Final Report

Eco Illuminator
James Mcdonough
May 5th, 2014

Daniel Peterson

Daniel Cho

Damiete Horsfall

Executive Summary
The flowing water from a sink faucet is an available source of energy that is seldom utilized.
The objective of our product is to capture this energy, and to utilize it productively. Research
showed that a product running on flowing faucet water was feasible, and also provided several
ideas for potential uses of this harnessed energy.
After conducting several customer surveys, it was concluded that the best option was to mimic
several previous products that made the faucet water glow in different colors. Many of these
older products ran on batteries, while the Eco Illuminator will run on the water flow alone. This
eco-friendly aspect will give an edge over competitors on the market. The concept design is a
very compact, water-tight extension of the sink faucet. A magnetic coupling system will be used
to make sure that the water will never reach the motor or LEDs.
The final prototype was tested provide a voltage output of about 2.3 volts, which is sufficient to
power the several LED lights. Economic assessments estimate that the product can be assembled
for under $35 when mass produced. This assembly price will allow for significant profits, at a
selling price of $50 each. This product would be marketed toward the eco-friendly community
for highest sales and profits.

Table of Contents
Executive Summary ....................................................................................................................... i
Introduction ................................................................................................................................... 1
Customer Needs and Specifications ............................................................................................ 2
Concept Development ................................................................................................................... 3
Detailed Design .............................................................................................................................. 6
Testing .......................................................................................................................................... 11
Conclusion ................................................................................................................................... 12
References .................................................................................................................................... 13
Appendix A .................................................................................................................................. 14
Appendix B .................................................................................................................................. 16
Appendix C .................................................................................................................................. 17
Appendix D .................................................................................................................................. 18
Appendix E .................................................................................................................................. 19
Appendix F .................................................................................................................................. 23
Appendix G .................................................................................................................................. 25

ii

1. Introduction
1.1 Problem Statement
The problem faced by customers today is how to produce electricity from an already current
water source. Customers are already paying for the water that flows from their sink faucets and
they are not using it to its fullest potential. The problem that this product aims to solve is to find
a use for that flowing water and utilize the potential electrical output that sink faucets provide.
There are both dimensional and performance based constraints for this product. The product
must not be taller than four inches and the product must also have a 3/8-18 NPS internal pipe
thread. This product must also produce one and a half volts when the electricity is sent through a
ten ohm resistor. It is desirable for the customer to be able to see the inner workings of the
product while it is in operation. This product will take that water that flows from the faucet and
use it to spin a turbine and generate current and voltage that will be used to power the lighting of
LED lights. This product will light up the sink below it making it useful for cutting costs on
electricity while also providing a calming and relaxing lighting for the room. The market
possibilities for this product are essentially endless due to the large amount of potential
customers. Any person with running water that wants to start cutting costs on their electricity
bill while also adding a great piece of home decoration will be interested in this product.
1.2 Background Information
This product uses a direct current driven motor also known as a DC motor. A DC motor is an
electric motor that converts electricity to motion by magnetism [1]. A DC motor utilizes magnets
that are mounted around a pole. A combination of pulling and pushing of the magnets will result
in rotating motion which in turn will produce electricity. For our design, we will be reversing the
function of the motor to act as a generator. This product will also use a pelton wheel for the
turbine. A pelton wheel is a water turbine wheel where a jet of water impacts on blades or
buckets around the perimeter of the wheel causing it to turn [2].
1.3 Project Planning
The marketing, designing, and manufacturing of the Eco Illuminator adhere to a strict schedule
to ensure that this product can be released into the market for purchase as quickly as possible.
The Gantt chart that helped to guide the progression of this project can be found in appendix A.
The selection of the final concept design led to group members being placed into individual roles
and splitting up the work. The group members and their roles and qualifications can be seen in
appendix A Table 1. Although the group has established a clear timeline in order to complete all
required tasks, the unpredictability that comes with a project such as this one may cause minor
deviations to the timeline. Therefore a project list plan has been developed to ensure that
deviations from the plan are small and can be accommodated so that there is as little impact on
the project performance as possible. The project risk plan can be viewed in the appendix section
A Figure 2.
1

