Академический Документы
Профессиональный Документы
Культура Документы
Table of Contents
I. Introduction A. Executive Summary B. Background Information C. Project Planning Needs and Specifications A. Identification of Needs B. Design Specifications C. Target Values D. Design Selection Criteria Concept Development A. External Search B. Problem Dissection C. Design Concepts D. Concept Selection Detailed Design A. Modifications to Proposal Sections B. Overall Description C. Detailed Drawings D. Final Theoretical Analysis E. Component and Material Selection Process for Mass Production F. Fabrication Processes for Mass Production G. Industrial Design H. Safety I. Economic Analysis 1. Unit Production Costs 2. Business Case Justification J. Testing Conclusion References Appendices A. Appendix A: Customer Documentation B. Appendix B: Team Documentation C. Appendix C: Project Documentation D. Appendix D: Material and Environmental Impacts E. Appendix E: Fabrication and Manufacturing F. Appendix F: Industrial Design and Analysis G. Appendix G: Safety Concerns H. Appendix H:Detailed Testing Report I. Appendix I: Detailed Drawings J. Appendix J: Prototype Iterations K. Appendix K: Bill of Materials L. Appendix L: NPV Analysis 3 3 3 3 4 4 4 4 5 6 6 6 6 8 8 9 10 11 11 12 12 12 12 13 14 15 16 19 21 23 25 28 31 33 34 39 40 40
II.
III.
IV.
V. VI. VII.
Page 2 of 40
I.
Introduction
Page 3 of 40
ME 340.5 Faucet Fiends Documentation). This Gantt Chart represents the project dates and helps keep the project on track. Some tasks tend to be very large tasks that will not only take a lot of time but also allow for changes throughout the process. Changes are key to this development process since throughout the prototyping/concept development phases, issues may be found which need to be addressed. The Gantt Chart delegates tasks among the group members within each project assignment. Katherine K., Tyler N., and Morgan S. meet at least once a week and base each meetings tasks and goals accordingly with the Gantt Chart. As outlined in the contract, the team both has its strengths and its weaknesses. It is the teams goal to to utilize the strength of its group members to efficiently complete the project. Weaknesses are seen as opportunities of improvement. Whenever the chance is presented with opportunity of grow, Faucet Fiend team members support one another.
II.
ME 340.5 Faucet Fiends installation, time to disassemble and reassemble the entire device, product material, number of cycles until failure, effects of varying water flow rate on power productions, and amount of contaminate in output water flow. Other constraints were based on the design constraints provided [1].
(**)- Minimum value requirement Table 2: Application of Target Values Scaled up Resistance (Ohms) Voltage (V) Power (W) 10 11.47 13.15 Watts
Page 5 of 40
ME 340.5 Faucet Fiends Manufacturing Ease Efficiency Maintenance Durability 7.1% 13.9% 19.0% 20.8%
Page 6 of 40
Figure 2: Concept #1
Figure 3: Concept #2
Figure 4: Concept #3
Figure 5: Concept #4
Page 7 of 40
ME 340.5 Faucet Fiends although it will decrease the efficiency. The generator will be connected via a shaft but with the use of rubber grommet and Vaseline, the team believes this will allow for easy rolling resistance but still provide a relatively water tight seal. The generator will be held in a cradle formed on the case.
Page 8 of 40
ME 340.5 Faucet Fiends not been finalized for this concept. However, the team wants to see if simply increasing the nozzle diameter without the tubing can control pressure. The concern is if the tubing is added that the pressure needed to spin the wheel will dramatically decrease inhibiting the voltage requirements of the course. Magnets are also going to used in the final design to eliminate the need for putting holes through the outside acrylic pieces.
Page 9 of 40
Note: Magnet covers and magnet holders are slightly different in dimension when looking at the set that attaches to the shaft and the set that attaches to the generator. This is due to the slightly different shaft sizes between the drive shaft connected to the fan and the generator driveshaft.
The Faucet Fiend Product has quality assembly that assures ease of use and manufacturing of the product. After testing the team decided that the final product would have a magnet design as a part of the enclosure to minimize leakage issues. The housing also holds the fan blade and allows for any excess of water to easily drip away out of the outlet.
