Final Design Report: Pedal-Powered Drivetrain System June 3, 2017 Team 34 - Callaghan Fenerty Geremy Patterson Bradley Welch Sponsor: Geoffrey Wheeler Advisor: Professor Rossman TABLE OF CONTENTS I – List of Tables ............................................................................................................................................. 8 II – List of Figures .......................................................................................................................................... 8 1 – Introduction ........................................................................................................................................... 9 1.1 -- Summary .................................................................................................................................... 9 1.2 – Persons Involved ........................................................................................................................... 10 1.3 – Previous Efforts ............................................................................................................................. 10 2 – Background........................................................................................................................................... 10 2.1 – Root Problem ................................................................................................................................ 10 2.2 – Our Problem .................................................................................................................................. 10 2.3 – Location (15.65°S,35°E) ................................................................................................................. 11 2.4 – Customers ..................................................................................................................................... 11 2.4.1 – Mr. Wheeler (Sponsor) ........................................................................................................... 11 2.4.2 – Mr. Apple and EWB (Consultant Organization) ..................................................................... 12 2.4.3 – Local Machinists & Potential Entrepreneur (Manufacturer) ................................................. 12 2.4.4 – Residents of Kumponda Group Village (User and Maintainer) .............................................. 13 2.5 – Benchmarking ............................................................................................................................... 13 2.5.1 – Bicycle Kit for GrainMaker® Mill ............................................................................................. 13 2.5.2 – US Patent US6983948B2: Human powered device and removable flywheel power unit .... 14 2.5.3 – Fluid2 Cycling Trainer ............................................................................................................. 15 2.5.4 – Exercise Bike Flour Mill, Provident Living New Zealand ......................................................... 15 2.5.5 – People Powered Flour Mill ..................................................................................................... 16 2.5.6 – Country Living Mill with custom bicycle power attachment.................................................. 17 2.5.7 – EWB Design 1 - Friction Drive ................................................................................................. 18 2.5.8 – EWB Design 2 - Chain Drive .................................................................................................... 19 2.5.9 - Concrete Bicycle Flywheel ....................................................................................................... 20 2.6 - Potential Power Sources ................................................................................................................. 21 2.6.1 – Electrical .................................................................................................................................. 21 2.6.2 – Hydro ....................................................................................................................................... 21 2.6.3 - Fuel Combustion ...................................................................................................................... 21 2.6.4 – Wind ........................................................................................................................................ 21 2 2.6.5 - Human (Pedal Power) .............................................................................................................. 21 2.7 – Maize Mill Project Team Relations ................................................................................................. 22 3. – Requirements ...................................................................................................................................... 22 3.1 – Problem Statement ....................................................................................................................... 22 3.2 – Goals ............................................................................................................................................... 22 3.3 – QFD Process ................................................................................................................................... 23 3.4 – Engineering Specifications ............................................................................................................. 23 3.5 – Discussion ....................................................................................................................................... 24 4. – Design Development ............................................................................................................................ 25 4.1 – Processes Overview and Methodology .......................................................................................... 25 4.1.1 – Problem Identification and Definition .................................................................................... 25 4.1.2 – Conceptualization ................................................................................................................... 25 4.1.3 – Evaluation and Analysis ........................................................................................................... 25 4.1.4 – Detail Design ........................................................................................................................... 25 4.1.5 – Manufacture ........................................................................................................................... 25 4.1.6 – Validation ................................................................................................................................ 25 4.1.7 – Documentation ...................................................................................................................... 26 4.2 – Functional Break-down ................................................................................................................. 26 4.2.1 -- Transmit Power ....................................................................................................................... 26 4.2.2 - Supply Required Work Rates and Magnitudes at the Output ................................................. 26 4.2.3 – Self Support ............................................................................................................................. 26 4.2.4 -- Support and Interface with Prime Mover ............................................................................... 26 4.2.5 -- Support and Interface with Driven Machine .......................................................................... 26 4.3 – Concept Generation ...................................................................................................................... 27 4.3.1 – Rotation ................................................................................................................................... 27 4.3.2 -- Support ................................................................................................................................... 27 4.3.3 -- Power Transmission ................................................................................................................ 27 4.4 – Concept Development and Selection ............................................................................................ 28 4.4.1 – Go/No-Go ............................................................................................................................... 28 4.4.2 – Pugh Matrices......................................................................................................................... 28 4.4.3 – System Concepts .................................................................................................................... 29 4.5 – Final Concept ................................................................................................................................. 35 4.5.1 – Design Safety Hazard Identification Checklist ......................................................................... 36 3 5 – Detailed Design ..................................................................................................................................... 37 5.1 – Functions / Requirement Satisfaction ............................................................................................ 37 5.1.1 – Output Capability and Range .................................................................................................