2. Customer Needs and Specifications

2.1 Identification of Customer Needs
The first step of the design process was to identify customer needs. This was done through the
use of surveys and interviews with prospective buyers of this product. After the surveys and
interviews were completed, the customer needs were then prioritized by importance so that they
could be the focus of future concepts. Some customer needs were also found by studying the
reviews of a similar product, Sylvanias Ecolight. The Ecolight product generates electricity
from water flowing through a shower rather than a sink faucet, and hence it was ascertained that
key aspects of the product were similar and in some cases identical to aspects of our product.
This approach was done in order to narrow down our sample of customers to represent the
targeted market segment as closely as possible. The reviews were carefully assessed and the
needs extracted, based on frequency of occurrence of issues which reflected the importance of
such aspects of the product to the consumers. This also helped in the prioritization of the
customer needs. The major customer needs were identified for the product to be inexpensive,
safe, compact, durable, and aesthetically pleasing.
2.2 Design Specifications
Based on the customer needs, specifications were established in order to fall in line with
expected appearance and functionality. Some specifications were pre-determined due to the
constraints placed on this product by the project guidelines. These specifications included max
height of product, size of the pipe insert, and performance specifications such as needed voltage.
After observing the constraints that were placed on this product, the next step was to generate the
remaining specifications. The most important of which being which motor this product would
use to achieve the maximum efficiency possible. In order to choose the best available motor, a
table was created to compare each motor. This can be found in appendix B Table 3. The table
displays the key specifications of each motor and then after studying the table, a group vote was
taken to determine which motor would be used. The housing of the product and most of its
components will be made from plastic material; this is in order to address the need for an
inexpensive product. In order to make the product aesthetically pleasing, nature inspired patterns
and geometries will be incorporated into the design. A belt drive transmission system will be
used which will help with the waterproofing of the system, as the turbine flow system will be
properly separated from the generator system. In addition the use of splash guards will further
enhance the water proofing of the system. In order to address durability the attachment point of
the product to the metal faucet will be metal to ensure that there are no cracks during installation.
The dimensions of the product will be within 7.5 by 4 by 2.25 inches which is roughly
comparable to a professional digital camera. The combination of Table 1 and Table 2 make up
the QFD chart. Table 1 assigns the numbers to each need and provides a rating of their relative
importance. Table 2 assigns a metric to each need. The QFD was used to facilitate the
construction of the specifications. Each of these tables can be found on the next page.

Table 2 - Metrics

Table 1 Customer Needs

No.
1
2
3
4
5

Need
Inexpensive
Safe
Aesthetically
Pleasing
Compact
Durable

Importance
4
4
2

Metric No.
1
2
3
4
5

Need No.
1
5
3
2
2

2
4

Metric
$50 maximum
Material
Nature inspired Design
Splash Cards
Distance of generator
from flow
Type of assembly with
faucet

Table 3 - AHP

Transmission
Transmission X
0.5
Turbine
0.5
Durability
0.33
Size

Turbine
2
X
0.5
0.33

Durability
2
2
X
0.5

Size
3
3
2
X

Total
7
5.5
3
1.16

Weight
0.420168
0.330132
0.180072
0.069628

The criteria used in selecting the design concepts were: the type of transmission system, the type
of turbine, the durability of the product, and the size of the product. In coming up with concepts
it was clear that the type of turbine as well as the transmission system were aspects of the
product which would significantly affect the feasibility of manufacturing as well as the
functionality of the product under set conditions. The durability and the size of the product were
extracted as key customer needs which would affect the concept selection process because they
differed most between concepts, relative to the other needs. An Analytical Hierarchy Process
(AHP) was employed to weight the selection criteria. The AHP illustrates that the transmission
system and the turbine were most important in concept selection, followed by the durability and
size in that order. The AHP can be seen above in Table 3.
3. Concept Development
3.1 External Search
Water powered generators are not a new concept, even on a pipe or faucet. Some previous
concepts have been developed that are intended to charge batteries, power faucet motion sensors,
and supply power to shower lights. One concept by designer Jin Woo Han utilizes the water
flow from a faucet to charge a battery, which in turn supplies power to an electrical outlet [5].
(See Figure 1)
Figure 1 Hans Design

Another concept that actually made it to market is the 3.6V Micro hydro generator available
from SeeedStudio in China. This product claims to produce a stable 3.6V with the help of a
rechargeable lithium battery. While this product is not designed for use on a faucet, it can be
mounted behind a shower head or between any two pipes in order to power a number of
applications [6]. (See Figure 2)
Figure 2 Micro Hydro Generator

A patent also exists for a similar product, which attaches to the faucet in order to generate ozone
water. (Patent WO 2008044262 A1) This product is powered by water flow jetted under a high
pressure nozzle into an impulse style turbine. This turbine powers an ozone generator that
synthesizes ozone and pumps it into the water. This is a good example of a working product of
similar design.
3.2 Problem Decomposition
The problem was divided and analyzed using the black box method. This allowed for a clearer
and more simplified view of the different subsystems of this product. The subsystems for this
problem were determined to be the turbine, transmission system, generator, and water removal
system. Each of these subsystems is required to work in unison in order for this product to work
effectively as advertised. Figure 3 below shows these subsystems.

