Me340 Final Report

ME 340.
2 Solar Powered Turbine Micro Pump 10/10/2012 1 | P a g e

Team D
12 December, 2012

Sean Munck
Nam Pham
Nick Pinn
Executive Summary
Underdeveloped countries depend on subsistence farming for food, and many lack the
resources and technology to efficiently irrigate crops. Instead, they rely on traditional
methods which waste both water and energy. The Micro Turbine Pump solves this
problem by providing ample water flow for drip-irrigation methods. Because the pump is
solar-powered, there is no need for connection to an existing power grid. This product is
intended for farmers looking to better irrigate their crops, especially in underdeveloped
regions.
The Sonic Boom Pump uses an in-water centrifugal impeller design to efficiently pump
water. The axial inlet impeller remains efficient even in this low power micro-pump
scenario. With only a 1.5 inch diameter tube extending 2 inches into the water, the Sonic
Boom Pump is small enough to be used in wells. The above-water, insulated housing for
the motor and other electrical components ensures durability and safety. The net present
value( NPV) of our project, according to the base model is positive and we plan to proceed
with development. We hope that this information will assist the client in further
investment. Part of our design strategy will revolve around delivering a 1.9 liter/min flow
rate as requested from the customer. Our design specs prove this to be a valid prediction.
By keeping specially fabricated parts and materials to a minimum, the Sonic Boom Pump
is very reasonably priced at $33.86. The reliable, cost-effective, and efficient design should
be well-suited for micro-drip irrigation agriculture.
ME 340.2 Solar Powered Turbine Micro Pump 10/10/2012 2 | P a g e

Table of Contents
__________________________________________________________________

Executive Summary

1. Introduction..4
1.1 Problem
1.2 Background Information
1.3 Project Planning

2. Customer Needs and Specifications.5

3. Concept Development..5
3.1 External Search
3.2 Problem Dissection
3.3 Design Concepts
3.4 Concept Combination
3.5 Concept Selection

4. System Level Design..8

5. Detailed Design...........8
5.1 Changes from Proposal
5.2 Theoretical Analysis
5.3 Industrial Design
5.4 Material Selection
5.5 Manufacture and Fabrication
5.6 CAD Drawings
5.7 Economic Analysis
5.8 Addressing Safety

6. Prototype Testing.......13
6.1 Test Procedure
6.2 Test Results

7. Conclusion and Recommendations.......15
7.1 Conclusion
7.2 Design Improvements
7.3 Project Experience

8. References....16


Appendices:

A. Gantt Chart
B. Product Specifications
C. Weighted Customer Needs
D. Concept Generation
E. Concept Generation
F. Patent Search References
G. Concept Combination
H. Bill of Materials
I. Dimensioned Drawings
J. Performance Curves


1. Introduction

1.1 Problem:
The goal of the project is to design a pump which can be used to provide water for drip crop
irrigation. The pump system must achieve a flow rate of at least 1.9 liters per minute over an
elevation change of 0.5 meters.

For this project, the team had to work within the constraints specified by Prof. Lamancusa. It had
to be self-priming, and powered entirely by an unmodified solar panel. Once it began running,
the pump had to operate without any user control. The system had to be insulated and protected
from any danger of electrocution. Every team was provided with a choice of four motors, from
which each could choose only one. This motor would not be replaced for any reason. Replicating
existing parts from other pump designs was permitted. The total budget for the project was
limited to $100.

1.2 Background Information:
Flood irrigation is the primary method of irrigating crops in many underdeveloped regions, even
though many other methods, including drip irrigation are more efficient. [1] Research on drip
irrigation techniques allowed the team to design a system which satisfies the requirements of a
farmer with limited knowledge of the pump and little or no access to an electrical grid. [2] It was
also determined that the pump system has a relatively low flow rate and high head requirement
for pumping. [3] This information helped to establish conditions for research on existing micro
pump types and designs. [4]

With the planets ever-expanding need for food, an efficient and cost-effective method of
irrigating crops is essential in the development of many Third World nations. Therefore,
designing a successful drip irrigation pump system is a valuable investment. Existing pump
research, established requirements and customer needs were combined to produce a fitting
design which will succeed across the entire customer base.

1.3 Project Planning:
The team used a series of given project milestones to generate a specific timeline and Gantt chart
(Appendix A). Each member was given leadership roles in various project steps. Nam managed
initial product research and assigned individual tasks evenly among members. Sean led concept
modeling, and will be managing prototype construction. Nick headed the proposal presentation,
and will be leading the design report.
Our team plans to follow a set design process, involving planning, concept development, system
level design, detailed design, testing and production. With this clear, step-by-step process we
expect to attain better results relative to timely task completion and increased project aid from
team documentation.


