RainfallPoweredBatteryCharger

By

N.DarrickSantaMaria
BassamM.Gorgi
EtayLuz

ECE345,SENIORDESIGNPROJECT

SUMMER2004

TA:GregSorenson

August2,2004

ProjectNo.2
 ABSTRACT

ThispaperpresentsthedesignandfunctionalcharacteroftheRainfallPoweredBatteryCharger
alongwithverificationandtestingprocedures.Themachinedrawsonrainfallfromresidential
gutterstodriveapermanentmagnetDCmotorthatistweakedtochargea12Vleadacidbattery.
Rainfallisimplementedasapressingforcetoturnawaterturbinethatdrivestheshaftofthe
motor.Agearboxisusedtooptimizetheturningmechanismbetweentheturbineandthemotor.
Themotorisemployedasageneratortoproducea2.516voltageoutput.Theintegratedcircuit
convertsthatoutputvoltagetoapresentof12V,aformsuitableforthechargingofabattery.
After9operatinghoursofquarterinchrainfall,thebatteryischargedto36wattsofpower.

ii
 TABLEOFCONTENTS

1. INTRODUCTION....................................................................................................................1
1.1PerformanceSpecification..................................................................................................1
1.2DesignBlockDiagram.......................................................................................................1
1.3Subprojects.........................................................................................................................2

2. DESIGNPROCEDURE...........................................................................................................3
2.1DesignDecisions................................................................................................................3
2.1.1WaterCollection........................................................................................................3
2.1.2WaterTurbine............................................................................................................3
2.1.3DCMotor..................................................................................................................4
2.1.4IntegratedCircuit.......................................................................................................4
2.1.5Battery.......................................................................................................................4
2.2ToolsUsed..........................................................................................................................5
2.2.1ElectricalMeasuringDevices...................................................................................5

3. DCtoDCBootstrappedConverter...........................................................................................6
3.1IntegratedCircuitComponents...........................................................................................6
3.2MAX1771Schematics........................................................................................................7
3.3CircuitSchematics..............................................................................................................8

4. DESIGNVERIFICATION.......................................................................................................9
4.1Testing................................................................................................................................9
4.1.1FaucetCalibrations....................................................................................................9
4.1.2TurbineOptimization..............................................................................................10
4.1.3DCMotorTests.......................................................................................................11
4.1.4IntegratedCircuitVerification................................................................................12
4.2Conclusion........................................................................................................................14

5. COST......................................................................................................................................15
5.1Parts..................................................................................................................................15
5.2Labor.................................................................................................................................16
5.3TotalCost..........................................................................................................................16

6. CONCLUSIONS....................................................................................................................17

APPENDIXA:PowerCalculations.......................................................................................18
APPENDIXB:Schematics.....................................................................................................19

iii
REFERENCES.......................................................................................................................20

iv
 1. INTRODUCTION

TheRainfallPoweredBatteryChargerisaprojectthataimstoharnessnaturalsourcesofenergy.The
projectincorporatesvariousengineeringdisciplinesincludingpowerelectronics,powersystems,and
electricmachinery.Theprojectissignificantasitbroadensthedevelopmentofalternativesourcesof
power.

Thegoalofthisprojectistoproduceandstoreasignificantquantityofenergytopowerlowvoltage
appliancessuchasfloodlight,foglights,etc.

The Rainfall PoweredBattery Charger collects rainfall fromresidential gutters thatdispense intoa
homemadewaterspunturbinethatdrivesaDCmotor.Themotorisdrivenasageneratorthatoutputsa
voltagethatissteppeduptoasteady12Voltsatwhichthebatterycancharge.