Figure 3 - Problem Decomposition

Energy (Pressure)
Turbine

Transmission
System

Generator

Energy (Heat,
electricity)

Water
Water
Water Removal
System

Energy
(Pressure)

3.3 Concept Generation

Prior to generating concepts, extensive research was conducted to see what options existed for
the turbine system [5] [6]. After this research was completed, many ideas were brainstormed by
all members of the team. Two of the turbine concepts that stood out were the cross-flow and the
pelton wheel designs, based primarily on efficiency and cost. Each of these concepts is an
impulse style turbine that works within the typical household water pressure range (see figures 4
and 5) [3] [4]. In addition to these two concepts, additional consideration was given to in-flow
turbines that did not seem to be ideal for this product.
Cross-Flow Concept
Figure 4

Pelton Wheel Concept

Figure 5

3.4 Concept Selection

In the interest of choosing the best transmission system for this product, a weighted selection
matrix was used (Table 4). Water resistance was given the highest weight, because the generator
must be kept dry in order for this product to function. While efficiency and cost were also
important factors, it was decided that ease of assembly should be considered a slightly higher
weighting in order to reduce production cost and time. This selection matrix made it clear that of
the four considered options, a direct shaft connection or belt and pulley system should be used.
From this point it was decided that the efficiency gained with a belt system was worth the
slightly higher difficulty of assembly and cost.

Table 4

Criteria
Water Proof
Efficiency
Easy assembly
Cost

Transmission System Selection Matrix

Direct
Belt-Pully
Gear Train
Shaft
System
Weight
(1-10)

Magnetic
Coupling

10

10

10

10

Total

245

220

254

224

A weighted selection matrix was used in the selection of a turbine for this product (Table5).
Assembly and efficiency were considered to be the most important aspects and were given the
highest weightings. Cost and size were also considered to be important. This process clearly
showed that a Pelton style turbine would be our top choice.
Table 5
Turbine Selection Matrix
Pelton
Criteria
Size
Efficiency at
faucet pressure
Easy assembly
Cost
Total

Cross Flow Propeller

Screw

Weight
(1-10)
7

10

289

241

226

201

4. Detailed Design
4.1 Modifications to Proposal Sections
The design from the proposal was modified and refined. The design was refined to use thinner
material for all sides and dividing walls. The design was modified to use magnetic coupling
instead of a belt drive system. The magnetic couplings were practical and functional as it will
require fewer materials and improve the performance. The thinner material and the use of
magnetic coupling allowed more room inside the box. In addition to the increase of space, it also
allowed to discard weight to the product. The modified design lessens the cost of materials and
the time to manufacture the product.
6

4.2 Overall Description and Detailed Drawings

Figure 6
7

9
6
4

3
1
8
5
10

12

11

Project Assembly Diagram

1) 12V DC motor attatched to magnetic disk
2) Short Blue LED lights (quantity 6)
3) Magnets attatched to disk that is coupled with the turbine
4) Turbine
5) Long Blue LED lights (quantity 2)
6) Injection molded housing
7) Nozzle for water flow entrance
8) Water flow Exit
9) 1/16 thick dividing wall between magnetic disks
10) Dividing wall with a pressed bearing
11) Injection molded bottom plate with formed grooves for housing.
12) Wall for motor mounting