2. Customer Needs and Specifications
The primary goal of Team D is to design a solar powered micro pump for the drip irrigation of
crops. The project limitations and requirements mean that the system shares many similarities
with pump systems in other markets, specifically small-scale plumbing and boating (emergency
water bailing). The team decided to generate customer needs from research of these established
systems as well as direct interviews with a local plumbing company, GoodCo.

An interview with Chris Good, an employee of GoodCo. Plumbing yielded valuable results. The
company uses micro centrifugal pumps almost exclusively for sump and sewage pump
applications, as they consistently exhibited better performance/durability vs. cost when compared
to positive displacement designs. Additionally, Mr. Good recommended researching battery-
powered micro pumps used in the evacuation of water from flooded basements or boats.

Online customer research regarding these pumps led us to conclude that although the battery-
operated pumps were very easy to install and use, many suffered from leakage issues, especially
into the motor housing. Since these pumps were not self-priming, they had to be immersed in
water to function, and suffered from poor build quality. US customers seemed to be willing to
pay more for a pump which had better durability.

Customer input and research was condensed into seven customer needs. A needs-metrics matrix
approach was used to generate product specifications for each need (Appendix B). An AHP
weighting matrix was used to weight each specification, giving the team a reasonably accurate
means of comparing product concepts. [5] The final list of product specifications and their
weights is shown below in Table 3 (refer to Appendix C for detailed information).

Need Weight Description
Safety 28% Product must pose no electrical or other hazard
Durability 24% Product should last for 5 years of irrigation cycles
Price 18% Product should be manufactured for less than $50
Ease of Use/Assembly,
Disassembly
12% Product components should be fully accessible,
and steps should be universally understandable
Efficiency 9% Pump should operate within solar power limits
Simplicity of Design 8% Parts should be common and kept to a minimum
Compactness 1% Product should be easily carried in one hand
Table 1. Concept Specifications and Weights

3. Concept Development
Research was done by all team members on existing irrigation pump systems and current patents
to help narrow down the top concepts. Eleven designs were produced, but were reduced to the
top four. A Concept scoring matrix helped the team to pick out the best design that met all of the
selected product specifications.


3.1 External Search:
The best-designed pump system must meet all product specifications, which were translated
from the most important customers needs. The potential product must also be durable so as to
withstand frequent wear and weather variation. With these points in mind, the team did external
searches on the different types and designs of pumps. The abilities to self-prime and to deliver a
constant flow of water with high efficiency were also high on the list of priorities. [6] Patent
searches related to the top four generated design concepts were done [7-10], which are shown in
Table 2 (refer to Appendix E for full patents details).
The external research proved to be extremely helpful in finding different pump designs. Mixtures
of centrifugal and positive displacement pump designs were presented as a result of the research.
[11] Even though the majority of the current existing irrigation systems are centrifugal based, it
did not limit the possible generated design concepts. There are many designs within each type
and the team considered both. The abundance of designs only helped toward generating new
concepts.
Double Acting
Piston [7]
Pat. #5076769
Filing date: Jul 16,
1990
Issue date: Dec 31,
1991
Multiple Magnetic [8]

Pat. #4678409
Issued July 7, 1987
Plastic Gear
Housing [9]
Pat. #6325604

Water Well [10]

Pat. #7837450
Issued:November
23, 2010
Filed: January 18,
2007
Descriptions
The piston is driven
by a gear motor
which acts as a
double piston
(double acting)
sliding back and
forth.
This is a double
magnetic pump system.
It has two inlets and
two outlets. A single
driving shaft is
connected through both
chambers.
This is a simple
gear pump
consisting of a
drive gear and an
idle gear. The
contact points
between the gears
and the interior are
sealed to pump
water.
This is a turbine
pump system. The
motor is submerged
with a long shaft
driving multiple
turbine impellers. It
draws low power, so
it can be powered by
solar panel.
Analysis
This patent provides
the same
functionality with
less complicated
parts. This could
possibly replace our
design of the double
piston.
This patent has an
interesting magnetic
design. Nevertheless,
this may possibly need
to be submerged in the
water. Since it is a
double pump, the motor
would have to be
powerful.
This is a simple
gear pump design.
With multiple
contact points,
wearing of gears
may prove to be a
problem.
This design has a lot
of parts. It could
possibly be hard to
manufacture and
assemble. Low
power input is a big
plus considering our
power source is solar
panel.
Table 2. Top Patent Search Summary


3.2 Problem Decomposition:

Figure 1. Pump System Functional Diagram

3.3 Concept Generation:
Eleven concepts were generated through brainstorming and using the sticky notes process. The
concepts were designed to meet at least most, if not all of the requirements. From there, the team
narrowed down the concepts to the top four by voting and weighting of the pros and cons. The
top concepts unanimously decided upon by the team are the double piston, floating magnetic
centrifugal, gear, and turbine. For detailed models and descriptions of these concepts, refer to
Appendix F.