OurRainfallChargerwillprovideseveralbenefitstothecustomer:
ReliableBatteryCharger
Freesourceofenergy
Nomanualoversightnecessary
Lowmaintenancecosts

1.1 PerformanceSpecification

Themachineiscompatiblewithawiderangeofrainfallvolumes(.03in/hour6in/hour).Ahomemade
waterturbinespinsastherainfallsetsitsbladesinmotion.TheturbinerotatesaDCpermanentmagnet
motorwiththeaidofamechanicalgear.Dependingonthequantityofrainfall,approximately2V13V
isgeneratedattheterminalsofthemotor.ADCDCconverterstepsupthevaryinginputvoltagetoa
constant12VDCoutput.Thecontrollerissetinabootstrappedconfigurationthateliminatestheneed
forexternalpowersupply.Energyisstoredina12V,3AHleadacidbattery.Thehomemadeturbineis
designedtooperateat50%efficiency.BoththeDCconverterandthemotorare90%efficientproviding
anoverall40%efficiencyoftransitionbetweenthemechanicalandelectricalmodesoftheapparatus.

1.2 Design BlockDiagram

Water Battery

DC/DC
Turbine Converter

Gear 1 Motor
 ......................................................................................

1.3 Subprojects

TheRainfallPoweredBatteryChargerisdividedinto3distinctsubprojects:watercollection,
mechanicaldevices,andelectricaldevices.

WaterCollectionconsistsof2plastic10residentialgutters,connectedinserieswithaguttercoupler.
Theseguttersareattachedtotheoutsideofabuilding(i.e.afireescape).Fortestingpurposes,ahose
connectedtoacalibratedfaucetisthesourceofwater,simulatingwaterrainfallduringarainyday.

MechanicalDevicesconsistsoftheturbine,thegearandthemotor.Theturbineisconstructedfroman
ordinarybicyclewheel,andPVCcapsthatareimplementedaspropellerblades.Ashaftandagearbox
bridgetheturbineandthemotortogether.Thegearratioisdeterminedbytheratedspeedofthemotor
andtheaveragespinningspeedoftheturbine.ThemotorisaPermanentMagnetDCmotorcapableof
generatingupwardsof30Wattsatlowtorque.

ElectricalDevicesconsistsoftheDCtoDCconverterandthebattery.TheDCconvertertransforms
theunsteadyinputDCvoltagetoaconstant12VDCoutput.Itispoweredfromtheinputvoltage,but
usesminimalpowerforitsoperation.Theconverterchargesaleadacidbatterythatprovidesupto36
WattHoursofpower.

2
 2.DESIGNPROCEDURE

2.1DesignDecisions

ThissectionoutlinesthedetaileddesignoftheRainfallPoweredBatteryCharger.Theselectionofthe
variousdesigncomponentsisexpoundedonwithrespecttotheirpropertiesanddesignatedfunction.

2.1.1DesignDecisions:WaterCollection

Wateristhedrivingforceoftheturbineaswellastheenergysourceofthedeviceapparatus.Itcomes
intheformofrainfallthatisdispensedbystandardhouseholdgutters.Thequantityofwateravailable
forturningtheturbineisdirectlyrelatedtothefinaloutputpowerofthemachine.Totalpoweroutput
from the falling water can be determined using equations (21), (22). All calculations for these
equationscanbefoundinAppendixA.

Water collected Rooftop squareinches Waterfall in / hour Collection time Collection efficiency (2
1)
Energy fromwater Waterflowliters / sec waterweight fallmeters gravity (22)

2.1.2DesignDecisions:Turbine,Shaft,andGearBox

Ahomemade device, the turbineisdesignedtocapturekinetic powerfromthefalling waterinan

optimalfashion.Itsdesignismostsimilartothatofawaterwheelturbine.Lightmeasuringcupsare
attachedtotherimofawheelandactasthebladesoftheturbine(Fig2.1).Theycapturethewaterasit
isdeliveredfromthegutterandprovidetherotationalforcenecessarytoturntheturbine.

3

(a) Straight On (b) Angled View

Figure2.1Turbine(includingdimensions)asseenfrom(a)straightonand(b)angledview

Someconsiderationsassociatedwiththedesignofthedevicearethenumberofcupsfastenedaroundthe
wheel,theradiusofthewheel,aswellasthedimensionsofthecups.Carefulexperimentationand
analysisisdevotedtoeachofthesepointswithrespecttotheirimpactontheoperationoftheturbine.