D.)
Page 11 of 40
F.)
The goal of the team is establish a credible product known for its ease of use, quality, and low manufacturing costs. First the team estimated the overall costs of these components. This included the inputs of raw materials, equipment used, and the energy put in by the team to create the product. This Table can be referenced in Appendix (E). Further indepth evaluation of the product and the cost manufacturing methods chosen are included in Appendix (K, L respectively) BOM and Economic Analysis . Appendix (E) is also referred to for several Faucet Fiends flowcharts of the Design Manufacturing Method, Input-Output Model, and Elements of Manufacturing Cost of Product.
G.)
Industrial Design
There is two major categories that team Faucet Fiends must consider for a successful design: ergonomic needs and aesthetic needs. Appendix (F) includes detailed break down of each of these categories and a table of the Needs, Level of Importance, and Explanation for Rating of the faucet generator product.
H.)
Safety
Faucet Fiends goal is to present the market with a product that is safe and easy to use that allows for easy access to generator and other parts. To enforce the safety of the product, all moving and electrical parts were covered up by with plastic PVC piping or acrylic. Other major areas of concern were the plastic being involved in the design and the electrical set up. Referring to Appendix (G), the reader will find a summarization of the major areas of concern along with the associated this product along with the correlating standards and regulations for safety.
I.)
Economic Analysis
1. Unit Production Cost See Appendix K for Bill of Materials Labor for the assembly of this generator will take a person approximately 1 hour to assemble with all parts in from of them. This estimate includes set time for some simple water-proofing caulk that will be used around the pipe ends. (Price: $7.50/hr) Tooling for the assembly is comprised of a milling machine or a CNC milling center. The CNC will be used to create the radii for the steel pipe in order to mate properly with the PVC radius as well as the thru holes in the PVC pipe. This milling center will save us a lot of time and money in the overall assembly but upfront cost for a 3 axis CNC. (Product: Haas VF-1 3-axis milling center | Price: $48,995.00)
Page 12 of 40
ME 340.5 Faucet Fiends Development cost for the assembly consisted of two different alpha prototypes along with a beta prototype was approximately fifty dollars total although the hours of 3 engineers working 3 weeks will also have to be added in as well(Price: $2000.00 for one quarter) For our analysis we will assume that we will produce 100,000 units per years and we will run this product for 3 years unless product sales continue to show improvement. Milling machine price per unit to recoup cost after 300,000 units (Price/unit: $0.163 / unit) Development cost per unit ($0.002) Cost per unit = parts + labor + development + tooling Cost per unit = $43.92 + $7.50 + 0.007 + 0.002 = Cost per unit = $51.43 2. Business Case Justification An appropriate mark-up according to our reference for an electrical apparatus is approximately 1.40 times the production cost. This mark-up estimation was approximately from a case study perform on the difference in markets due to country [12]. According to this mark-up the team plans to market the product for sale at seventyfive dollars. We will also use a typically cost for a marketing campaign for our product to be introduced into stores and homes. Our website will cost approximately 5,000 dollars for a professional marketing agency to design and format it along with continuous maintenance of the site, maintenance will run us another 1,500 dollars per quarter. We will also market by means of 4 magazine slots per month which are 1,500 dollars apiece [13]. As mention above we estimated a development cost of approximately 2,000 dollars due to the parts and labor cost of 3 separate prototypes that led the team to the final design. The ramp-up cost the team estimated at approximately 1,000 dollars for the first two quarters, this is due to the need to train individuals and understand the tooling and efficiencies of the systems. We estimated a engineer would have to work with the assembly line people for approximately 15 hours per quarter at a pay rate of 40 dollars per hour and the assembly individuals being paid 7.50 dollars an hour working approximately 54 hours per quarter on the project. NPV analysis found in appendix L.
J.)