3.4 Concept Combination:
The conversions of energies are broken down to just a solar panel, and a motor. More freedom is
given when discussing about applying mechanical transmission (Appendix G).

3.5 Concept Selection:
Multiple concepts based on both types of pump systems undertook the design selection criteria
screening. The concept scoring matrix helped with choosing the best design (Table 2, Appendix
D).

The top concept proved to be the magnetic design. Through further discussion, the team
disagreed with the outcome considering that a physical shaft is much more reliable and better
suited to the problem than a magnetic design. The magnet may slip in situations where the
resistance to spinning overcomes the strength of the magnets. Additionally, having magnets
which are strong enough to provide the required torque may cause too much friction as a result
of their bond. The team decided to combine the floating feature of the magnetic pump design
with the second concept, the turbine. This combination will remove the needs to water-proof the
sensitive parts individually, such as wiring and the motor. Water will be able to travel vertically
upward as the axial impellers rotate. The finished product should be light, simple, rigid, and
compact. In general, turbines do not require a lot of power and can be easily run by solar power.
It also produces a constant flow of water even with the low RPM.
Converted to
electricity by
solar panel
Trigger
opens
circuit
Mechanical energy
applied to water
Motor converts
electricity into
mechanical energy

4. System Level Design
The team wanted to produce a safe,
durable, and cost-effective micro-
pump for crop drip irrigation. The
finalized design utilizes PVC
housing, and is placed in-water. A
series of 3 axial impellers draws
water up through the filter into the
pump. The water is forced through
an exit nozzle of much smaller
diameter than the pump inlet, so as
to increase exit water velocity. The
section of PVC housing containing
the motor and switch are insulated
from the environment by a screw-on
cap. All housing components are
secured using PVC cement.

PVC is used for the housing because
of its low cost, abundance, and ease
of manufacturing. The plastic
impellers are based on micro RC
boat propellers, also selected with
ease of replacement and cost-
efficiency in mind. The motor
selected is the Jameco RS-385SH. It
provides the best efficiency within
the operating range of our pump, and
should generate the highest flow rate.
The motor is connected to the impeller
shaft by means of an axial adapter,
maintaining 100% shaft efficiency.

5. Detailed Design
5.1 Changes from Proposal
After reviewing the proposed concept, several important changes had to be made. The position
of the nozzle was changed to allow for the motor. The cap separating the impeller tube from the
motor housing was reduced in size to decrease cost and required length of the pump. The
diameter of the impeller tube was increased to allow for a pre-fabricated PVC grate. Insulating
rubber liners were added to increase waterproofing between the motor and impellers, after it was
discovered that there was some water leakage through the cap.
Figure 2. Current Prototype Design
Flow Direction

Figure 3: Exploded View of Pump
Power Switch
End-Cap Adapter
Plastic Cap
End-Cap Screw
Size 1.5 Pipe
Motor
Rubber Liner
2 to 1.5 Adapter
Plastic Cap
Shaft Coupler
Inlet Cover
Impeller
Housing Rings
Rubber
Liner
Impeller
Barb Mounting
Tube
Barbed Hose
Attachment

5.2 Theoretical Analysis

The specification of the pump in production must be the following requirements:

Flow () Head ()
0.5 1.64042

Unfortunately, the motor was chosen based on the speed and torque that it produces. Through
reanalyzing the different motors speed, the motor that produced the most revolutions per minute
should not have been chosen. The efficiency for the motor with the lowest speed (3000 RPM) is
roughly 82%. An analysis was conducted to produce a graph of the DC motors performance at
12 volts (Appendix J Fig. 12-13).

Part no. 2125528 Part no. 174693
Motor Efficiency ~ 63% ~ 82%

The turbine pump design proved to be ineffective and inefficient with the high speed motor and
it did not meet the minimum specifications during testing. A different design (axial centrifugal)
was chosen. Thus a new performance curve data was pulled for analysis. Head and flow rate
values are pulled from Dr. Lamancusas Little-Giant pump analysis sample report.

Little-Giant Pump Specs
Diameter () Speed ()
1.5 3250

A new generated relationship is produced to show the different curves of head versus flow
operating at a variety of speeds. The following affinity laws helped with the iterations of these
curves:

A new pump diameter of 1.0 and 1.5 are compared to the existing centrifugal pump 1.5
diameter. The iterations produced three equivalent head versus flow rate relationships
operating at 2400, 2800, and 2950 RPM for the slower motor, and at 8170, 6400, 400 RPMs for
the bigger motor.