The Ecoilluminator uses a 12V DC motor that is magnetically coupled to a turbine. Water flows
into the system through a nozzle which will increase the velocity of the water and the force
acting on the turbine. The turbine spins as the water hits the blades and causes the shaft that the
turbine is joined with to spin as well. The shaft spins with little resistance due to friction because
the shaft is mounted between two bearings. The rotating shaft causes the disk with attatched
magnets to rotate. The disk with magnets is coupled to another disk with magnets and they are
seperated by a 1/16 thick wall to prevent water from coming into contact with the DC motor.
The second disk with attatched magnets is attatched to the motors shaft and will cause the shaft
to rotate as the disk rotates. The spinning shaft causes the motor to create power which is then
sent into the LED lights to illuminate them. The whole system is waterproofed by the addition of
walls that separate different sections of the Ecoilluminator from the flowing water. For more
detailed drawings please see appendix E. A bill of materials can be found in apendix B.
4.3 Theoretical Analysis
The volumetric flow rate was calculated prior to connecting the nozzle attachment to the faucet.
The areas were calculated from measured diameters of the faucet and the nozzle, and the
velocities were calculated from these. For this theoretical analysis it was assumed that when the
turbine reached its maximum speed, the point of contact of with the water would be moving at
the same speed as the water flow.
Q is the Volumetric Flow rate from the faucet.
A1 is the area of the faucet without the nozzle.
v1 is the calculated water velocity from the faucet.
A2 is the area of the faucet with the nozzle.
(

v1 is the calculated water velocity from the nozzle.

The point of contact with the water flow occurs at a distance of about from the center of
rotation, and the distance this point would travel in one rotation is represented by C. It was
assumed for this theoretical analysis that that point would maintain a constant velocity that was
calculated above as v2 for the entire rotation, because the other blades will remain in contact.
The voltage output was calculated to be 4.99V from the rotational speed and the EMF constant
of the DC motor, which provides some room above the required 1.5V. The EMF constant was
found in the motor specification documentation.
C is the distance the point of contact will travel.
t is the time it takes for revolution.
is the rotational speed of the turbine.
Ke is the EMF constant of the DC motor.
V is the voltage output of the motor.
8

4.4 Component and Material Selection Process for Mass Production

This product was designed to be easily manufactured and inexpensive. With injection molding
techniques, the body of our design can be created quickly and in mass quantity out of a clear
plastic material. The magnetic coupling casings and the pelton wheel can also be injection
molded with this material. Each of the remaining items is standard parts that can be purchased in
bulk to reduce costs. The drive shaft is 2.5 by diameter and is made of 303 Stainless Steel,
this material was chosen because it was the cheapest of the stainless steel options that suits our
needs. Two miniature stainless steel ball bearings were chosen because they allowed for the
expected rpm of the shaft, and also because it may be in contact with water. Standard magnets
were chosen with dimensions thick and diameter in order to fit our design.
4.5 Fabrication Processes for Mass Production
The materials of the product can be bought and molded. The materials that will be bought are the
shafts, motors, LEDs, nozzle, bearings and magnets. These materials can be bought in bulk to
reduce the cost of the materials. The material of the product is acrylic plastic. Acrylic plastic can
be injected molded which will allow the mass production to be done without any difficulty. The
top and the sides can be injected molded into one piece to facilitate the production of the
housing. The bottom piece of the product will have to be molded separately as it will have the
grooves for the inner walls to be placed on. The bottom will be adhesively attached to the top
pieces to complete the box housing. The turbine and the magnet housing will use the same
material as the box housing. This will allow the turbine and the magnet housing to be injected
molded.
4.6 Industrial Design
The goal of this product is to please the customers. The key features that the intended customer
wanted were the cost, safety, and the durability of the product. This also includes the ease of use
and the aesthetics of the product; however, it is not important to the customer (Table 1). To use
the product, the customer can screw the product into the faucet and turn the faucet on. The motor
will then create power from the flow of the water passing through the turbine. There are LED
lights attached to box to create a calm ambient environment. The lights will illuminate under the
faucet to increase visibility. These LEDs will not harm the customer as the wires and the lights
will be inside the box. The material and the design of the product will guarantee that the product
is durable and inexpensive to purchase.
4.7 Safety
The most important feature of the product is safety. Safety was also one of the top rated needs
from the customers (Table 1). The product meets the standard safety regulations. The safety
regulations that the product complies with are IEC 60038, IEC 60335, UL 2778, and UL 8750
(see Appendix D Table 1 for more information). The motor can be one of the biggest risks for
the product because of the water. If the water comes in contact with the motor, it can cause
electric shock or even cause a fire. However, the motor will produce fewer voltages than 120V.
Therefore, according to Appendix D Table 2, the motor will be a low risk motor. From the
motor, there will be LEDs connected from a wire. These LEDs are standard LEDs used for
9

lighting products. Those wires will be excluded from any water exposure which makes our
product a safe household product.
4.8 Economic Analysis
The unit production cost of the product is outlined in Table 6 and is based on the cost of the parts
and materials used for building. Table 6 combines the cost of materials and parts with the cost of
labor, tooling, development cost and overhead costs which were estimated by the team. The bill
of materials required for mass production is included in appendix B Table 2. In addition the
breakdown of material cost per unit can be found in appendix B Table 1.
Table 6 Production Cost

