
setup
of
the
water
pump
takes
about
one
and
a
half
minutes.
With
our
portable
power
providing
system
we
are
simultaneously
tackling
many
of
the
problems
mentioned
before.
First
and
foremost,
we
hope
to
provide
people
with
more
convenient
access
to
water
and
electricity.
This
will
give
people
the
opportunity
to
use
their
extra
time
for
work,
study
or
leisure.
Besides
this,
we
are
creating
work
for
an
enterprising
entrepreneur,
not
only
for
the
owner
of
our
device
but
also
for
a
mechanic
or
welder
who
can
build
and
sell
our
design.
We
envision
an
entrepreneur
in
Kenya
could
make
an
initial
investment
to
purchase
or
fabricate
the
device
and
then
provide
a
service
for
his
fellow
villagers.
This
model
of
single
ownership
will
ensure
that
the
device
and
all
its
subsystems
are
well
maintained.
Additionally,
we
hope
that
this
model
will
enable
an
unemployed
villager
to
earn
additional
income.
If
the
concept
of
bike
power
were
to
become
a
business,
it
could
be
used
to
solve
a
number
of
problems
in
Kenya.
With
the
help
of
our
advisor
Dr.
Jackson,
who
has
in-­‐field
experience,
we
learned
that
villagers
often
collect
rainwater
but
have
no
way
of
pressurizing
it
for
sinks
and
faucets.
Our
product
could
easily
address
this
need
by
pumping
water
from
a
ground-­‐level
rain
barrel
to
a
secondary
storage
container
5-­‐10
m
off
the
ground.
These
issues
were
present
in
every
step
of
our
design
and
redesign
processes,
and
we
made
several
major
changes
in
our
design
with
portability
and
simplicity
being
our
priorities
until
we
reached
the
final
optimal
solution.
To
achieve
these
goals,
our
project
is
designed
to
be
easy
to
build
with
the
resources
available
in
Kenya.
For
this
reason,
we
decided
to
use
as
many
old
bike
parts
as
possible,
since
bikes
are
very
common
there.
Welding
is
also
a
common
resource
in
Kenya,
where
it
is
not
difficult
to
find
a
welder
in
any
village.
They
also
have
access
to
scrap
metal
which
can
be
welded
together
to
construct
most
of
the
structures
required
by
our
design.
Although
we
aimed
to
use
as
many
recycled
components
as
possible,
we
did
not
limit
ourselves
to
using
recycled
parts
when
it
was
impractical
or
unnecessary.

5. MECHANICAL
ENGINEERING
DESIGN
PROJECTS
FINAL
STATUS
REPORT
5
|
P a g e
Detailed
Overview
Bike
stand:
The
stand
is
the
base
of
our
system.
It´s
main
purpose
is
holding
the
bike
stationary
while
the
user
pumps
water.
It
flips
up
to
form
a
rack
when
the
bike
is
being
ridden
as
a
regular
bike.
It
is
also
the
support
for
the
two
main
subsystems:
the
water
pump
and
the
electric
generator.
The
bike
stand
functions
as
follows:
Although
our
first
idea
was
manufacturing
our
own
bike
stand
out
of
repurposed
metal
bars
obtained
from
an
old
bicycle,
the
lack
of
access
to
welding
resources
and
the
delays
that
would
entail
by
having
it
welded
by
an
external
source
were
prohibitive.
We
decided
instead
to
buy
the
bike
stand
to
save
time.
This
stand
is
originally
a
bike
trainer
for
at-­‐home
cyclists.
This
triangular
structure
has
2
screws
on
the
top
corner
of
the
triangle.
These
screws
attach
to
the
axle
of
the
rear
wheel
of
the
bike
lifting
the
rear
wheel
to
make
the
bike
stationary.
The
screws
allow
the
stand
to
rotate
around
the
point
of
contact
with
the
bike.
We
took
advantage
of
this
feature
to
design
our
system
in
such
a
way
that
the
stand
can
be
flipped
up
and
be
held
in
that
vertical
position
via
a
bungee
system.
By
doing
this,
the
stand
that
originally
provided
a
stable
platform
to
hold
the
bike
now
provides
a
flat
surface
on
the
back
of
the
bike,
similar
to
a
rack.
This
surface
can
be
used
to
accommodate
a
crate
in
which
the
user
can
carry
all
the
tools
needed,
as
well
as
the
main
components
of
the
other
subsystems:
the
water
pump,
the
battery,
the
inlet
and
outlet
hoses
that
will
be
connected
to
the
pump,
and
tools.