A system load relationship is then produced to find the operating torque. The system load shows
the correlation between the total head at flow rate ranges from 0 to 16 GPM. The intersection
between the system load and the equivalent performance curves (Appendix J Fig. 14-17) enable
the team to find the equivalent motor torque at certain voltages (12V, 10V, 7.5V, 5V) using the
following properties and equations:

Specific Gravity of H2O
(
)
62.4
Pump Efficiency 0.7
() 66.67
.0633
.001899

*Hand-calculations and a quadratic solver are used to find the intersection points between the
curves. The numbers represents the data from the smaller motor with a 1 inch Dia. impeller.

() 2577.73 2530.3 2471.01 2411.73
( ) 32.63 25.62 16.87 8.113

() 269.94 264.97 258.76 252.56

The total torque lost (
) can also be related to the torque loss (
), and the torque constant

(
):

Relates the equations to find current
,

Power to Motor
Voltage Current ()
12 0.55
10 0.43
7.5 0.30
5 0.16

Relates the power to motor data to the solar panel output and check where it intersects. This
intersection represents the operating point of the pump (Appendix J Fig. 18-21).

Operating
Point @ 3K
RPM Motor
Voltage
()
Current
()
Power Input to
Motor ()
Head

Flow
Rate

Performance
Efficiency
@ 1 DIA. 8.92 0.379 3.381 1.92 0.656 ~72%
@ 1.5
DIA.
8.95 0.391 3.499 3.60 1.73 ~81%

Operating
Point @ 10K
RPM Motor
Voltage
()
Current
()
Power Input to
Motor ()
Head

Flow
Rate

Performance
Efficiency
@ 1 DIA. 4.22 0.458 1.933 1.88 0.598 ~28%
@ 1.5 DIA. 4.1 0.462 1.895 5.715 2.49 ~26%

The above results demonstrate that the higher speed, 10,000 RPM, motor is extremely inefficient
in performance. The smaller, and lower speed 3,000 RPM motor performance efficiency is
extremely high. There is an inverse relationship between the two motors. The faster motor
efficiency increases as the impeller diameter decreases. The slower motor efficiency decreases as
the impeller diameter increases.

It would be the teams best interest to go with the smaller motor due to its high performance
efficiency. The data shows that all impeller sizes, at both motors, will provide sufficient head
and flow rate.

The best motor will be the Part no. 174693, operating at 3000 RPM.
The best impeller size will be at 1.5 inch diameter.

*These calculations have been verified by testing the data points from the sample report Little
Giant Pump. The results turned out to be relatively the same.

5.3 Industrial Design
The Sonic Boom Pump is sturdy, compact, and offers a pleasing design. It is easy for users to
hold and operate. The clear plastic inlet cover protects the impeller from debris, while also
providing an efficient means of drawing water. The screw-on cover ensures a waterproof seal to
insulate the motor and allows for users to easily access all electrical components. The pump
includes a hose which is easy to attach. The durable housing is assembled using PVC cement,
creating a single, piece. The foam floats around the body of the pump allow it maintain a steady
flow rate as water levels change, while also keeping electrical components from being
submerged. The wires leading to the PV panel are also well insulated, ensuring safe operation.
5.4 Material Selection
The housing for the Sonic Boom Pump will be assembled from Schedule 40 PVC pipe and
fittings. Using standard-size PVC components eliminates costs for injection molding, and
creates a housing which is very cost-effective for its durability and ease of assembly. The pump
is designed for Third World agricultural use. Pleasing colors and designs are less important than
a product which feels tough. The impellers will be injection-molded out of
Polyetheretherketone, a type of plastic commonly used for pump impellers due to its thermal
stability, abrasion resistance and low moisture absorption. This will reduce costs and
manufacturing time, while still providing adequate strength and performance.
5.5 Manufacture and Fabrication
Fabrication of the Sonic Boom Pump combines ease of assembly with low cost. Wholesale PVC
orders are very cost-effective, and the majority of components will be cut from longer pipe
sections. PVC cement will be used to permanently assemble the housing, fusing it into one
piece. The 2 to 1.5 adapter and the barb mounting tube will be injection-molded as one piece.
The impeller will be injection-molded, as purchasing pre-fabricated impellers becomes more
expensive with a production run of 100,000 units. The impeller housing rings will be
permanently attached to the inlet cover. The impeller shaft will be cut from pre-fabricated brass
wire. All electrical components (switch, wire, motor) will be ordered to avoid fabrication costs.

5.6 CAD Drawings
The Sonic Boom Pump is constructed out of 17 separate components, many of which are
purchased off-the-shelf. Components which must be injection molded or modified during
manufacture are detailed in Appendix I. A detailed exploded view showing all parts is shown in
Section 5.1.

