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

� 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

� Projector issues with battery recharging

� Solar panels

� Existing hand crank generators

� Problems with existing models

To research, design, build and test a

prototype of a multifunctional human

powered generator that is more

ergonomically efficient than currently

available models.

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 mAh lithium-ion battery

in 2 hours

Voltage/

Current

Multimeter

Protect batteries from over voltage and over

current

Integrate small solar panel

Indicator that battery is fully charged

Be capable of connecting to different sized

batteries

Portable – easy to transport by single individual

Have an onboard battery

Easy to operate

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

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

Voltage 12V

Current 125 mAh Max

Power 1.5 W

Dimensions 13.75 x 4.75 x .5“

Weight 1.6 lb

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: ≥18.2V DC

Lifetime: ≥3000h

Made of 2 2200mAh cylindrical 18650 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

� 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

Drive Shaft

Flywheel

Analysis of

drive shaft with

4x rated

loading of

generator.

Even under

extreme

circumstances,

the shaft

experiences

stress well

below it’s yield

point.

� Case side with load

incident on drive shaft

mount section.

� Load is 2 x the

maximum human

loading on the device

Diodes: 1N4001

Capacitors: 10 uF

Resistor 2 : 56k Ohm

Resistor 1: 82k Ohm

Voltage Regulator: 7805

D D D

DD D

C

V B

V A

Dynamo

V C

V -

V +

Bridge Rectifier Circuit

5V

Regulator

C C

V +

V -

USB

Port

D1

Vcc

Internal

Gnd

D2

USB Port Circuit

R1 R1

R2

R2

Data Lines at 2 V

Capacitors: 10 uF

LM 393: Voltage Comparator

LM 317 Regulator Formula:

1.25( 1 + 1370/240) Volts = 8.4 Volts

Adjustable Voltage Regulator

C C

V +

V -

Battery Voltage Reduction Circuit

240 Ohm

1370 Ohm

V +

V -

8.4 V

LM 317

1M Ohm

2.2k Ohm

10k Ohm

1 Ohm

1N5819

3

2

1

84

-

+

LM 393A

1k Ohm

D2

LED

V +

V -

Battery Charging Indicator Circuit

V +

V -

Charging Source

Battery

3

2

1

84

-

+

LM393

C

1370 Ohm1

240 Ohm

LM 317

D D D

D D D

C

V C

V B

V A

Dynamo

V +

V +

V -

Solar Panel

Diodes: 1N4001

Resistor 1: 82k Ohm

Capacitors: 10 uF

Voltage Regulator: 7805

Resistor 2 : 56k Ohm

5V

Regulator

C

V -

V +

USB

Port

D1

Vcc

Gnd

D2

Internal

R1 R1

R2 R2

Data Lines at 2 V

1M Ohm

2.2k Ohm

10k Ohm

1 Ohm

1N5819

1k Ohm

LED

V -

V +

7.4 V Battery

� Multimeter attached to

leads from projector

battery.

� Monitors voltage at

ten minute intervals

over the course of the

charge cycle.

Part Projected

Cost

Fasteners (Screws, Nuts

Bolts, Washers)

$33.20

Electrical Components $24.61

Solar Panels $16.08

Plastic Components $31.95

Batteries $21.95

Mechanical Components $111.51

Misc. $65.97

Total Cost (per prototype) $305.27

Table 9.3- Funding SourcesSource Amount

One Media Player per Teacher $1,500.00

Associated Students Sustainability

Fund

$3,500.00

Total Funding for Project $5,000.00

Table 9.2 Hours

Name Total

Hours

Total Cost Per Person

Bill 112.5 $14,647.50

Chris 119.5 $13,472.43

Bader 105.5 $11,894.07

Ahmed 106.5 $12,006.81

Alex 111 $12,514.14Total

Cost $64,534.95

� 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

� 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.