Asshallbeexplainedinsection4,theRPMoftheturbineismaximizedwhenaquantityoftwentycups
arefastenedaroundthewheeloftheturbine.Eachcuphasacapacityof130mLandaradiusof3.25cm
(Fig2.2).Thetorqueontheturbinefromthefallingwatercanbedeterminedusingequation(23)and
(24).AllthecalculationsfromtheseequationscanbefoundinAppendixB

(a) Side View (b) Top View

Figure2.2Cup(includingdimensions)asseenfrom(a)sideviewand(b)topview.

1
TotalForce onTurbine mass water velocity water mass water gravity height
2 (23)
TotalTorqu eonTurbine TotalForce onTurbine (radiusturbine radiuscup ) (24)

4
Theshaftandgearboxbridgetheturbineandthemotortogether.Theshaftextendsfromtheturning
axelofthewheeltothechainofthegearbox.Thegearboxhasa3:1ratio,meaningthattheshaftofthe
motorspinsatthreetimesthespeedoftheturbine.Whiletherearefrictionalenergylossesassociated
withthegearbox,itisanecessarycomponentforoptimaloperationofthemachine.

2.1.3DesignDecisions:DCMotor

ApermanentmagnetDCgearmotorisimplementedasavoltagegenerator.Themotorisratedat90
Voltsandturnsat1750RPM.Therotorexperiencesalternatingfieldsthatinduceacurrentintherotor
windings and transform the rotational energy into electrical energy. Depending on the volume of
rainfall,thegeneratoroutputsvoltagesintherangeof016V.

2.1.4DesignDecisions:IntegratedCircuit

Anintegralaspectofthedesign,theintegratedcircuitisthemostintricateandinvolvedcomponentof
the RainfallPoweredBatteryCharger. TheICtransformsthepowerfromthemotorgeneratorintoa
formthatmaybeusedtochargethebattery.Section3dealswiththeprecisedetailsthatpertaintothe
operationanddesignoftheIC.Section4elucidatesallofthetestsandverificationsthatwereconducted
fortheIC.

Theintegratedcircuitstepsupthemotorgeneratedvoltagefromarangeof2.516Voltstoapresentof
12Volts.Thecircuitryimplementedforthepurposesofthismachineisabootstrappedconfiguration.
Onlyaminimalpercentageoftheinputcurrentisrequiredtopowerthedevice.TheICfunctionswith
90%efficiencyandensuresasmoothtransitionofenergyfromthemotorgeneratortothebatterystorage
unit.

2.1.5DesignDecisions:Battery

A12VDCleadacidbatteryat3AHisusedtostoretheenergythatthemachinegenerates.Thebattery
ischargedatarateof4Wattsperhourtakingupto9hourstofullycharge.Itmaybeusedtopower
sidewalklighting,emergencyphones,andotherlowvoltagehouseholdappliances.

Itmaybeappropriatetonoteatthisjunctionthatathresholdvoltageof12Voltsisrequiredtocharge
thebattery.IftheICdoesnotoutputthisamount,themachineisconsideredtobefunctionallyidleand
thebatterydoesnotcharge

2.2ToolsUsed

Thetoolsthatwereusedinthisprojectservedintherecordingandcalibrationprocessesofthevarious
componentsofthemachine.