5.7 Economic Analysis
Because so many of the parts used were easily available in hardware stores and online,
calculating the majority of expected costs was quite easy. The cost of the PVC segments and
caps was based on online wholesale rates, and the cost of injection molding the impellers was
calculated from the raw material cost. Net Present Value (NPV) analysis was performed on the
Sonic Boom Pump over the first four years of production, based on researched analysis
guidelines [5]. Based on the NPV analysis, the product is expected to be profitable by the 2
nd

year. By the 4
th
year, the product expected revenue should be around 4.1 million dollars. For
more information, see Appendix H.


Table 3. Bill of Materials
5.8 Addressing Safety
As shown by Weighted Customer Needs (see Appendix C), safety is of primary importance to
users. The Micro Turbine Pump addresses primary concerns, such as electrical hazards and the
dangers of the spinning impellers. The well insulated and waterproofed housing protects
electrical components and floats keep them above water. A sturdy grate prevents damage to the
blades and to users. The pump is intended for adult users, but is safe for those over the age of
10. Production of The Micro Turbine Pump does not involve any chemicals which may be
hazardous to users or to the water used in irrigation. Drop-testing of the pump demonstrates its
durability in field use. In the event of impeller blade failure, the grate may be removed to install
a new blade shaft. We plan to protect the motor and electrical components from water damage
using a thin-walled rubber sheet which is designed to completely insulate the device. Safety is
our highest concern, and we made sure our pump passed all ULxxx and IECxxx Safety
requirements.

Component Quantity
Component Cost ($)
for 100k Quantities
Labor Costs
($)
Total Cost
per Pump ($)
Size 2 PVC Pipe 3 inch 0.28 per foot = 0.07 0.05 0.12
Size 1.5 PVC Pipe 1 inch 0.11 per foot = 0.01 0.05 0.06
Size 2 to 1.5 PVC Impeller Housing (Molded) 1 0.40 0.10 2.84
Plastic Inlet Cover 1 1.50 1.50
PVC End-Cap Screw and Adapter 1 2.85 2.85
Plastic Cap 2 0.45 0.05 0.95
Gasket 2 sq. inch 0.65 per sq. ft. = 0.01 0.05 0.06
Impeller (Molded) 3 0.30 0.10 1.00
Power Switch 1 0.25 0.25
Shaft Coupler 1 0.05 0.10 0.15
Shaft Mounting Bar 1 0.05 0.10 0.15
Impeller Shaft 3 inch 2.00 per ft. = 0.50 0.05 0.55
Motor 1 0.50 0.50
Brass Barb Hose Fitting 1 1.89 1.89
Plastic Tubing 1 meter 1.50 0.05 1.55
Wiring (18 gauge) and insulation 3 meters 0.15 0.15 0.30
14.72
Overhead 2.21
Total Cost
to Produce
per Unit 16.93
Retail Price
@ 100%
Profit 33.86
Unit Production Cost
15% of Unit Production Cost
Annual Production Volume = 100,000 Units

6. Prototype Testing
6.1 Test Procedure
Name of Prototype Micro Turbine Pump Floatation/Impact Test
Purposes Select material for floats
Confirm suitability of PVC housing for floatation
Confirm housings durability
Level of Approximation Correct housing dimensions
Correct weight
Experimental Plan Place prototype in water tank, observing any
leakage points and relative buoyancy
Note any points of weakness
Drop prototype onto concrete floor from standing
height of 5 ft.
Observe damage to prototype
Schedule November 5 Complete Alpha
Prototype
November 7 Perform floatation test
November 14 Perform impact test
November 15 Analyze test results
In order to present the most efficient design, it is important to develop an alpha prototype as well
as a way to test the model. In developing our pump we tested turbine speed vs. torque, motor
speed vs. Torque and the combine system output. The power of the motor relative to the energy
produced by the power source and the impeller size were biggest factors in our test results.
For experimental testing we attached our motor to the solar panel and a voltmeter to observe our
predicted calculations for current and voltage to the device. We were able to calculate the
predicted power of the system mathematically multiplying the RPM (speed) of the motor by the
torque. As a result of centrifugal pump research, we were a able to observe our specs verses
similar devices in the same size category. Considering our pump will be in the water, water
proofing the internal motor and electric components will be one of our top priorities. It is
important to understand how the device will float or sink in water to determine how to make the
right changes to our final design. Initially, the device sank during our float test and we had to
devise a plan to increase buoyancy. We decided to add a foam floatation device around the outer
shell to keep the device afloat.
Test instructions:
1. Connect the wires between the solar panel, and pump motor
2. Turn on the light source (Can use the voltmeter to measure voltage/current of the circuit
3. Submerge pump in water tank
4. Set tanks 0.5m apart
5. Turn on pump (Observe flow, head, flow rate)