Rack
and
crate:
In
order
to
take
advantage
of
the
flat
surface
that
provides
the
stand
when
it
is
flipped
up,
we
created
a
quick
release
system
to
accommodate
the
crate
in
a
secure
way.
To
do
so,
we
used
a
repurposed
the
seat
stays
(piece
of
tubing
connecting
the
main
frame
to
the
rear
axle)
of
an
old
bike.
The
shape
of
this
part
makes
it
ideal
to
mate
with
the
stand,
and
it
is
secured
in
place
via
a
bungee
cord
as
well
as
a
peg
and
slot
system.
The
assembly
and
disassembly
of
this
system
takes
no
longer
than
10-­‐15
seconds,
and
its
utility
resides
in
its
ability
to
carry
all
the
tools
and
components
in
an
easy
way,
keeping
the
bike
balanced
and
not
interfering
with
the
natural
pedaling
motion.
To
absorb
the
vibration
that
may
be
caused
by
riding
the
bike
in
rural
areas,
all
the
contact
points
are
cushioned
with
rubber.
This
also
increases
the
grip
between
removable
parts.
Water
pump
subsystem:
The
purpose
of
this
subsystem
is
transmitting
the
power
from
the
pedals
to
a
secondary
output
shaft
that
drives
the
water
pump.
After
several
iterations
and
redesign
steps,
we
decided
to
create
a
double
chain
system
because
it
was
the
most
optimal
solution
that
fulfilled
our
requirements
of
efficiency,
portability
and
simplicity.
The
benefits
of
using
this
double
chain
design
are
as
follows:
The
power
transmission
has
high
efficiency
in
chain
systems,
up
to
95%
in
well-­‐lubricated
and
tensioned
systems.
The
design
is
robust
and
compact.
The
second
chain
is
permanently
attached
to
the
output
shaft,
even
when
the
pump
is
not
connected
and
the
stand
is
flipped
up.
Thanks
to
this,
the
device
is
portable
and
the
setup
time
is
drastically
reduced,
to
the
point
that
it
takes
no
more
than
1
minute
and
30
seconds
from
the
moment
the
user
arrives
to
his
destination
riding
the
bike
until
the
moment
he
is
actually
pumping
water.
Since
the
output
shaft
is
well
lubricated,
the
power
loss
due
to
friction
when
it
is
freewheeling
(with
the
pump
disconnected)
is
negligible.
In
addition,
the
second
chain
can
be
obtained
from
and
old
bike.
The
output
shaft,
which
is
welded
into
the
stand,
is
a
repurposed
bottom
bracket
(the
axle
that
the
pedals
rotate
on)
of
an
old
bike.
Custom-­‐made
couplers
attach
to
both
sides
of
this
axle.
The
couplers
connect
the
water
pump
on
the
outer
side
and
the
extra
gear
system
on
the

6. MECHANICAL
ENGINEERING
DESIGN
PROJECTS
FINAL
STATUS
REPORT
6
|
P a g e
inner
side.
These
couplers
have
been
machined
with
a
tapered
hole
that
mates
perfectly
with
the
shape
of
the
axle
from
the
old
bike
making
it
easy
to
attach
or
remove
them.
The
quick
connection
of
the
pump
consists
of
a
setscrew
through
the
axle
of
the
pump
and
a
wing
nut.
In
order
to
prevent
the
pump
from
freewheeling,
we
designed
a
small
stand
for
the
pump
that
sits
on
the
ground
and
accommodates
the
circular
shape
of
the
pump.
The
pump
is
a
positive
displacement
pump,
specifically
a
rotary
vane
pump.
We
chose
plastic
because
it
is
light,
durable,
resistant
to
corrosion
and
inexpensive.
The
tubing
is
the
same
for
the
inlet
and
the
outlet.
We
used
¾”
clear,
vinyl
tubing.
The
¾”
hose
diameter
was
chosen
based
on
the
results
of
our
Matlab
model
(implementing
the
Colebrook
equation
for
frictional
losses).
The
model
predicts
the
pressure
lost
depending
on
the
flowrate,
distance
and
height
to
which
you
are
pumping.
Another
important
parameter
that
was
taken
into
account
was
the
weight
of
the
hose.
The
inlet
tubing
is
15
feet
long
and
the
outlet
is
90
feet.
Minimizing
weight
was
important
so
that
the
user
could
have
a
long
enough
hose
to
make
it
useful
for
pumping
distances
but
at
the
same
time
practical
and
portable.