2.2.1ToolsUsed:ElectricalMeasuringDevices

Thefollowingdeviceswereusedinthetestingandverificationofthisproject:

ValhallaScientificmodel2101RMScoltamperewattmeterandValhallaScientificmodel2111
RMSvoltamperepowerfactorwattmeter.
5
 Flukedualdisplaymillimeter
Powerresistor1.5,78W
TektronixmodelTDS3034digitaloscilloscopewithTCP/IPinterfaces.
TektronixmodelTCP202currentprobeandP5205differentialvoltageprobe.
TektronixmodelTM504instrumentpluginunitwithmillimeters,functiongenerator,andpower
supply.
KenwoodPD5610ADpowersupply,056V,010A.
Dualpowersupplies,12Vand+5V

3.DESIGNDETAILS

3.1IntegratedCircuitComponents

3.1.1MAX1771chip

TheMAX1771isastepupconverterthatacceptsinputvoltagesaslowas2Voltsand30mAandsteps
themuptoasteady12V.Itfunctionswith90%efficiencyrequiringaslittleas110uAofsupply
currentandisidealforbatterypoweredapplications.ThefunctionaldiagramoftheMAX1771chip,
pinlocationsandpinconfigurationcanbeseenonFigures3.2,3.3.1,andTable3.33respectively.

3.1.2 Transistor

TheNchannelMOSFETpowertransistorprovidesthehighestefficiencysinceitdoesnotrelyonDC
gatedrivecurrent.Thetotalgatechargeshouldbe50nCorless.Themaximumcurrentrequiredto
chargetheNFETsgateismax*Qg (500Hz*13.4nC).Somepowerlossesassociatedwiththetransistor
6
areI2Rlossesandswitchinglosses.Wewillimplementlowonresistance(R DS(on)) andreversetransfer
capacitance(CRSS)tominimizetheselosses.RDS(on) canbereducedbyswitchingthevoltageapplied
acrossthetransistorgatefromVouttoground.

3.1.3 Capacitors

Input Bypass Capacitor

Theinputbypasscapacitordeliversthepropergatechargeinorderreducepeakcurrentsandreduce
noisefromthemotorgeneratedvoltage.Serat68uFforcurrentsof1Amporlarger,thecapacitoris
optimalataloweffectiveseriesresistance(ESR).

Ceramic Capacitor
TheceramiccapacitorisplacedbetweentheV+andGNDpinsoftheMAX1771chipasseeninFigure
3.3.2.Itissetat0.1uFtobypasstheintegratedcircuitandmodulatenoisepeaks.

Reference Capacitor
ThereferencecapacitorbypassestheREFpinwhichcansupplyupto100uAofcurrent.

Output Filter Capacitor

TheoutputfiltercapacitorperformsoptimallywhenselectedatlowESR.Theproductoftheinductor
currentandthecapacitorsinternalESRyieldstheamplitudeoftheoutputvoltageripple.Lightloads
cantolerateahighdegreeofvoltageripple,thereforeallowingforavarietyofESRs.

3.1.3 Diode

The Schottky diode is a consummate highspeed rectifier that is needed for the MAX1771s high
switching frequency. These include pulsefrequency modulation (PFM) for low supply current and
pulsewidthmodulation(PWM)forhighefficiencywithheavyloads.Weareexpectingavoltagefallof
about5Vacrossthediode.
3.1.4 Resistor
Rsenseisselectedwiththeaidofthefollowingcurrentgraph(Figure3.1).WepickedanRsensevalueof20
mtoyieldthegreatestcurrentgenerationpossible.

Figure3.1Max.OutputCurrentvs.InputVoltage

7
3.1.6Inductor
Ourmanuallybuiltinductorisadjustedat22uH.Thisvalueisstandardforidealstartuptimesand
filtersundesirablecurrentripplesassociatedwithlightloads.Ourinductoriscomprisedofashielded
ferritecoretweakedtominimizenoiseradiation.ItfeatureslowDCresistance(lessthan20m)to
reducepowercopperlosses.

3.2MAX1771Schematics

Figure3.2FunctionalDiagramofMAX1771CPA

3.3CircuitSchematics

8

Figure3.3.1MAX1771Chip Figure3.3.2IntegratedCircuit(bootstrapped)

Table3.3.3PinConfigurationforMAX1771

4.DESIGNVERIFICATION

9
Numeroustestswereconductedtoverifythequalityofoperationofthevarioussubprojects.Thewater
turbinesystem,12VDCMotor,andtheDCDCconverterweretestedindependently.Inaddition,the
Faucet Calibration was done in order to calculate the water flow. After independent tests were
performed,theDCDCconverter,12VDCMotor,andthewaterturbinesystemweretestedtogether.

