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AZ MESA - Engr Design Process

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Michael Guyer

on 19 September 2014

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Transcript of AZ MESA - Engr Design Process

Design Process Extended
Materials: Wooden dowels, 1/2 inch, wood glue, photo frame nails
We hoped that wood dowels would be strong enough to support the wheel and the glue reinforced the nails
We dont expect water contact to affect the frame much if at all
The power generator (alternator) will be in the back connected by a belt of some type to the main wheel: string, dental floss, or maybe rubber band(s)
Axle and Arms
Materials: Large wood popsicle sticks, glue,
wire,rubber bands, sewing spool, paper clips
We need strength and minimum weigh to maximize rotation speed
Gear System
Motor Block
With some interesting crafting popsicle sticks we made a nice frame for the alternator.
We assembled it with popsicle sticks and lots of glue
Like this, it is VERY accessible to us for repairs/modifications and judges during testing
Final Design
Engineering Design Process
Photos Courtesy of Google Images/Michael Guyer
The Water Wheel
I. Explore
Issue: Rubber and plastic will
stick --> Resistance on axle
Issue: Not very strong
One of our team members likes to ride a bike, which caused us to think about the gears on a bike and how certain gears allow for more speed while others less work. Our goal was to try to find a balance between a "big" gear and a "little" gear to make our alternator spin at max speed but with least effort
Materials: 2 cd's, staples, lighter, pliers, hot glue set, scissors, spool
Large Front
Issues & Known Problems
Broken Pieces
High tension of Rubber Band
Slipping of small rear gear
Splits in wood
Poor choice of "buckets"
Overall small size
Designed by: Michael Guyer,
Arizona MESA
What do you....
Think about?
Learn in school?
Hear about?
Funds of Knowledge is the idea that we all have knowledge about the world around us from our own unique experiences. By thinking about what you know, you can solve engineering design problems you may face.
The Engineering Design Process
I. Explore
II. Design
III. Test
IV. Repeat!
Set research & design goals
Set research & design timeline
Choose Variables to optimize
Build a new version
Draw & photograph version
Make a testing process
Make hypothesis about results
Gather Data
Note the good and bad in the design
Reflect on the team's process
Set research & design goals
Set research & design timeline

How can you add these things to your design?
II. Design
Choose Variables to optimize
Build a new version
Draw & photograph version

Choose Variables to optimize
Build a new version
Draw & photograph the new version
Items our team is optimizing for:
-Maximize RPM (revolutions per minute) of
rear wheel (the alternator)
-Minimize friction/resistance of main wheel
-Maximize strength and durability
-Minimize cost
Issues we expect to encounter:
-Water proofing: water may damage the wheel
-Electricity & Water: might this cause a misreading of the power output if wet?
-Structure: What kinds of glues are strong enough to hold the wheel and are water proof?
-Availability of materials
Nails marking holes for drilling so the wood does not split
Wood glue reinforcement
on nails
We thought by scoring the wood we could better secure the alternator with string or wire
Some of our parts broke during the assembly of the arms due to wood splits. As a team we decided that these damages were not important enough to come up with a new design and due to our time frame we would let it be for at least this trial.
We decided on this style of assembly because it allows mounting to the dowel that will serve as our main axel
We learned nails may
split the delicate wood
glue is probably our best
option due to limited
resources and time
The spool will "buffer" the main arms so they dont shift around when hit by water. A bent paper clip makes a good lock on top.
We alto tried rubber bands to hold the axle in place but this caused some problems for us
Here we are also messing with dental floss as a belt and rubber bands
Punched holes in the cd's by heating up thumbtacks or wire with a lighter and pushing through.
With small peaces of wire through each hole, we hope to make a large front gear. The belt material (still being debated) will go in between the cd's
Another break!
Dental floss with knots. Without knots, its too slipery and wont catch on the wires of the gear
Same kind of idea for the rear wheel
We tried making it out of wood, but it was a disaster (top left)
We cut pieces of another cd and tried with a 3-point gear and a 6 point gear shaped just by carefully cutting
Spool will be used to hold this gear in place
A standard alternator/generator
After finally giving up on the dental floss idea, we went with a rubber band
Make a testing process
Make hypothesis about results
Gather Data
Note the good and bad in the design
Reflect on the team's process
III. Test
Testing Process
Measuring Voltage Output
Each Trial
-Team Member 1 - Water flow
-water speed/amount
-Team Member 2 - Announcements
-voltage per time increment
-end of time
-any issues (etc)
-Team Member 3 - Record data
-voltage per time increment
Each member gives their view on
what went well/wrong and any
suggestions to alter design
Prepare to plan design change

This is how we did it,
this is NOT how you
or MUST do it.
Hypothesis and Data Gathering
Trial 1
Voltage output
max: 30volts
mean: 20volts
5 gallons of water
Variable speeds:
Voltage output
max: 4
mean: 2
total: 63

This shocked us because we had such high hopes for the project. In future tests we will adjust our hypothesis and increase the water flow
We recorded the "total" as the sum of the volts we recorded to compare how much power is being made over all among our trials.
Trial 1
Trial 2 & 3
Trial 2 & 3
An increase of water flow will increase the power output
Voltage output
max: 15volts
mean: 10volts
5 gallons of water
Flow speed: "medium"
The increase in water flow did raise the power output, as was expected, however by hardly anything. The flow will be increased again
Trial 4 & 5
Another increase of water flow will reach our predicted power output
Voltage output
max: 16volts
mean: 11volts
5 gallons of water
Flow speed: "full"
Trial 4 & 5
The increase in water output finally did reach a number we predicted but only the max. The average is still very low. The team is excited to try another where we try to max out the motor with 5 minutes of water regardless of volume.
Custom Trial
In this trial, the goal is to max out the output voltage.
The more increase of water flow, the more power output. Perhaps there is a limit, but we probably wont reach it.
Unlimited water
5 minutes
Flow speed: garden hose on max
-Our predictions for output voltage were much worse than we though realistic. Perhaps this is a flaw in our measuring device or we simply cannot get enough speed from our main wheel. We need to make some modifications to allow the wheels to spin faster with less effort and thus increase our power output
- It is more beneficial to increase the water flow because we noticed the "total voltage" value continued to rise even though there were fewer and fewer instances in each of the trials.
-Our Custom Trial confirmed this. We produced much more power when more water flow was applied.

In your own words, state the design problem, its success criteria and constraints
What is your goal in doing this project?
What is the criteria by which you are being assessed?
What are the limitations to which you must adhere in order to complete your task?

Our team's goal in building this water wheel is to successfully construct a machine that will generate a maximum amount of voltage from a small generator/alternator.
Our team is being assessed on voltage production, cost of building the wheel, explanations of our various designs and prototypes and of our testing trials in our Engineering Design Notebook, and our effectiveness as a team.
We are limited by the competition spec sheet to a specific size of ___ x ___ x ___ (units), as well as a total cost of $____, and we are allowed/disallowed to use the following materials:
1)---- 2)---- 3)---- 4)---- 5)---- 6)---- 7)etc

Statement of Purpose & Design Criteria
An example water wheel with animation
An example of animated gears
Full transcript