To
make
the
transportation
of
the
hose
easier,
there
is
enough
clearance
between
the
crate
and
the
seat
of
the
bike
so
that
the
hose
can
be
coiled
around
the
crate.
The
connection
between
the
pump
and
the
tubing
is
made
via
standard
gardening
hose
connections.
A
check
valve
is
attached
to
the
outlet
of
the
pump
to
prevent
back
flow
allowing
the
user
to
take
a
break
without
losing
pressure.
In
the
inlet
hose
we
attached
a
small
filter
to
prevent
debris
from
getting
into
the
pump,
damaging
the
mechanism.
The
inlet
of
the
hose
is
weighted,
so
that
it
stays
submerged
preventing
dry-­‐running
of
the
pump.
On
the
other
side
of
the
output
shaft
we
have
an
extra
gear
system,
entirely
made
out
of
repurposed
bike
parts.
The
main
part
is
the
rear
gear
hub,
which
is
screwed
to
the
coupler
mentioned
before.
This
rear
gear
hub
accommodates
several
laser
cut
spacers
and
the
biggest
gear
of
an
old
bike
cassette.
The
spacers
allow
the
user
to
place
the
gear
in
the
desired
position.
This
is
important
as
the
second
gear
needs
to
be
in
the
same
plane
as
the
biggest
gear
of
the
cassette
of
the
main
bike
so
that
the
second
chain
is
aligned,
reducing
friction
and
consequently
increasing
efficiency.
The
second
chain
links
the
biggest
gear
of
the
cassette
of
the
bike
with
the
gear
on
the
output
shaft.
With
this
setup,
the
gear
ratio
between
the
pedaling
motion
and
the
RPM
in
the
output
shaft,
and
consequently
in
the
pump
is
3/2
(assuming
that
the
user
chooses
the
recommended
gear
ratio).
The
placement
of
the
second
chain
is
such
that
does
not
interfere
with
the
derailleur
of
the
bike,
so
the
user
can
still
switch
gears
as
desired,
except
for
the
biggest
two
gears
in
the
cassette,
which
are
occupied
by
the
second
chain.
This
exception,
however,
is
not
a
big
inconvenience
since
those
are
less-­‐commonly
used
gears.
It
should
be
noted
that
although
the
primary
purpose
of
this
extra
axle
is
to
pump
water,
it
could
easily
be
used
for
any
other
application
that
requires
rotary
motion,
such
as
a
grinding
mill
or
knife
sharpener.

7. MECHANICAL
ENGINEERING
DESIGN
PROJECTS
FINAL
STATUS
REPORT
7
|
P a g e
Electric
generator
subsystem:
The
lack
of
electricity
inhibits
education
and
studying
for
young
people.
Children
often
must
spend
most
of
their
daylight
hours
doing
chores
(such
as
collecting
water)
and
by
the
time
they
are
done
with
their
work
it
is
already
dark
and
therefore
they
have
no
light
to
study
by.
For
this
reason,
we
added
a
small
electrical
generator
to
our
project.
The
generator
is
powered
by
the
wheel
of
the
bike
in
a
roller-­‐fashion.
The
generator
can
be
engaged
anytime,
not
only
when
riding
the
bike
from
one
place
to
the
other
but
also
when
the
bike
is
stationary
or
while
pumping
water.
It
can
be
connected
to
a
12V
battery
or
directly
to
any
electronic
device
that
uses
a
USB
port.
This
way,
the
battery
can
be
used
to
power
LED
lights
or
to
charge
cellphones,
or
the
cellphones
and
LED
lights
can
be
charged
directly.
The
user
can
decide
which
option
is
more
convenient
at
any
time
and
change
from
one
to
the
other
by
flicking
a
switch.
The
generator
is
supported
by
a
custom
aluminum
plate
which
is
screwed
into
the
back
of
the
bike
stand.
This
plate
can
rotate
around
a
fixed
point
in
the
stand
until
the
generator
gets
in
contact
with
the
wheel,
and
it
can
be
locked
in
place
by
adjusting
a
set
screw
with
a
wing
nut.
Power
is
transmitted
to
the
generator
in
a
roller-­‐fashion
because
it
gives
the
user
a
high
gear
ratio,
which
in
turn
allows
the
user
to
easily
generate
a
high
RPM
in
the
generator.
Consequently,
it
is
easy
for
the
user
to
generate
a
high
voltage
in
the
generator
even
while
pedaling
at
slow
speeds.
Because
the
generator
is
AC,
we
designed
a
compact
circuit
that
rectifies
the
voltage
via
a
bridge
rectifier.