Experiment Materials:
1. Voltmeter
2. Pump
3. wire clamps
4. Two Water Tanks 21x33x18 cm
6.2 Test Results
The data from our floatation test showed that while the foam does provide enough buoyancy, it
was a bit cumbersome. It was concluded that the foam should be replaced with an air-filled
floatation device. The results of the impact test were very positive. Every component remained
unharmed, and the PVC housing proved to be a durable design. Because these tests were
observational, no quantitative data could be gathered. The most recent test performed examined
the motors performance within the housing when run from the PV panel. This test was also
successful, but only after the amount of insulation between the motor and shaft was reduced.
This calls for a redesign of the waterproofing method.
Based on the flow rate test, the turbine pump design did not meet the project required
specifications. The pump only achieved about 4 inches of head and insufficient flow rate.
Further analysis revealed that the axial turbine design would not provide enough head and flow
rate within the limitation of the motor (Part no. 2125528). As a result, the design needed to be
change.
The turbine axial design was altered into an axial centrifugal design. Consequently, the new
centrifugal design did meet the project required specifications.
The first test was performed by placing the pump in a bucket filled with water. The pump was
turned on, and the outlet tube was slowly raised vertically until water stopped flowing from the
outlet. This is where the maximum head was measured.
The flow-rate test was performed by again placing the pump in the water bucket. This time, the
head was set at a fixed height, and the pump was turned on. Water flowing from the outlet tube
was collected in a 1 liter beaker, and the time taken to fill the beaker was measured.
Results gathered from the two designs:
Design Type Flow () Head ()
Turbine Insufficient ~ 0.333
Axial Centrifugal 0.647 ~ 1.70

*Based on the competition performance, our new design pump failed to perform. Significant
water leakage was observed during the performance. As a result, the motor were completely
overflowed with water. Our waterproofing method failed to deliver.
Another flow rate test was performed in the aftermath of the leakage:

Flow () Head ()
~ 2.0 ~ 0.5
Insufficient ~ 1.64 (minimum specification)

Once again, this calls for a redesign of the waterproofing technique.
7. Conclusion and Recommendations
7.1 Conclusion
Progress on the Sonic Boom Pump has completed final beta prototype development and testing.
Several major changes were made to the final prototype as a result of initial beta testing. The
purely axial impeller design provided inadequate head for the required application. The housing
of the pump proved to be durable, but several issues were discovered with sealing the motor
shaft. Further development of this prototype is required to ensure that the Sonic Boom Pump is
safe and reliable for users.
The Sonic Boom Pump has an ergonomic design, and is no bigger than a portable flashlight.
Although it is a design primarily inspired by practicality, the pump has a pleasing shape, size and
feel. Continued support in the Sonic Boom Pump would be of great value to the team and to
customers. The amount of useful research, prototyping and testing will support a successful final
pump design, providing farmers in the Third World with much needed improvement in
irrigation.

7.2 Design Improvements
The biggest improvement made to the final beta prototype was a redesign on the impeller. Axial
impellers, which displayed inadequate head, were replaced with a single centrifugal impeller. In
initial testing, both head and flow specifications were dramatically improved. Ultimately
though, the beta design proved to be unsuccessful in its reliability. Performance that was
initially up to requirements dropped when water leaked into the motor through the rubber seal.
Improving the seal around the motor shaft is the biggest change which will need to be made
further prototypes. Theoretical analysis of motor performance also revealed that the current
motor should be replaced with a smaller, more efficient motor to improve performance.
Although several very important changes need to be made to the current design, the knowledge
gained from current prototypes is very valuable, and a very important step in the design process.

7.3 Project Experience
The Solar Pump Project was very valuable in all team members understanding of the design
process, from the importance of customer research, to concept development and testing, to
starting over on a dead-end design. The steps involved in creating a successful product can feel
slow and overly-detailed, but each is very important. The values and challenges of working as
part of a team were perhaps some of the most important lessons learned this semester. Those
same struggles exist in the working world, and are instrumental in becoming a successful
engineer. This project was the first time several team members really felt like engineers.


7. References
1) "Flood Irrigation Introduction." Alliance for Water Efficiency. Alliance for Water
Efficiency, 2010. Web. 22 Sep 2012.

2) Brunet, Edward. "Pumps - Centrifugal vs. Positive Displacement." PHDEngineer. N.p.,
n.d. Web. 20 Sep 2012.

3) Cengel, Yunus A., and John M. Cimbala. Fluid Mechanics: Fundamentals and
Applications. Boston: McGraw-Hill Higher Education, 2010. Print.