Production Component
Parts
Materials
Tooling
Labor
Development Cost
Overhead
Total Cost

Unit Cost
$21.69
$4.1
$1
$4
$0.05
$3
$33.84

Annual Cost
$2169000
$410000
$100000
$400000
$5000
$300000
$3384000

The cost of producing a unit product is $33.84. A reasonable 20% markup at each stage of
distribution was decided by the team, resulting in the selling price of $48.73. This selling price is
within the acceptable range that customers are willing to pay. The net present value (NPV) for
this product represents the present worth of the total costs and profits enquired in production.
The NPV analysis included inputs of ramp-up costs as well as marketing and support costs, all
estimated by the team. The NPV for the product is $670,140 over a four year period at an annual
discount rate of 10%. The positive NPV indicates that indeed the project is a profitable venture.
The full NPV analysis can be found in appendix C.
4.9 Construction Process of Beta Prototype
Construction of the beta prototype began with the design of the housing components on Solid
Works. The components were laser cut out of inch thick acrylic and then drilled to add any
necessary holes. The bottom plate had a 3/8 diameter hole drilled through it to allow for the
fluid flow to exit the device. The sidewall and dividing wall had a diameter hole cut into it
to allow for the bearings to be glued in. The motor holding walls had a 0.95 diameter hole cut
out to allow for the motor to rest in place. The holes of the dividing walls were all designed after
precise calculations were completed to confirm that the shafts, discs, and bearings were aligned.
The discs that hold the magnets in place were made by laser cutting four, one-sixteenth inch
thick circles out of acrylic. Each disc was made of two circles glued together. One circle had
holes cut into it to hold to magnets in place while the other circle was solid and gave the magnets
a base to be glued to. Each disc has two magnets, one north facing and one south facing, to
couple with the other disc and ensure their motions remain in synch (see Figure 7).
10

Figure 7
Nozzle

Disc to
hold
magnets

The turbine was laser cut out of thick acrylic and then drilled to fit on the shaft. The turbine
and the bearings were then glued onto a stainless steel shaft of diameter. The bearings were
then glued into their respective walls and a magnetic disc was glued to the end of the shaft. The
motor was placed in the walls designed to hold it and a magnetic disc was glue to the end of the
shaft. The device was assembled by gluing the walls together to create a water proof seal and
split the device into separate compartments. The top plate of the device was then laser cut out of
thick acrylic and a hole was drilled in the spot that would maximize the turbines efficiency.
A nozzle with 3/8 pipe thread and a 3/16 diameter outlet hole was placed in the drilled hole
and secured by surrounding the outlet of the nozzle with rubber tubing that had a larger diameter
than the drilled hole the nozzle was placed through (see Figure 7). The top plate was then glued
to the other walls to finalize the waterproofing. Connecting a wire to the positive terminal of the
motor and the center terminal of the switch completed the first step of wiring. Then a wire was
connected from a side terminal of the switch to the center terminal of the jack. Lastly a wire was
connected from the sleeve shunt terminal (bottom left terminal if looking at the jack with the
center terminal oriented above the other two) to the negative terminal of the dc motor to
complete the circuit and also the construction of the device. Photos of the completed prototype
can be found in appendix F.
5. Testing
5.1 Test Plan
Although many tests were completed on the alpha prototype, the new modified design for the
beta prototype had to be tested again in order to see how much the improvements helped. The
plan was to test how the new turbine and the magnetic coupling system would work under the
flow of water before wiring up the resistor and testing the voltage. After making adjustments
based on the results of this, the device would be connected to a sink faucet and the voltage
generated by the motor would be measured over a resistor.
5.2 Test Results and Discussion of Results
The test results were not very satisfying. The team ran into problems with the construction of the
prototype. The parts that were ordered were delivered later than expected therefore the prototype
was not built on time. In addition to the delay, the faucet was damaged so the team was not able
to do any additional proper testing before the formal testing date with the professor. The day of
the testing was first trial of the beta prototype as a result. The beta prototype was hooked up to
the inlet adapter of the faucet. The wires, which were connected to the motors output, were
11