It
also
allows
the
user
to
choose
between
“battery
mode”,
in
which
the
battery
can
be
directly
connected
to
power
and
ground
outputs
or
“USB
mode”,
which
can
be
used
to
connect
any
USB
device.
Cell
phones
are
quite
common
in
Kenya
but
charging
them
without
access
to
electricity
is
a
constant
struggle.
In
order
to
charge
their
phones,
owners
typically
have
to
leave
their
village
and
walk
a
long
way
until
they
have
access
to
the
grid
or
to
a
diesel
generator
where
they
can
pay
to
get
their
phone
charged.
The
entire
circuit
is
housed
in
a
small
box
which
remains
attached
to
the
bike
stand
but
that
can
be
disengaged
at
any
time.
The
whole
system
works
as
follows:
Once
the
owner
of
the
bike
arrives
to
the
place
where
he
would
like
to
pump
water,
he
flips
down
the
stand
to
make
the
bike
stationary
and
connects
the
water
pump
to
the
exterior
side
of
the
axle.
After
that,
he
has
to
connect
the
inlet
and
outlet
hose
and
place
the
pump
stand
right
under
the
pump.
Then,
the
last
step
is
to
drop
the
inlet
hose
into
the
water
source
and
the
outlet
hose
to
the
desired
storage
vessel.
After
that,
he
can
start
pedaling
to
pump
water.
This
whole
process
shouldn´t
take
more
than
one
and
a
half
minutes.
Also,
as
mentioned
before,
the
generator
can
be
engaged
at
any
time.
Since
the
amount
of
power
that
it
extracts
is
not
very
great,
it
can
be
engaged
when
riding
the
bike
from
one
place
to
the
other,
taking
advantage
of
the
time
spent
travelling.
Once
the
user
decides
to
start
pumping
water,
he
can
leave
the
generator
engaged
if
the
head
he
wants
to
pump
to
is
not
too
high,
or
he
can
just
disengage
it
to
transmit
all
the
power
to
the
pump.
Once
the
process
of
pumping
water
is
over,
the
packing
process
is
the
same
as
the
setup
process
but
in
the
opposite
direction:
he
has
to
disconnect
the
hoses
and
the
pump,
flip
up
the
stand
and
secure
it
with
the
bungee
system
and
place
the
rack
and
the
crate
on
top
of
it,
again
using
another
bungee
system.
To
conclude,
he
has
to
put
the
pump,
the
pump
stand
and
the
hose
in
and
around
the
crate
respectively
and
he
is
ready
to
ride
his
bike
to
a
different
location.

8. MECHANICAL
ENGINEERING
DESIGN
PROJECTS
FINAL
STATUS
REPORT
8
|
P a g e
TESTING/PROTOTYPING
RESULTS
Setup and Methods
Numerous
rounds
of
testing
were
conducted
both
to
test
component
integration
and
system
performance.
Pump
testing
was
conducted
by
pedaling
the
bike
and
measuring
the
flow
rate
of
the
water
as
well
as
the
pressure
head
generated.
Testing
was
done
at
a
gentle
power
input
to
simulate
the
ability
of
someone
pedaling
for
an
extended
period.
We
tried
testing
with
two
different
pressure
gauges,
neither
of
which
provided
any
useful
measure
of
pressure
head
within
the
system
because
of
constant
fluctuations.
As
such,
we
resorted
to
calculating
the
pressure
head
based
on
pumping
to
different
vertical
heights.
This
is
not
truly
a
measure
of
the
pressure
built
up
in
the
pump
as
it
doesn’t
account
for
frictional
losses
in
the
tubing,
but
it
provides
a
good
lower
bound
of
pump
capabilities.
Testing
was
performed
in
Skirkanich,
with
the
bike
on
the
ground
floor
and
someone
on
a
different
floor
measuring
the
flow
rate.
We
also
tested
outside
near
Penn
Park
to
simulate
what
it
would
be
like
to
actually
use
the
bike
outdoors
up
a
more
sloping
hill.
We
set
up
the
bike
with
a
bucket
of
water
at
the
bottom
of
the
hill
and
again
had
someone
at
the
top
measuring
flow
rate.
The
height
of
the
hill
was
about
15
feet
and
at
a
leisurely
pace
we
achieved
a
flow
rate
of
about
4
GPM.
We
also
tested
the
electrical
components
of
our
product.
Current
and
voltage
output
from
the
generator
were
tested
with
a
digital
multimeter
while
one
person
pedaled.