4) Dee, James. "Different Pumps for Irrigation Systems." Government of Western Australia
Dept. of Agriculture and Food. Western Australia Agriculture Authority, 2011. Web. 22
Sep 2012.

5) Ulrich, Karl T., and Steven D. Eppinger. Product Design and Development. New York:
McGraw-Hill Higher Education, 2011. Print.

6) Morales, Teresa, and John Busch. Oregon. "Natural Resources Conservation Service".
Design of Small Photovoltaic Solar-Powered Water Pump Systems. Washington, DC:
United States Department of Agriculture, 2010. Print.

7) Shao, Jian-Dong. Double Acting Pump. U.S. Patent 5076769. Filed Jul 16, 1990.
Issued Dec 31, 1991

8) Kurokawa, Toshio. Multiple Magnetic Pump System. U.S. Patent 4678409. Filed Nov
21, 1985. Issued Jul 7, 1987

9) Du, Benjamin. Plastic Gear Pump Housing. U.S. Patent 6325604. Filed Mar 29, 2000.
Issued Dec 4, 2001

10) Moreland, Jerry. Water Well Pump. U.S. Patent 7837450. Filed Jan 18, 2007. Issued
Nov 23, 2010

11) "SX 330 30 Watt Photovoltaic Module." bpsolar.com. BP Solar, Jun 2007. Web. 1 Oct
2012.

12) Chavez, J.L., D. Reich, J.C. Loftis, and D.L. Miles. "Irrigation Pumping Plant
Efficiency." Colorado State University Extension. 4.712 (2011): Print.

13) "VT Series - Vertical Turbine Pumps 60Hz Performance Curves." Taco-HVAC. Taco,
Inc., 25 2009. Web. 27 Nov 2012.


Appendix A. Gantt Chart


Appendix B Product Specifications


Appendix C Weighted Customer Needs


Appendix D Concept Generation


Appendix E Concept Generation

Figure 1. Double Piston Pump
Description: The two pistons are driven by a single motor in the middle. As the disk rotates, it
pushes the pistons back and forth. It creates suction in one side and pumps on the other. This
pump generates a pulse-free flow and self-priming. Unfortunately it has a high number of parts.

Figure 2. Magnetic Pump
Description: This is a simple centrifugal pump. However, the driving shaft is not directly
connected to the impeller. The impeller is magnetically coupled to the motor. The two tubes on
the side serve as floats. It is an interesting design, but the magnetic field could be slower than
direct contact by a shaft if resistance in the system overcomes the magnetic bond.

Figure 3. Gear Pump
Description: The driving gear is attached to the motor and is in contact with the idler gear. The
motor powers the driving gear, of which would drive the idler gear as it rotates. The design is
simple and self-priming, but the manufacturing of the housing to fit closely to the gear teeth may
be difficult. With multiple contact points, there is a high potential of wear.

Figure 4. Turbine Pump
Description: This is a simple turbine pump design. A long shaft with multiple impellers is
connected to the motor (at bottom in gray). The number of impellers may be reduced during
manufacturing, based on which numbers produce maximum efficiency. The RPM is low for
turbine, but it provides a constant and reliable flow.

Appendix F: Patent Search References
Patent 1: Double Acting Pump


Patent 2: Multiple Magnetic Pump System


Patent 3: Plastic Gear Pump Housing


Patent 4: Water Well Pump


Appendix G: Concept Combination

Figure 5. Pump System Concept Classification Tree (The top 4 concepts are highlighted)

Figure 6. Pump System Concept Combination Diagram
Pump Types
Dynamic
Axial Flow Single Stage
Closed
Impeller
Open
Impeller
Turbine
Centrifugal
Open
Impeller
Magnetic
Positive
Displacement
Reciprocating
Rotary
Single Rotor
Vane
Flexible
Impeller
Piston
Mutliple
Rotor
Gear
Screw
Convert Solar Energy to
Electrical Energy
Solar Panel
Covert Electrical Energy
to Mechanical Energy
Rotary motor
Apply Mechanical
Transmission
Piston creats
pressure
difference
Axial Impeller
draws liquid
through vertically
Radial Impeller
forces liquid
outward
horizontally

Appendix H: NPV Analysis

Y
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1
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)
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1
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3
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Q
1
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2
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1
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Appendix I: Detailed Drawings

Figure 7. Dimensioned Drawing of Impeller

Figure 8. Dimensioned Drawing of Impeller Housing


Figure 9. Dimensioned Drawing of Screw-Cap

Figure 10. Dimensioned Drawing of Outer Impeller Housing Ring


Figure 11. Dimensioned Drawing of Inner Impeller Housing Ring


Appendix J: Performance Curves

Figure 12. Jamco Part no. 2125528 DC Motor Performance @ 12V

Figure 13. Jamco Part no. 174693 DC Motor Performance @ 12V
0.00
10.00
20.00
30.00
40.00
50.00
60.00
70.00
0 2000 4000 6000 8000 10000 12000
C
u
r
r
e
n
t