hooked up to a multimeter. The multimeter was connected to a 10 Ohm resistor. Once, the faucet
was turned on the multimeter would give the voltage reading from the motor. The predicted
performance was 4.99 V (sect. 4.3). However, with the prototype having its first testing, the beta
prototype got up to 2.3V at the maximum flow. At first, the multimeter was giving a reading of
0.7-1.0V. The reason for the low readings was because the water was filling up where the turbine
was located. Once the water was filled up to the turbine, the water made the turbine harder to
spin which led the motor to have low RPMs. However, when the team tested with the faucet
flowing at its maximum, the multimeter gave a reading of 2.3V. If the outflow of the prototype
was the same as the inflow of the water, the motor may have performed as the team had
predicted in the prior calculations.
6. Conclusion and Recommendations
6.1 Project Summary
The Eco illuminator is a product that will surely capture the eye of the beholder with its
luminescence. Its design is simple but its effect is soothing. As blue light is known to be the
color of light that promotes a calming effect, The Eco illuminator makes use of this principle
such that the blue reflective glass reflects the blue LED light to the corners of the room, to create
a relaxing atmosphere. The attachment point is made of metal which greatly reduces the
possibility of cracking during installment which proved by our customer preference research, to
be highly dissatisfactory. The unit price of production is currently $33.84 and the selling price is
$48.73 which is within the affordable range for the customers. The NPV comes out to $670,140
which indicates that production will be an economically reasonable venture.
6.2 Recommendations
After testing of the beta/final prototype was complete, the team noticed changes that should be
made to improve the quality and efficiency of the Eco illuminator. The main problem of the
system is that water does not drain out as fast as is needed to ensure the turbine does not get
backed up. This will be solved by further testing to find the optimum location for the nozzle in
accordance to the turbine and the outlet hole. Another solution is to create a sloped surface that
will lead all the water into the exit hole instead of the flat plate that was used in the beta
prototype. This slope will create a funnel that will direct all the water into one spot instead of
letting it pool at the bottom of the system. Another recommendation is to completely change the
shape of the housing into a tube shape instead of the bulky box shape that was produced. The
tube will encircle the turbine and have holes cut for the inlet and outlet flow. The tube will cycle
all water into the bottom exit hole and send it out of the system at a higher flow rate. We know
that if our system does not have to worry about the issue of draining water that it is capable of
producing at least 2.3 volts across the 10 ohm resistor, so by solving the problem of water
collecting in the system, the efficiency and appeal of the product can be greatly increased. The
other problem facing the system is the seals created by the super glue are easily broken by the
force of the flowing water leading to water flooding into all chambers of the product. To solve
this problem silicon could be used to seal the walls of the product instead of super glue. The
silicon will create a much tighter and more water proof seal than the super glue. By sealing the
12

walls with silicon it ensures that even if water does pile up and eventually flood the compartment
with the turbine, the water will not spread to other compartments of the system and the motor
will remain dry. As long as the motor stays dry the system can be used as many times as needed
even if water backs up.
6.3 Lessons Learned
As the team progressed through the stages of the development process, more and more was
learned about design methodology and product development. We learned how the steps of the
product development process must be completed in order to produce a successful project.
Starting with the planning phase, we learned that it is never too early to get started working. The
group learned how to work around the schedules of each member while also making sure that an
adequate amount of time could be devoted to the project every week. In the concept
development stage we learned that this stage may just be the most important stage of all.
Creating a successful concept will lead to a much smoother product development process,
especially in the later stages. The more time that is spent developing concepts and generating
ideas, the less problems that are likely to arise in the future. We learned that no idea is a bad
idea, and that even the craziest concepts can have unique aspects, which can be incorporated into
the final project. When the team reached the design phases we learned that it is vital to establish
a set of base specifications that the rest of the project can then be designed around. For example
it is impossible to know what bearings to purchase for the motor shaft if the motor has not been
chosen yet. We also learned that in the real world it takes time for parts to arrive and the sooner
an order for parts can be made the better. While the construction of the product was being
completed, the group learned how to best utilize the strengths of each group member to ensure
that the best possible product was made. When testing the product we learned not to be afraid of
starting from scratch if it meant that we could get better performance out of our system. This
project and course as a whole has taught us how to develop a product from the first stages, to the
production of the final model, and then take that model and market it in a way that will generate
interest in the product and eventually a profit when the product is taken to market.
7. References
[1] Cook, David. DC Motors. 1st. 1. Apress, 2010. 223-254. Print.
[2] Gorse, Christopher, David Johnston, and Martin Pritchard.A Dictionary of Construction,
Surveying and Civil Engineering$ A Dictionary of Construction, Surveying and Civil
Engineering. 1st. 1. Oxford University Press, 2013. Web.
[3] Cross-flow Turbine. 2011. Graphic. Tanaka HydropowerWeb. 20 Mar 2014.
[4] Pelton wheel. 2012. Graphic. Indian Institute of Technology, Kanpur. Web. 20 Mar 2014.
[5] Han, Jin Woo. Mini Hydro Turbine. 2009. Photograph. Yanko DesignWeb. 20 Mar 2014.
[6] Micro hydro generator. 2013. Photograph. SeeedStudioWeb. 20 Mar 2014
[7] "International." Welcome to the IEC. N.p., n.d. Web. 05 Apr. 2014.
[8] "SERVICES." UL. N.p., n.d. Web. 05 Apr. 2014.
13