The
generator
was
also
tested
by
charging
a
cell
phone,
both
while
stationary
and
riding.
Cell
phone
charge
time
was
measured
to
give
an
indication
of
generator
performance.
The
aspect
of
testing
that
we
struggled
the
most
with
was
that
we
couldn’t
measure
power
input.
There
was
no
way
for
us
to
practically
measure
power
output
of
the
person
pedaling,
so
we
had
no
way
to
validate
our
model.
The
best
we
could
do
were
smart
estimates.
However,
because
the
goal
of
our
project
was
to
pump
water
and
generate
electricity,
most
of
our
testing
focused
on
simply
getting
the
system
to
work.
Prototyping effect on design
Doing
a
lot
of
testing
early
on
was
key
in
ensuring
system
functionality.
Our
initial
tests
were
promising
(we
were
able
to
pump
water
via
pedaling),
but
were
not
ideal.
As
of
the
submission
of
the
midterm
report,
our
design
made
use
of
an
extra
gear
engaged
with
the
main
bike
chain.
This
required
a
lot
of
tension
to
be
added
to
the
derailleur
(40-­‐60
lbs.)
which
was
more
than
was
practical
via
any
additional
tensioning
system.
All
of
the
designs
we
tested
to
add
tension
to
the
chain
were
bulky
and
awkward.
We
also
noticed
after
testing
our
system
several
times
that
applying
such
great
tension
to
our
derailleur
was
permanently
deforming
it,
and
we
nearly
broke
it.
Doing
a
lot
of
testing
and
playing
around
with
different
ideas
for
power
transmission
led
us
to
the
double
chain
system.
At
some
point
in
all
of
our
design
iterations,
we
had
been
contemplating
the
double
chain
system,
but
had
discounted
it.
We
were
doubtful
because
the
extra
chain
would
absorb
one
of
the
gears
rendering
it
unusable,
and
we
were
worried
about
space
constraints.
We
were
also
concerned
that
a
double
chain
system
would
require
the
user
to
remove
the
chain
with
every
setup
and
breakdown
of
the
pump.
Examining
the
bike,
we
realized
that
the
double
chain
could
be
permanently
engaged
with
the
back
gear
to
prevent
this
issue.
Prototyping
confirmed
that

9. MECHANICAL
ENGINEERING
DESIGN
PROJECTS
FINAL
STATUS
REPORT
9
|
P a g e
this
designed
functioned
well
given
the
space
constraints
and
that
the
extra
chain
could
remain
on
the
back
gear
without
problems.
Leaking
was
also
an
important
factor
in
our
testing,
and
we
experimented
with
thread
tape
and
sealant
as
well
as
different
types
of
hose
connectors
to
see
which
ones
worked
the
best.
Results of Testing
Our
final
round
of
testing
gave
us
the
following
results
for
our
pump:
From
our
initial
generator
testing,
it
was
clear
that
we
could
easily
output
over
12
Volts.
We
even
found
that
we
could
generate
voltages
larger
than
12
Volts
while
pedaling
at
an
easy
pace.
After
our
circuit
was
complete,
we
tested
it
by
charging
a
cell
phone.
Our
generator
was
able
to
charge
a
cell
phone
from
0%
battery
to
20%
in
20
minutes,
similar
to
charging
via
wall
outlet.
Additional
applications
such
as
a
bike
light
were
also
hooked
up
the
USB
port
and
charged
easily.
Height
(meters)
Flow
Rate
(GPM)
4.70
6
9.25
4
13.25
2

10. MECHANICAL
ENGINEERING
DESIGN
PROJECTS
FINAL
STATUS
REPORT
10
|
P a g e
PROPOSED
IMPROVEMENTS/LESSONS
LEARNED
Along
the
process
of
designing
and
manufacturing
our
project
we
faced
different
problems
ranging
from
the
lack
of
access
to
some
resources
(as
welding)
to
the
strict
constraints
in
terms
of
cost
and
materials.
Because
simplicity,
reliability,
portability,
low
cost
and
manufacturability
in
developing
countries
were
our
main
goals,
we
struggled
to
find
materials
and
components
that
met
these
requirements
while
still
being
useful
in
our
design.
One
of
the
biggest
lessons
learnt
during
this
process
is
how
to
design
and
manufacture
what
we
had
in
our
minds
while
being
subject
to
the
constraints
mentioned.
We
realized
that
the
easier
design
is
usually
the
better
one.
One
major
breakthrough
that
we
had
is
that
using
repurposed
parts
from
old
bicycles
was
an
optimal
solution
balancing
practicality
and
our
initial
goals
of
using
all
recycled
material.