Testing
Tests were conducted to evaluate the voltage and water flow output of the device. The Alpha and Beta prototypes will be connected to a classroom faucet where these values will be assessed and recorded. As a result of Alpha prototype tests of April 9, 2014, it was determined that the turbine housing flooded and leaked. Changes to the design were made via the Beta prototype. From tests of the Beta prototype on April 23, 2014, the team recorded an output voltage of 1.2 Volts and an outlet flow rate of less than 50% of the inflow rate. Changes were made to the design to ensure the design meets the requirements of an output voltage of 1.5 Volts and an outflow rate
Page 13 of 40
ME 340.5 Faucet Fiends at least 50% of the inflow rate. Refer to Appendix (H) for Detailed Testing Report documentation
V.
Conclusion
Team Faucet Fiends has successfully completed the beta prototype power check and power requirement this far in the project. The next steps are making the power generation more accurate and finalizing the beta prototype. The team plans on keeping a similar design to the beta prototype, however Team Faucet Fiends is prototyping a design with magnets to avoid a shaft sticking out of the product. This will minimize safety hazards and increase the aesthetic appeal of the design. There are several engaging factors of the Faucet Fiend design that have the consumer interested in the teams product. The consumer is able to enjoy a user-friendly product that grants the consumer an opportunity of becoming environmentally concise on how much water is currently wasted from a typical faucet sink. In addition to this, the consumer benefits from the rechargeable sump pump batter that provides a form a safety and peace of mind when disasters such as power outages occur. Instead of being helpless to flooding damaging the home, consumers have a plan of action. The team believes a backup generator for a sump pump is invaluable in times of flooding and is fully dedicated to its success.
Page 14 of 40
VI.
References
[1] Brennan, Sean, Dr. Project_description_SP14. University Park: Mechcanical Engineering Deptarment - PSU, n.d. Word Document. [2] "Marine Batteries." Boat Batteries. Deka, n.d. Web. 01 Mar. 2014. [3] "DC Source Chargers for Charging 12 Volt Lead Acid Batteries from a 12 Volt (8-16 Volt) Source." 12V Input Lead Acid Battery Charger. Power Stream, n.d. Web. 01 Mar. 2014. [4] Spiller, Andrew. "Water Faucet Generated Emergency Lighting System." Google N.p., 14 Mar. 2000. Web. 01 Mar. 2014. [5] Zurn - Z6913-GEN. Sanford: Zurn Industries, 19 June 2013. PDF. [6] "EC-HYDROGEN Chekpoint Hydro Generator Accessory." Low Flow Spray Valves, Commercial Faucets & Plumbing. T & S Brass, n.d. Web. 04 Mar. 2014. [20] Terry, Robert L. "Water powered rotating shower brush." Google Patents. N.p., n.d. Web. 27 Apr. 2014. [21] Yumita, Yukinobu. "Small power generating device and water faucet device." Google Patents. N.p., n.d. Web. 27 Apr. 2014. [22] Baarman, David W. "Self-powered miniature liquid treatment system." Google Patents. N.p., n.d. Web. 27 Apr. 2014. [7] http://www.materialproject.org/wiki/Acrylic. [8] http://homeguides.sfgate.com/pvc-disposal-recycling-79234.html. [9] http://homeguides.sfgate.com/pvc-disposal-recycling-79234.html [10] http://www.sustainability-ed.org.uk/pages/pvc2-1.htm [11] http://www.styron.com/sustainability/operations/eco-profiles.htm [12] - http://www.oecd.org/regreform/reform/1863340.pdf [13] - http://yourbusiness.azcentral.com/average-cost-national-advertising-campaigns-26091.html Safety Concern References, Appendix G: [14] http://www.nsf.org/newsroom_pdf/nsf61-372_lead_insert_LWD-1350-0513.pdf [15] http://www.ul.com/global/eng/pages/search/?searchTerms=faucets&submit= [16] http://www.epa.gov/watersense/docs/faucet_suppstat508.pdf Books - Patents.
Page 15 of 40
US006876100B2
US006927501B2
US 6,927,501 B2
Aug. 9, 2005
(54)
*
*
(54)
3,551,091 A
TREATMENT SYSTEM
(75) Inventors: MI (US); David (Us); Thomas W. Terry Baarman, Leppien, Lee Lautzenheiser, Fennville, Grand Haven, MI
3,845,291 A
3,913,399 A
10/1974 Portyrata
10/1975 Sheeks .... ..