Appendix A
Table A.1 Member Roles

Member
James
McDonough

Role
Product
Assembly

Daniel
Peterson

Lead
Programmer/
Recorder

Daniel Cho

CAD
Designer

Damiete
Horsfall

Data
Calculations/
Analysis

Description
Determines which materials need to be
used in order to make product assembly
as routine as possible.
Takes detailed meeting minutes and
communicates with team members after
meetings to determine future tasks for
each member to complete.
Creates detailed SolidWorks models of
the product to allow for better
visualization of the final product by all
group members.
Records data measurements from
experiments and performs calculations
to better predict results.

Qualifications
Machining,
Communication
Computer
Programming,
Organization,
Preparation
SolidWorks,
Attention to Detail

Skilled with Microsoft

Excel, Excellent Math
Skills

Figure A.1 Gantt Chart

14

Figure A2 Risk Analysis

Risk

Risk Level

Actions to Minimize Risk

Work with customers to

estimate cost and effiency
predictions.
Change in Customer Needs

Low
Involve customers
throughout the product
development process and
encourage feedback.

Poor Turbine Performance

Delays in Learning Factory

Production

Water Damage to the Motor

Moderate

Place a large amount of time

and effort into ensuring that
the turbine is designed
correctly.

Moderate

Complete all tasks related to

the machining of a custom
part early enough to allow
ample time for
manufacturing.

High

Propertly design water

protection features of
product to ensure minimal
chance of water damage to
the motor.

15

Appendix B
Table B.1 Component Cost

Component
Motor
Bearings
Acrylic Sheets
Switch
Nozzle
Magnets
LEDs
Shaft
Wires

Individual Cost Cost per Unit Vendor

$3.49
$2.25 Jameco
$5
$10 McMaster Carr
3
$4 McMaster Carr
$0.118/in
$1.50
$1.50 Jameco
$1.50
$1.50 McMaster Carr
$3.32
$3.32 Jameco
$1.12
$1.12 Jameco
$0.67/in
$2 McMaster Carr
$0.05/in
$0.10 Jameco
$25.79

Part #
174693
57177K347
8560K264
76523
5346K24
2181327
2006764
1257K83
36856

Table B.2 Component Quantity

Description

Quantity per unit

Motor
Bearings
Acrylic Sheets
Switch
Nozzle
Magnets
LEDs
Shaft
Wires

1
2
34 in3
1
1
12
8
3 in
2 in

Quantity for
mass production
100000
200000
3400000in3
100000
100000
1200000
800000
300000in
200000in

Table B.3 Motor Selection

motor
nominal voltage (volts)
voltage range (volts)
current at max efficiency (A)
torque at max efficiency (g-cm)
speed at max efficiency (RPM)
shaft diameter (inches)
shaft length (inches)
motor height (inches)
motor length (inches)
motor width (inches)
load (R=V/I ; ohms)
part number

2.5
24
12
12
12
1--6 12--30
9--14
3--12
9--30
0.06
0.126
0.015
0.17
0.35
3.3
4.54
85.06
187
44.5
2190
3538
3000
4840
4930
0.078
0.09
0.08
0.078
0.09
0.7
0.315
0.71
0.346
0.45
0.962
1.5
1.19
1.213
1.3
0.712
1.15
0.97
0.96
1.09
0.712
1.15
0.97
96
1.09
41.6667 190.476
800 70.5882 34.2857
238465 2120461 174693 238473 206949