4.1Testing

Measurementsweremadetoindicatetheoptimalnumberofcupsforthewaterturbinesystem.Output
voltagewasmeasuredfortheDCDCConverter.EfficiencycalculationsweremadefortheDCDC
converter,12VDCMotor,andthewaterturbinesystem.Theoverallefficiencywas28%.

4.1.1FaucetCalibrations

Forfaucetcalibration,ourteamuseda3gallonbucketalongwithastopwatchinordertocalculatethe
waterflow.Themeasurementsshowninthetablebelowweretakenat6designatedpositionmarks.The
calculatedwaterflowassumes90%efficiencyofwatercollectionona1200ft2roof.

Table4.1.1FaucetCalibration

Flow Quantity
Mark (in/hour) (gallons/hour)
1 0.031 20.571
1.5 0.047 34.783
2 0.076 51.429
3 0.157 105.883
4 0.289 194.595
5 0.356 240

As shown in the table above (4.1.1), maximum water flow obtained at position 5 was 0.356
inch/hour.ThisamountofrainfallcanbeobtainedinsuchareasasWashingtonandFloridaasshownin
themapbelow(4.1.1).

Figure4.1.1AverageAnnualPrecipitationintheUnitedStates

10
4.1.2TurbineOptimization

Cups
Inordertoverifytheoptimalnumberofcupsforthewaterturbine,avariousnumberofcupswere
fasten,andRPMoftheturbinewascalculated.Thevariousnumbersofcupsrangedfrom10cupsto24
cups.Asshowninthetableandthefigurebelow(Fig4.1.2),maximumRPMwasobtainedat20cups.
Asnumberofcupsincreasedbeyond20cups,theRPMwasdecreasedbecauseofwaterlosses.Ideal
distancebetweencupswas4.17cm.

Table4.1.2NumberofCupsVsRPM(At0.289inch/hour,NoMotor)

Number of Cups RPM

10 40
12 46
14 52
16 58
18 62
20 66
22 50
24 32

70

60

RPM 50

40

30
10 12 14 16 18 20 22 24
Cups amount

Figure4.1.2NumberofCupsVsRPM(At0.289inch/hour,NoMotor)

RPM
Oncethewaterturbinewascompletelybuilt,finaltestsfortheRPMoftheturbinewereconducted.
VariouswaterflowswereappliedandRPMofthewaterturbinewasmeasured.54RPMofthewater
turbine was measured at0.356inch/hour. Testes were performed withnomotor andwithanopen
circuit.Asshowninthefigurebelow(Fig4.1.3),increaseofwaterflowimpliesanincreaseintheRPM
ofthewaterturbine.

11
 60

50

40

RPMoc 30

20

10

0
0 0.05 0.1 0.15 0.2 0.25 0.3 0.35 0.4

Inches perHour

Figure4.1.3:WaterFlowvs.RPM,NoMotor

4.1.3DCMotorTests

Power
Fortheoutputpowerofthe12VDCMotor,thepowergeneratedbythemotorwasrecordedwiththe
aidofawattmeter.
6

Power 3

0
0 0.05 0.1 0.15 0.2 0.25 0.3 0.35 0.4
Inches perHour

Figure4.1.4WaterFlowvs.OutputPower

12
RPM
TotesttheRPMofthe12VDCmotor,various voltages wereappliedacross theterminal ofthe
generator.TheRPMofthemotorsshaftwasmeasuredwiththeuseofastrobelight.Ata90Vinput
voltage, the motors shaft rotated at 1750 rpm. The graph below (Fig 4.1.5) demonstrates a linear
relationshipbetweentheinputvoltageandtheRPMoftheMotor.