(
A
)
,

P
o
w
e
r

(
W
a
t
t
s
)
,

T
o
r
q
u
e

(
m
N
m
)

RPM
Jamco Part no. 2125528 DC Motor
Performance @ 12V
Current
Torque
W_out
W_in
Efficiency %
Linear (Torque)
0.00
10.00
20.00
30.00
40.00
50.00
60.00
70.00
80.00
90.00
0.00
2.00
4.00
6.00
8.00
10.00
12.00
0 500 1000 1500 2000 2500 3000 3500
C
u
r
r
e
n
t

(
A
)
,

P
o
w
e
r

(
W
a
t
t
s
)
,

T
o
r
q
u
e

(
m
N
m
)

RPM
Jameco Part no. 174693 DC Motor
Performance @ 12V
Current
Torque
W_out
W_In
Efficiency %

Figure 14. Motor (Part no. 2125528) Output Vs. Pump Input Power @ 1.5" Dia.


0.00
10.00
20.00
30.00
40.00
50.00
60.00
70.00
0.00
5.00
10.00
15.00
20.00
25.00
30.00
35.00
40.00
45.00
50.00
0 2000 4000 6000 8000 10000 12000
T
o
r
q
u
e

(
m
N
-
m
)

RPM
Motor (Part no. 2125528) Output Vs.
Pump Input Power @ 1.0" Dia.
12V
10V
7.5V
5V
Power to Pump
Operating T @ 4.22V
Motor Efficiency %
0.00
10.00
20.00
30.00
40.00
50.00
60.00
70.00
0.00
5.00
10.00
15.00
20.00
25.00
30.00
35.00
40.00
45.00
50.00
0 2000 4000 6000 8000 10000 12000
T
o
r
q
u
e

(
m
N
-
m
)

RPM
Pump Input Power @ 1.5" Dia.
12V
10V
7.5V
5V
Power to Pump
Operating T @ 4.1V
Motor Efficiency %



0.00
10.00
20.00
30.00
40.00
50.00
60.00
70.00
80.00
90.00
0.00
5.00
10.00
15.00
20.00
25.00
30.00
35.00
40.00
45.00
50.00
0 500 1000 1500 2000 2500 3000 3500
T
o
r
q
u
e

(
m
N
-
m
)

RPM
Pump Input Power
12V
10V
7.5V
5V
Power to Pump
Operating T @ 8.92V
Motor Efficiency %
0.00
10.00
20.00
30.00
40.00
50.00
60.00
70.00
80.00
90.00
0.00
5.00
10.00
15.00
20.00
25.00
30.00
35.00
40.00
45.00
50.00
0 500 1000 1500 2000 2500 3000 3500
T
o
r
q
u
e

(
m
N
-
m
)

RPM
Pump Input Power
12V
10V
7.5V
5V
Power to Pump
Operating T @ 8.95V
Motor Efficiency %

Figure 18. BP SX330 Panel Output Vs. Motor (Part no. 2125528) Input Power @ 1.0" Dia.

0
5
10
15
20
25
0 0.5 1 1.5 2 2.5 3 3.5
V
o
l
t
a
g
e

Current (amps)
BP SX330 Panel Output Vs. Motor
(Part no. 2125528) Input Power @ 1.0" Dia.
Unregulated
12V Regulator
Motor Input
0
5
10
15
20
25
0 0.5 1 1.5 2 2.5 3 3.5
V
o
l
t
a
g
e

Current (amps)
BP SX330 Panel Output Vs. Motor
(Part no. 2125528) Input Power @ 1.5" Dia.
Unregulated
12V Regulator
Motor Input



0
5
10
15
20
25
0 0.1 0.2 0.3 0.4 0.5 0.6
V
o
l
t
a
g
e

Current (amps)
BP SX330 Panel Output Vs.
Motor (Part no. 174693) Input Power @ 1.0" Dia.
Unregulated
12V Regulator
Motor Input
0
5
10
15
20
25
0 0.1 0.2 0.3 0.4 0.5 0.6
V
o
l
t
a
g
e

Current (amps)
BP SX330 Panel Output Vs.
Motor (Part no. 174693) Input Power @ 1.5" Dia.
Unregulated
12V Regulator
Motor Input

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ME 340.

2 Solar Powered Turbine Micro Pump 10/10/2012 1 | P a g e

( ) 32.63 25.62 16.87 8.113

) can also be related to the torque loss (

), and the torque constant

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