240/26
73/229
236/1212
(75)
Inventor:
4,963,780 A
5,349,985 A
10/1990 Hochstrasser ..
8/1997 Weisser
..... .. 310/104
.. 137/607
(73) Assignees: Kabushiki Kaisha Sankyo Seiki Seisakusho, Nagano (JP); Toto Ltd., Fukuoka (JP)
(*) Notice: Subject to any disclaimer, the term of this patent is extended or adjusted under 35
DE EP EP JP JP JP JP JP JP JP JP JP
5,659,205 A *
6,441,508 B1 * 6,512,305 B1 *
290/52
4,101,777 2 A
(Continued)
FOREIGN PATENT DOCUMENTS
198 13 544 A1 10/1999 ........... .. C02F/1/32
DE
JP
201 05 341 U1
2001334179
9/2002
12/2001
C02F/1/32
........... .. B05B/1/18
10/276,265
May 16, 2001
PCT/JP01/0407 9
A A A
disinfectants against Legionella in Water Systems, Water Research, Elsevier Science Publishers, Amsterdam, NL, vol. 36, No. 18, Nov. 2002, pp. 44334444, XP004380727.
International
Search
Report
of PCT/US2004/001484,
* cited by examiner
(65)
(65)
(57)
ABSTRACT
(30)
(51)
(52)
(57)
ABSTRACT
Asmall generator includes a hydraulic turbine provided in a ?uid path rotating With a passage of a ?uid in a predeter mined ?oW and a rotator coupled to the hydraulic turbine rotating together With the hydraulic turbine Which acts as a
a ?rst ?OW Path- The ?rst ?OW path may provide treated liquid at a ?rst outlet of the liquid treatment system. A
second ?oW path included in the liquid treatment system
(58)
(56)
4,276,482 A 4,511,806 A
References Cited
U.S. PATENT DOCUMENTS
*
6/1981 4/1985 Crockett .................... .. 290/52 May .......................... .. 290/43
12
rotor portion opposed to a stator portion having multiple layers in a stepping motor including the stator portion, Wherein the rotor portion relatively rotates With respect to the stator portion With the passage of the ?uid, thereby
generating a poWer.
(58)
(56)
Field of Search
""""""""""""""" "
290/40 43 54
290/52
References Cited
US. PATENT DOCUMENTS
692 714 A 2/19O2 S 1 t 1
1 56O535 A
ZZ436Z683 A 2,663,541 A
2,743,375 A
3,233,164 A
Water
10
Treatment
System
\_/
42
45
FLUID PATH-/7
221/14
15
\, 48
'v\
2,18
12
50/ i Ti
54 52
\44
\20
Figure 10: These illustrations are of either a patent or working device currently using technology team Faucet Fiends is looking into. From left to right on the top row, the first picture is patent [4] of an emergency light patent, the next picture in the middle is patent [5] the
Page 16 of 40
Patent Search
[4] US Patent #6036333 Water faucet generated emergency lighting system [5] Zurn Z6913-GEN Lavatory Faucet with Hydroelectric Generator Price: $531.99 [6] T&S Brass Hydro-Generator Accessory Package Price: $185.70 [20] Patent #4841590 - Water Powered Rotating Shower Brush [21] Patents #6876100 Small power generating device and water faucet device [22] Patent #6927501 Self-powered miniature liquid treatment system
Research Specifications
[2] Marine Battery Typical marine battery will power a standard sump pump for up to 7-12 hours. [3] Battery Charger Need to get 8-16 volts to run the charger.