2000

1500

RPM 1000

500

0
0 10 20 30 40 50 60 70 80 90
Volts

Figure4.1.5Inputvoltagevs.RPMofthemotor(noload)

4.1.4DCDCConverter

Current
OncetheDCDCconvertercircuitwasbuilt,measurementsoftheoutputcurrentfromthecircuitwere
takenatvariousinputvoltagesandtwodifferentRsensetestvalues(Rsense=20 ,Rsense=50 ).The
testdemonstratedthatmorecurrentwasgeneratedatthelowerRsensevalue.Asshowninthefigure
below(Fig4.1.6),theoutputcurrentofthecircuitwasincreasedastheinputvoltageincreasedwith
regardtothetwoRsensevalues.

3.5

2.5
CurrentatRequal20
2
CurrentatRequal50

1.5

0.5

0
2 4 6 8 10 12
Voltage

13
Figure4.1.6Inputvoltagevs.theoutputcurrent

Voltage
Oncethe12VDCmotorwasconnectedtotheDCDCconverter,variousinputvoltageswasappliedto
theinputterminalsofthemotor.Theoutputoftheintegratedcircuitwasconnectedtotheoscilloscope.
Asshowninthefigurebelow(Fig4.1.7),channel2displaystheinputvoltageofthe12VDCmotor
(2.81V)whileChannel1displaystheoutputvoltageoftheDCDCconverter(12.1V).

Figure4.1.7OscilloscopeReadings

Also,avoltagesourcewasapplieddirectlyattheinputofthecircuittoverifyproperfunctionoftheDC
DCconverter.At2.5V,thecircuitwastriggeredandsteppedupthevoltagetoaconstantof12V+/
1.5%.AsshownintheFigurebelow(Fig4.1.8),theICwasnottriggereduntiltheinputvoltagereached
2.5V.

Figure4.1.8Inputvoltagevs.outputvoltage(opencircuit)

14
4.2Conclusions

4.2.1WaterTurbineSystem

The water turbine system worked accordingly with preliminary expectations. The efficiency of the
turbinewas40%.Somealterationsmaybedonetoimprovetheoverallefficiency.Inordertoincrease
the output power of the turbine, a larger wheel radius is necessary. If the radius of the turbine is
increased,moretorquewillbedelivered,thusprovidingforgreateroutputpower.

4.2.2DCMotorandGear

Themotorusedinthisprojectwasratedat90Volts,1.8Ampsat1750RPM.Theefficiencyofthe12V
DCmotorandthegearboxtogetherwasat80%.Inordertoimprovetheefficiency,asmallerRPMrated
motorisnecessaryforhigheroutputvoltage.Thisalterationwouldeliminatetheneedforagearbox,
thusreducingfrictionalenergylosses.

4.2.3TheDCDCConverter

TheDCDCConverterfunctionedwithanefficiencyof90%inthefinaldesign.AchangeofRsense
from40mto20misneededforhigheroutputcurrentfromthecircuit. Inaddition,afusecouldbe
connectedtoPin2topreventthechipMAX1771fromgettingburned.

15
 5.COSTS
5.1Parts

ThetotalcostofallthecomponentsusedinthisprojectislistedinTable5.1.