Bike
parts
are
cheap
and
easy
to
find
in
developing
countries.
They
are
universal
and
easy
to
understand
and
fix,
which
we
considered
really
important
to
implement
our
system.
Besides
this,
using
bike
parts
that
are
already
manufactured
drastically
reduces
the
complexity,
number
of
tools,
and
time
required
to
construct
the
system.
This
way,
the
whole
system
can
be
made
by
a
welder
by
just
using
and
old
bike
(from
which
he
would
take
the
bottom
bracket,
the
chain,
the
rear
gear
hub,
the
cassette
and
the
seat
stays).
The
frame
of
an
old
bike
or
scrap
metal
could
be
used
to
build
the
stand
instead
of
having
to
buy
one.
If
we
had
to
do
this
project
again,
we
would
make
several
changes.
Due
to
the
lack
of
access
to
welding
facilities,
we
decided
to
buy
a
bike
stand.
Although
this
stand
works
well,
it
is
heavy
and
expensive.
The
stand
alone
was
as
expensive
as
the
water
pump
and
the
generator
together,
and
it
represents
the
majority
of
the
extra
weight
added
to
our
design.
Since
the
design
of
the
stand
is
really
simple,
we
are
confident
that
it
could
be
made
from
the
frame
of
a
scrap
bike.
That
would
make
the
design
lighter
and
cheaper.
Another
feature
that
we
would
like
to
change
for
a
second
iteration
is
the
integration
of
the
output
shaft.
In
our
current
design,
the
shaft
is
welded
into
the
frame
in
a
fixed
position.
This
system
works
efficiently,
but
has
some
drawbacks,
mainly
the
initial
setup
and
adjustment
of
the
second
chain.
Because
the
shaft
is
fixed
in
place
in
our
current
design,
the
user
has
to
modify
the
length
of
the
second
chain
to
accommodate
whatever
extra
gear
he
uses.
In
some
instances,
he
may
not
be
able
to
use
the
gear
size
he
wishes
because
chains
come
with
a
discrete
number
of
links,
and
as
such
only
certain
size
gears
will
work.
Further,
although
this
is
a
setup
need
only
be
done
once
(since
after
the
first
setup
the
chain
is
going
to
be
permanently
engaged),
this
process
could
be
made
easier.
We
thought
that
having
the
output
shaft
mounted
in
a
rail
system
along
the
frame
of
the
stand
would
make
the
system
more
user-­‐friendly.
It
would
not
only
make
this
initial
setup
easier
but
it
would
allow
the
user
to
change
the
gear
on
the
shaft
fast
and
easily.
Although
the
current
gear
ratio
is
optimal
for
pumping
water,
the
user
may
be
interested
in
a
having
broader
range
in
order
to
power
other
potential
functions.
Other
improvements
that
could
be
proposed
for
a
second
iteration
of
this
project
are
the
implementation
of
a
compact
water
filtration
system
or
a
hose
system
that
could
be
used
for
irrigation.
Last
but
not
least,
another
improvement
that
would
like
to
propose
is
to
make
the
whole
electric
system
waterproof.
Although
we
know
that
our
generator
is
water
resistant
(it
is
meant
to
be
used
for
outdoor
purposes
such
as
wind
turbines),
we
could
not
verify
that
capability.
Further,
the
USB
port
and
the
connections
for
the
battery
are
exposed.
Although
the
whole
electric
system
can
me
removed
easily
to
prevent
it
from
corrosion
in
the
case
of
rain,
we
think
that
is
necessary
to
make
it
completely
waterproof
because
the
device
is
mainly
meant
for
outdoor
use.

11. MECHANICAL
ENGINEERING
DESIGN
PROJECTS
FINAL
STATUS
REPORT
11
|
P a g e
In
terms
of
the
lessons
learnt,
apart
from
the
constrained
design
mentioned
before,
we
also
learnt
the
importance
of
system
integration.
The
fact
of
having
different
subsystems
working
smoothly
and
perfectly
does
not
imply
that
they
are
going
to
work
once
they
are
put
together.
That
was
one
of
the
main
challenges
we
faced
during
the
design
of
the
double
chain
system.
Due
to
the
presence
of
the
derailleur
and
the
tight
space
between
the
bike
and
the
stand
we
had
several
issues
with
parts
interfering
with
each
other,
which
made
us
make
several
redesigns
until
we
found
the
final
solution.