Standards
1. 2. 3. 4. 5. 6. ADA - American Disabilities Act ASME - American Society of Mechanical Engineers NSF - National Science Foundation Energy Policy Act of 1992 EPA - Environmental Protection Agency NPS - Nominal Pipe Size
Comments on Standards Search: There are many standards and laws that must be considered when designing our water turbine. First, is the American Society of Mechanical Engineers, which sets hardware standards for pipes, fittings, etc. These hardware standards ensure a product will work with existing infrastructure without modification. Additionally, the National Science Foundation set the NSF/ANSI Standard 61. This is a set of national standards that ensure potable water is not contaminated through contact with equipment that leaches harmful chemicals. This set of standards will control the materials we use in our final design. In addition, the Energy Policy Act of 1992 and the Environmental Protection Agency (EPA) set standards about water consumption and allowable flow rates for residential water supplies. Finally, we must consider the ! in. by 18 thread Nominal Pipe Size (NPS) which is a national standard for the size of pipes in homes and buildings. This diverse collection of standards and laws will control the design of our water turbine as well as the materials we use to build it.
Page 17 of 40
Page 18 of 40
VIII.
Individual Roles
Individual roles were based off of each of the team members strength. There is overlap of tasks for both time and individual, in which individuals will have to use and improve team work skills to be able to meet time rescritions. Even though some tasks will be delegated to individuals with strong skill sets in that particular category, all team members are required to participate in all aspects of design, construction of prototype, and reporting. Morgan Stear Background: Certified Solidworks Associate Major Role: Develop and improve Solidworks models and analysis Katherine Kennedy Background: Computer Systems (Word and Excel) and Organization Major Role: Group dignitary, technical writer Tyler Nelson Background: Computer systems and manufacturing Major Role: Prototyping and error analysis
Page 19 of 40
Gantt Chart
Page 20 of 40
!"#$%&'(%)*+$&,$+$%"#-% ("")' ;.&/$"<1 >793#?$793# @))$"17(9&#.&/..<&"# A5%$?&%793#&7(+$"1B&#.&7(1#"// C"1B&#.&0"7(#"7( @22.%D"E/$+F*D9$# G*%"E7/7#B @D")#"E/$ G.$1&(.#&5.(#"07("#$&?"#$%&1.*%5$
= =
? ? ? ? ? ? ? ? ?
? ? ? ?
Page 21 of 40
ME 340.5 Faucet Fiends Manufacturing Cost Manufacturing Ease Efficiency Maintenance Durability 0 0 + + 0 0 0 + -
Page 22 of 40
Page 23 of 40
Disposal in Incineration: The chemicals added to PVC create additional concerns when incinerated, but large amounts of PVC are handled by municipal and hospital waste incinerators each year. When burned, PVC releases the gas form of highly corrosive hydrochloric acid. Incineration regulations state that this and other resultant toxins must be contained and neutralized, but troubling amounts have been found to leak into the atmosphere. Ash from PVC incineration also contains toxic elements, most often cadmium and lead. The presence of these two heavy metals means that the ash must be sent to controlled landfills, where space and groundwater contamination are eventual concerns. If done properly, there are two main methods of recycling: Mechanical Recycling: Used PVC can become new source material through mechanical recycling -- a process that grinds plastic into a powder base for new products. This process does not remove any of the toxins from PVC, but adding new material can dilute the existing toxicity. The mechanical recycling process is a common part the PVC industry in the reuse of post-industrial scraps. Post-consumer PVC recycling rates lag behind due to material retrieval costs, and chemical composition issues. While mechanical recycling for other post-consumer plastics is common, the additives in PVC
Page 24 of 40
ME 340.5 Faucet Fiends can contaminate mixed batches and hinder system efficiency. Similarly sourced PVC is easier to recycle mechanically, so many product manufacturers run collection or buyback programs that accept and process specific post-consumer PVC products [8]. Chemical Recycling: Chemical recycling methods break down plastics at a molecular level. This process is potentially beneficial because chemical separation allows the removal and reclamation of chlorine content and other toxins. Chemical recycling requires elaborate, dedicated facilities and is more costly than mechanical recycling. For this reason, the process is less preferred for general PVC waste, but it stands as an option for many materials that are too impure or contaminated for mechanical recycling [9]. The difficulties in the disposal and recycling of PVC have lead policymakers to focus on reduced production and usage of the material. Research is exploring less harmful PVC additives and more environmentally responsible recycling processes. Cleaner coincineration methods are also being attempted to test the feasibility of burning waste plastic as fuel for heat generation. The notable durability of the material inspires many individuals and small-scale ventures to reuse and "upcycle" PVC products -- prolonging the life of the material. Team Faucet Fiends would like to make it clear that even though these components are hazardous to the environment, establishing reuse of components in manufacturing, promotions such as discounts for returning a product back to the facility for recycling, and encouraging other proper recycling methods is something the team takes very seriously