Table5.1TotalCostList

Part # / Serial Date Date Qt

# Mnft. Descrip. Component Ordered Received Price y Total
DC to DC
68 uF Bootstrapped 6/29/200
267M* Matsou Capacitor Converter 4 6/29/2004 $0.30 1 $0.30
DC to DC
0.1 uF Bootstrapped 6/29/200
267E* Matsou Capacitor Converter 4 6/29/2004 $0.25 2 $0.50
DC to DC
300 uF Bootstrapped 6/29/200
595D* Sprague Capacitor Converter 4 6/29/2004 $0.39 1 $0.39
DC to DC
22 uH Bootstrapped 6/29/200
CD54* Sumida inductor Converter 4 6/29/2004 $0.49 1 $0.49
DC to DC
Schottky Bootstrapped 6/29/200
1N5817* Motorola Diodes Converter 4 6/29/2004 $0.89 1 $0.89
DC to DC
Bootstrapped 6/29/200
N/A* ECS 20 m-ohms Converter 4 6/29/2004 $0.29 1 $0.29
DC to DC
Maxim/ Max1771 Bootstrapped 6/27/200
MAX1771ESA Dallas chip Converter 4 7/8/2004 $14.18 1 $14.18
DC to DC
Transistor Bootstrapped 6/29/200
D20N03HDL* Motorola MOSFET Converter 4 6/29/2004 $0.60 1 $0.60
Motor 6/22/200
2013 ECS Motor Kit Research 4 6/22/2004 $6.00 1 $6.00
Urbana Bike 6/23/200
N/A Shop Bike Wheel The Turbine 4 6/23/2004 $4.00 1 $4.00
Plastic 6/24/200
23900 Lowes Cups The Turbine 4 6/24/2004 $0.95 29 $27.43
Channeling 6/24/200
N/A Lowes 10' Gutter Rainfall 4 6/24/2004 $7.75 2 $15.50
Gutter Couples the 6/24/200
N/A Lowes Coupler 2 x10' gutters 4 6/24/2004 $3.99 1 $3.99
N/A Lowes Gutter/PVC Funnels 6/24/200 6/24/2004 $3.99 1 $3.99
Adaptor water to a 2" 4

16
 PVC tube
DC to DC
350-piece Bootstrapped 6/24/200
0313** Elenco wire kit Converter 4 6/24/2004 $13.00 1 $13.00
Chinapack Aluminum 6/28/200
QTB59B** Ningbo. Pipe & Bar The Shaft 4 7/05/2004 $7.95 1 $7.95
DC to DC
Global Bootstrapped 6/29/200
P-040001*** Specialties ProtoBoard Converter 4 6/29/2004 $95.00 1 $95.00
Gear Chain/2 6/29/200
N/A*** REI Gear Discs 3:1 4 6/29/2004 $24.99 1 $24.99
Sterling 12V DC Generating 6/29/200
STB0026E*** Instrument Gear Motor Power 4 6/29/2004 $150 1 $160
Power- 12 Volt 3.0 A Lead Acid
100X Sonic Amp Hour Battery 7/7/2004 7/29/2004 $15.49 1 $15.49
DC to DC
Max1771 Bootstrapped 7/12/200
MAX1771CPA Maim/Dallas chip Converter 4 7/26/2004 $14.18 4 $56.72
Total $451.70

*ThesepartswerefoundinthePowerElectronicsLab.
**ThesepartswerefoundintheseniordesignLab
***ThesepartswerefoundintheMechanicMachine
Shop.

5.2Labor

Salary: $30perhour
Hours: 40hours
Workers: 3people

$30/hourx50hoursx3peoplex2.5=$11,250

5.3Cost

LaborCosts $11,250.00
PartsCost $451.70
GrandTotal $11,701.70

17
 6.CONCLUSIONS

The objective of this project was to design a machine that has the capacity to transform hydro
mechanicalpowerintoelectricalpower.Thedesignoutlinedinthispapersuggeststhatthiscanbe
achievedwithhighlevelsofoperationandefficiency.Severalsuccessesreigninthevarioussubprojects,
althoughsomeimprovementsarecalledforaswell.

Theturbinegearboxshaftapparatussmoothlyoperateswithminimalpowerloss.Inaddition,themotor
outputsasubstantialamountofpower,althoughmoreresearchisneededtodeterminethebestrated
motorforthepurposesofthismachine.TheintegratedcircuitDCtoDCconverteroperatesoptimally
and is ideal forthelight load implementation ofthis machine. Anapparatus that can bemanually
attenuatedforvariousbatterycapacitancesisapointoffutureimprovement.

Thetestingandverificationresultsdemonstrateahighefficiencythatbroadenstheimplicationsfor
hydroelectricpower.Withfurtherresearch,thenotionofhydroelectricpowerconversionmayserveasa
premiseforthedevelopmentofalternativesourcesofenergyinoursociety.