12. MECHANICAL
ENGINEERING
DESIGN
PROJECTS
FINAL
STATUS
REPORT
12
|
P a g e
REQUIREMENTS
COMPLIANCE
Initial Goals:
Flow Rate 13 GPM
Pump Head 0.5 miles (horizontal)
Cost $20 - $100
Materials Entirely recycled or
scrap
Our
initial
goals
were
set
before
we
fully
understood
the
needs
of
people
in
developing
countries
and
the
limits
of
human
abilities.
Because
of
this,
they
are
a
little
unrealistic.
They’ve
since
been
scaled
back
while
keeping
in
mind
customer’s
needs.
Furthermore,
we
added
in
several
new
quantitative
and
qualitative
metrics.
Revised Goals:
Flow Rate 3 GPM
Pump Head 15 m
Generator Charge 12 Volt Battery
Charge cell phone or small appliances via
USB
Cost $20 - $100
Materials Incorporate recycled materials where
possible. Use as many recycled bike parts as
possible.
Additional Goals Portability, usability, ability to use any bike,
ease of set up
As
our
design
went
through
several
iterations,
our
priorities
and
design
focus
changed.
We
abandoned
the
goal
of
making
the
project
from
completely
recycled
materials
for
several
reasons.
Requiring
that
the
entire
project
be
made
from
recycled
materials
came
to
be
viewed
as
an
impractical
and
unnecessary
constraint.
Instead,
we
attempted
to
incorporate
recycled
materials,
especially
any
type
of
bike
part,
when
practical
and
feasible.
The
team
decided
that
making
certain
components,
the
pump
for
instance,
out
of
recycled
material,
was
an
unnecessary
step
as
pumps
are
manufactured
to
specific
tolerances
which
is
especially
important
given
concerns
with
sealing,
and
manual
pumps
are
inexpensive
anyway.
Our
final
design
is
a
good
compromise
between
recycling
components,
functionality,
and
cost.

13. MECHANICAL
ENGINEERING
DESIGN
PROJECTS
FINAL
STATUS
REPORT
13
|
P a g e
We
scaled
back
our
flowrate
goal
as
our
initial
estimate
of
13
GPM
was
probably
more
than
necessary
for
an
average
village
and
not
practically
possible.
Instead
of
focusing
on
horizontal
distances,
we
instead
used
vertical
distances
as
our
metric
for
pressure
due
to
the
impracticality
of
testing
over
long
distances.
We
were
successfully
able
to
pump
2
GPM
up
to
13.5
m.
Our
model
indicates
that
with
a
¾”
diameter
pipe
about
15-­‐20%
of
pump
head
is
lost
to
frictional
losses
(depending
of
course
on
flowrate).
Conservatively
estimating
that
15%
of
our
pump
head
was
lost
to
friction,
13.5
m
of
vertical
head
would
give
a
total
pump
head
of
15.8
m.
As
such,
we
accomplished
just
under
our
revised
goal
of
3
GPM
and
a
little
bit
above
our
revised
goal
of
15
m
of
pump
head.
It
is
likely
that
we
could
have
hit
the
3
GPM
at
15
m
metric
had
we
tested
our
system
with
a
greater
power
input.
Many
qualitative
goals
were
added
into
the
project
between
the
beginning
of
the
year
and
now
including:
portability,
usability,
ability
to
use
any
bike,
and
ease
of
set
up.
We
feel
that
we
have
met
or
exceeded
all
of
these
qualitative
goals
as
discussed
in
detail
in
the
previous
sections.
In
terms
of
cost,
should
our
product
be
manufactured
at
scale
and
with
the
stand
made
from
scrap
metal
instead
of
purchased,
it
could
certainly
be
manufactured
for
around
$100.
The
bulk
of
the
cost
is
due
to
the
pump
($66)
and
the
generator
($40).
The
addition
of
the
generator,
which
was
not
part
of
the
design
with
the
initial
$20-­‐100
cost
estimate,
adds
a
lot
of
value
to
our
product
even
though
it
is
a
major
cost
driver.

14. MECHANICAL
ENGINEERING
DESIGN
PROJECTS
FINAL
STATUS
REPORT
14
|
P a g e
COST
In
terms
of
literal
expenses
throughout
the
entire
year,
we
spent
$814.84,
which
is
$81.16
under
our
allotted
$900
budget.
However
in
terms
of
what
we
spent
that
was
actually
used
in
our
final
project,
it
comes
out
to
be
significantly
cheaper.
The
actual
cost
of
everything
that
was
used
in
our
final
product
was
$448.
The
tubing
was
a
large
part
of
this
cost
at
$180.