16

Appendix C
Table C.1 NPV Analysis
($ values in thousands)
Period

Q1
0

development cost
ramp-up cost
marketing and support cost
production cost
production volume
unit production cost
sales revenue
sales volume
unit price

-115

period cash flow

PV Year
Project NPV

($ values in thousands)
Period
development cost
ramp-up cost
marketing and support cost
production cost
production volume
unit production cost
sales revenue
sales volume
unit price
period cash flow
PV Year

Q2

Year 1
Q3
1
-115

-115
-115
-115 -112.20
670.14

Q1

Q2
8

171.5
140.76

171.5
137.32

Q1

-115

-115
-100

-115
-109.46

Year 3
Q3
9

-200
-200
-846
-846
25000
25000
-0.0338 -0.0338
1217.5 1217.5
25000
25000
0.0487 0.0487

Q4

-200
-846
25000
-0.0338
1217.5
25000
0.0487
171.5
133.98

-100
-200

Q1
11

-200
-200
-846
-846
25000
25000
-0.0338 -0.0338
1217.5 1217.5
25000
25000
0.0487 0.0487
171.5
130.71

171.5
127.52

Q4
7

-200
-846
25000
-0.0338
1217.5
25000
0.0487

-200
-846
25000
-0.0338
1217.5
25000
0.0487

-200
-846
25000
-0.0338
1217.5
25000
0.0487

171.5
151.58

171.5
147.88

171.5
144.28

Q2
12

Year 2
Q3
5

-215
-300
-199.65 -271.79

Q4
10

Q2

Year 4
Q3
13

Q4
14

15

-200
-846
25000
-0.0338
1217.5
25000
0.0487

-200
-846
25000
-0.0338
1217.5
25000
0.0487

-200
-846
25000
-0.0338
1217.5
25000
0.0487

171.5
124.41

171.5
121.38

171.5
118.41

17

Appendix D

Table D.1

Safety Regulation
IEC 60038
IEC 60335

The Regulation
Standard Voltages
Safety of electrical household appliances

UL 2778
UL 8750

Products Made From Recycled Plastic

Standard for Light Emitting Diode (LED) Equipment for Use in Lighting
Products
Table D.2

IEC Voltage Range

AC

DC

Risk

High Voltage

> 1000 Vrms

> 1500 V

Electrical Arcing

Low Voltage

50-1000 Vrms 120-15000 V

Extra-Low Voltage

< 50 Vrms

< 120 V

Electrical Shock
Low Risk

18

Appendix E: Detailed Drawings

Figure E.1

19

Figure E.2

20

Figure E.3

21

Figure E.4

22

Appendix F
Figure F.1

Figure F.2

23

Figure F.3

Figure F.4

24

Appendix G
Dan Petersons Contributions
For this final report, my primary contribution was to update and fix all sections of our previous
documents that were out dated or that had be corrected by the instructor. In addition, I compiled
and edited all of the new sections and formatted the document. In addition I completed the
concept development portion of the document for the project proposal and the theoretical
analysis and material selection sections of the detailed design report.
Damiete Samuel-Horsfalls Contributions
For this document I was in charge of writing the conclusion section that discussed the economic
viability of the document as well as the summary of the project. I also completed the customer
needs and QFD section previously for the project proposal as well as the as well as the NPV
analysis and bill of materials sections of the DDR.
James McDonoughs Contributions
I was responsible for adding the recommendation and lessons learned sections to this document
as well as the construction process. For the project proposal I was also in charge of the
introduction section as well as formatting and for the DDR I completed the overall description
and detailed drawing sections of the document, including much of the work done in SolidWorks.
Daniel Chos Contributions
For the final report I was in charge of the testing plans and results sections. I was also in charge
of the fabrication process, industrial design, and safety sections of this document for the Detailed
Design Report and I completed the system level design segment for the project proposal.
By signing this document we all attest that it provides an accurate representation of our
individual efforts in the completion of this work.
Date: 5/5/2014
Member Name Printed:

Daniel Peterson

Daniel Peterson
Signature:_____________________________
Member Name Printed:

James McDonough

James McDonough
Signature:_____________________________
Member Name Printed:

Daniel Cho

Daniel Cho
Signature:_____________________________
Member Name Printed:

Damiete Horsfall

Damiete Horsfall
Signature:_____________________________
25