18
APPENDIXCALCULATIONSA

19
For our project, we will assume that:

Minimal rainfall will be .031 inches/hour

Max rainfall will be .356 inches/hour
An average home has 1200 square feet of rooftop to collect water
It will rain for a duration of 9 hours
Efficiency of collecting water in gutters is 90%
Rooftop is approximately 25ft from ground (20ft fall)
Efficiency of waterturbine (40%)
Efficiency of motor (90%)
Efficiency of control circuit (92%)
in in
MinRainfall .031 MaxRainfall .356 fall 20ft
hour hour
2
AvgSqFt 1200ft CollectEfficiency .9 fall 6.096m

TurbineandGearEfficiency .4 MotorEfficiency .89 ControlEfficiency .92

MaxCollectedWater MaxRainfall 9hour AvgSqFt CollectEfficiency

MinCollectedWater MinRainfall 9hour AvgSqFt CollectEfficiency
3
MinCollectedWater 187.836gallon MaxCollectedWater 2.157 10 gallon

MaxCollectedWater liter
MaxWaterflow MaxWaterflow 2.268
hour s
MinCollectedWater liter
MinWaterflow MinWaterflow 0.198
hour s
gram
waterweight 1
.001liter
MaxWaterPower fall MaxWaterflow gravity waterweight MaxWaterPower 135.595W
MinWaterPower fall MinWaterflow gravity waterweight MinWaterPower 11.807W
MaxCapturedPower MaxWaterPower TurbineandGearEfficiency MotorEfficiency ControlEfficiency
MinCapturedPower MinWaterPower TurbineandGearEfficiency MotorEfficiency ControlEfficiency
MaxCapturedPower
MaxCapturedPower 44.41W 4.934W
9
MinCapturedPower 3.867W MinCapturedPower
0.43W
9

AvgCapturedPower 4W
TotalCapturedPower AvgCapturedPower 9hour
TotalCapturedPower 36W hour

TotalCapturedPower
BatteryStorage
12V
BatteryStorage 3 A hour

20
APPENDIXCALCULATIONSB

21
For our torque calculations, we will assume that:

Measured water in a cup = 130mL

At any given second, 2 cups are completely full of water
The water takes approximately 1.12 seconds to fall 20feet
The force of the water makes the turbine move .3 meters
The radius of the turbine (bike wheel) 26cm

turbineradius 26cm
turbinedisplacement .3m
turbinewatercapacity 130mL 2

fall 2
falltime falltime 1.115s
gravity

m
velocityfallingwater gravity falltime velocityfallingwater 10.934
s

KineticEnergy fallingwater
1 s MinWaterflow waterweight velocity 2
fallingwater
2
KineticEnergy fallingwater 11.807N m

PotentialEnergy fallingwater turbinewatercapacity waterweight gravity turbinedisplacement

PotentialEnergy fallingwater 0.765N m

TotalEnergy fallingwater KineticEnergy fallingwater PotentialEnergy fallingwater
TotalEnergy fallingwater
TotalForce onTurbineCup
turbinedisplacement

TotalForce onTurbineCup 41.908N

Cupefficiency .75

Torque onTurbine TotalForce onTurbineCup turbineradius Cupefficiency

Torque onTurbine 8.172N m

Torque onTurbine 72.328inlbs

Turbineefficiency .4

Torque onMotor Torque onTurbine Turbineefficiency

Torque onMotor 28.931inlbs

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 REFERENCES

[1] A. E. Fitzgerald, C. Kingsley, Jr. S. Umans, Electric Machinery. Chicago: Mc-Graw Hill
Publishing, 2002.

[2] MAX1771, 12V or Adjustable, High-Efficiency, Low IQ, Step-Up DC-DC Controller, Maxim
Integrated Products, 2002.

[3] P. T. Krein, Elements of Power Electronics. New York: Oxford University Press, 2000.

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[4] P.T.Krein,ECE369LaboratoryInformationandGuide.Urbana:UniversityofIllinois2000

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