The
generator,
pump,
and
stand
amounted
to
$177.
The
extra
$41
came
from
miscellaneous
expenses
like
screws,
bungee
cords,
nuts,
a
check
valve,
and
hose
connectors.
We
also
had
to
buy
a
bike,
however
we
bought
a
used
one
at
Neighborhood
Bike
Works
for
only
$50.
The
discrepancy
between
the
product
cost
and
the
total
cost
of
$914.84
comes
from
expenses
not
directly
toward
the
final
product,
such
as
costs
associated
with
prototyping,
development,
and
testing
equipment.
The
costs
associated
with
prototyping
and
development
were
for
items
that
were
ordered
but
ended
up
not
needing
due
to
design
changes.
Our
first
pump,
which
was
made
of
cast
iron,
rusted
and
was
too
heavy,
so
we
ordered
a
second,
plastic
pump
which
was
used
in
our
final
design.
We
also
ordered
two
generators
because
we
were
unsure
which
model
would
work
best
and
wanted
to
avoid
delays
due
to
ordering
a
second
generator.
We
only
ended
up
using
one,
however.
Miscellaneous
items
ordered
from
McMaster
in
the
beginning
of
the
year
when
we
wanted
to
make
the
pump
ourselves
amounted
to
another
$150.
About
$40
was
spent
on
accessories
for
the
bike
such
as
a
12
Volt
battery
and
a
bike
light.
Both
were
ordered
to
demonstrate
what
the
bike
was
capable
of
accomplishing.
The
remainder
of
the
costs
resulted
from
testing.
A
check
valve,
a
gate
valve,
a
pressure
gauge,
and
smaller
amounts
of
tubing
were
purchased
for
testing.
Things
like
thread
sealant,
latex
tape,
various
types
of
hose
connectors,
and
thread
connectors
were
also
used
for
testing.
We
really
used
these
items
primarily
in
testing,
so
they
were
a
necessary
cost,
but
didn’t
actually
go
into
the
final
product.
This
combined
with
smaller
expenses
like
tape,
spray
paint,
and
glue
made
up
for
the
rest
of
the
expenses.

15. MECHANICAL
ENGINEERING
DESIGN
PROJECTS
FINAL
STATUS
REPORT
15
|
P a g e
Summary
of
Expenses
Items
Ordered
Through
the
Business
Office
Cost
RAD
Cycle
Products
Indoor
Portable
Work
Out
Bicycle
Trainer
$75.18
Cast
Iron
Rotary
Drum
Pump,
10
GPM
$43.95
Plastic
Rotary
Polypropylene
Drum
Pump
For
Chemicals
#
4649-­‐99
$66.10
Small
Alternator,
Mini
Generator
$36.50
Small
Alternator,
Mini
Generator
for
Wind
Turbine
$49.00
EPDM
O-­‐Ring
AS568A
Dash
Number
242,
packs
of
10
$6.29
Sheet
Gasket
Assortment
Includes
14
Sheets,
6"
X
6"
$24.26
High-­‐Strength
Adhesive/Sealant
Marine,
10.2-­‐Ounce
Cartridge,
Clear
$9.74
Zinc-­‐Plated
Steel
Bolts
with
Two
Hex
Nuts
and
Washers
$9.33
Machine
Screw
Hex
Nuts,
Zinc-­‐Plated
Steel
$1.21
3/4"
Air
and
Water
Hose,
Black
Hose
$17.70
Two
Male
Fittings
for
3/4"
Air
and
Water
Hose,
Black
Hose
$16.24
Business
Office
Total
$355.50
Reimbursements
Home
Depot
$46.00
Bike
and
Parts
$60.00
Lowes
Mar
24
$34.39
Home
Depot
Mar
31
$9.66
Bike
Church
Mar
28
$5.00
Radioshack
Mar
29
$25.89
Lowes
Mar
31
$198.22
Dr.
Jackson
Hardware
Store,
Swing
Check
Valve
$11.76
Monarch
Hardware
$12.13
CVS
Pharmacy
$4.85
CVS
Pharmacy
$4.85
Radioshack
Apr
6
$4.53
Radioshack
Apr
9
$5.92
Hardware
Store
Apr
10
$4.96
Hardware
Store
Apr
11
$6.47
Lowes
April
8
(Alyssa)
$26.04
Home
Depot
Apr
8
(Alyssa)
$2.67
Reimbursement
Total
$463.34
Sum
of
Expenses
$818.84
Total
Budget
$900.00
Difference
-­‐81.16