ME 340.5 Faucet Fiends manufacturing process of the product. Only a cost estimate of fabrication based on the quantity of the material or component is provided in this table. The following is a table that includes the fabrication and manufacturing on the teams product. Quantity of detailed components list is included in Section 4.B of the report with the Overall Description. Note, the BOM and a more detailed overview of cost assessment can be found with the Economic Analysis (Section (4.I) of the report, Appendix (K, L) respectively) Material, Fabrication Process, and Cost Per Unit for Mass Production Component Generator Shaft Fan housing Generator Housing Fan blade Nozzle Flow Guide Housing Inlet and Outlet pieces Screws Material Pre-fabricated (composite) PVC Piping Acrylic Polycarbonate Acrylic PVC and Acrylic Brass and steel tubes The Manufacturing Process Pre-fabricated Cut Cut to reshape and hot glued Drawn in Soliworks, laser cut, hot glued Water Jet Drawn in Soliworks, laser cut, hot glued Drawn in Soliworks, laser cut, hot glued Prefabricated Prefabricated
Page 26 of 40
ME 340.5 Faucet Fiends The following flow chart outlines the limitations on the manufacturing of the teams design:
Page 27 of 40
ME 340.5 Faucet Fiends This chart is an example of the inlets and the outlets that will go into completing this product:
Page 28 of 40
ME 340.5 Faucet Fiends Number of User Interactions: User interaction is friendly with the teams product. There are two main interactions with this product. The consumer twists in the product similar to any other water feature and lets it generate power when the faucet is turned on. The teams product will stop generating power when the faucet is turned off. On a bigger scale application with the rechargeable battery feature attached for the sump pump, the consumer is able to the mount the battery pack on the counter beside the sink, or under the counter. This will connect to the generator. Novel Interaction Needs and Safety: Refer to Level of Importance Chart provided below
Aesthetic Needs: Visual Differentiation: The teams product is a sleek, gray tone. This makes it a product that is one with the sink or an extension of what the consumer is already familiar with. The product blends in, but stands out in the market place because of its natural appeal. Faucet Fiends emphasizes the importance of the technology behind the product while maintaining it functionality. Image and Fashion: The overall product has a rounded shape making it smooth and futuristic. Rounded designs are more appealing to the eye and give off a clean cut effect. Another great feature about the product is the ability to see the fan blade when it is in motion. This allows the customer to enjoy the product, but also alerts the customer if maintenance needs to be considered. The fan blade itself is also has a thin, sleek, and efficient look about contributing to the modern day construction and visual appeal. The only major issue of concern is concealing the wires that attach to the battery back up feature for the sump pump.
Page 29 of 40
Medium Medium
High
Image or Fashion
Medium
Page 30 of 40
Page 31 of 40
ME 340.5 Faucet Fiends regulations older generation faucets do not. With the teams product this excess flow rate can be converted to usable energy for the sump pump rechargeable better [16]. The U.S Department of Energy regulates the water consumption level of faucets. The maximum pressure of a regulated faucet is 60 psi. The faucet where the testing will be conducted has a maximum pressure of 50 psi. It is important to note that Faucet Fiends design does meet this standard. For the teams product, realistically the product will never reach this 50 psi due to friction losses and other factors such as head loss. The criteria for the flow rate is also well within the maximum flow rate of a standard kitchen faucet [17]. There are several types of back up sump pumps. Included in this sections are some of the regulations that must be met regarding the sump pump along with faucet specifications Analyzing the upscale application of the product the sump pump has several regulations that the team recognizes for emergency back up pumps [18]. These requirements can be found in the PDF reference [18].
Page 32 of 40
Schedule
Schedule
Page 33 of 40
Page 34 of 40
Page 35 of 40
Page 36 of 40
Page 37 of 40
Page 38 of 40
Page 39 of 40
43.92
Page 40 of 40