System Design & Project Plan
Contents
1. 17 Network Diagram Spring 2010 lei E Ed EEES A EAS Appendices Appendix A Budget References Copper Tubing Company www PlumbingSupply com Item Diameter Soft Copper Tubing Price 2 99 per foot Quantity Expected 4 feet Silicone Tubing Company MSC Industrial Supply Co Item Diameter Silicone Tubing Price 3 98 per foot Quantity Expected 1 foot Thermoelectric Generator Fan Company Thermal Enterprises Item 40 mm Thermoelectric Generator Price 14 99 each Quantity Expected 10 Company Newegg com Item MassCool Case Fan Price 1 49 Quantity Expected 1 2 Electrical Outlet Company Lowe s Item Commercial Grade Duplex Grounding Receptacle Price 52 49 Quantity Expected 1 On Off Switch Company Lowe s Item 15 Amp Lighted Grounding Switch Price 56 27 Quantity Expected 1 20 Insulation Company Lowe s Item Insulating Foam Sealant Price 3 58 Quantity Expected 1 Sheet Metal Company Lowe s Item 12 x 18 Steelworks Plated Sheet 26 Gauge Cost 4 66 Quantity Expected 5 ft 8 ft Inverter Company Amazon com Item Belkin F5C400 300W 2 Outlet DC AC Inverter Cost 34 24 Quantity Expected 1 21 Appendix B Requirements Specification Background There is a large interest in today s market for sustainable energy Consumers are looking for devices that can provide electricity to their home not only when power2. 0 S 8 0 S 9 0 Inverter Testing User Interface Testing Project Status System Integration System Testing amp Modifications User s Manual Final Report tF Fall S Spring K Kevin Jensen D Drew Messick J Jeremy Verzosa Ensure that the inverter meets specifications Ensure that the user interface meets specifications Presentation of project status Integrate the sub functions with one another Test the device and make any needed corrections Describes how to use the device and any special considerations Final presentation of the prototype device 14 Test results modification recommendations Test results modification recommendations Document Presentation Prototype Working Prototype Document Document Presentation K D J K D J K D J K D J K D J Gantt Chart Fall 2009 10 Dec 09 weg EIERE F3 0 Project Choice 25 Aug 09 10 sep 09 179 F 4 0 Requirements Specification 10 Sep 09 29 sep 09 198 T F5 0 Functional Decomposition 29 sep 09 15 0ct 09 178 Wen y F 6 0 System Design and Project Plan 29 sep 09 15 0ct09 17d T oo F7 0 Device Design 15 0ct 09 12 Nov o9 294 WE 0 F7 1 HeatPipeDesign 15 0ct 09 5 nov o9 ad El _ F7 2 TEGDesign 5 Nov 09 12 Nov 09 7d O o F7 3 CoolingDesign 15 0ct 09 s nov o9 ada COA es F7 4 EncasementDesign 5 Nov 09 12 Nov
3. heat pipe assembly tElectrical Components refers to any wires resistors capacitors inductors fuses or other miscellaneous items needed for the electrical system to function properly 11 Work Breakdown Structure Fall 2009 Taskt Activity Description Deliverables Start Stop Peoplet F1 0 Project Ensure that the team is on Constraints and Aug 25 K Management schedule and under budget specifications met Dec 10 F2 0 Documentation Keep records of all design Documents Aug 25 K D J work research and tests Engineering Dec 10 Notebooks F3 0 Project Choice Make a final decision of Confirmation Email Aug 25 K D J which project to pursue Sept 10 F4 0 Requirements Document describing Document Sept 10 K D J Specification quantifiable goals of the Sept 29 project F5 0 Functional Initial system design amp sub Device Flowchart Sept 29 K D J Decomposition function requirements Oct15 F 6 0 System Design System design proposal Document Sept 29 K D J amp Project Plan budget proposal schedule Presentation Oct 15 proposal F7 0 Device Design Design the sub functions Detailed Design Oct 15 K D J Test Results Nov 12 F7 1 Heat Pipe Collects heat from the fire Detailed Design Oct 15 K Design and transports it to the Test Results Nov5 generator F7 2 TEG Design Converts a temperature Detailed Design Nov 5 K differential to DC electricity Test Results Nov 12 F7 3 CoolingDesign Coolsthe cold side of the Detai
4. 09 7d E O F7 5 InverterDesign 15 0ct 09 SNovo9 ad e _ 76 User interface Design 5 Nov 09 t2 Novo9 7d E O F9 0 System Design Analysis 12 Nov 09 3 Deco9 lol F10 0 FinalDesgn 12 Nov 09 toDecos sa Al 15 Gantt Chart Spring 2010 January February weg April Te S 1 0 Project Management 11 Jan 10 2 May 10 112d Documentation 11 Jan 10 2 May 10 1120 III Initial Build 11 Jan 10 4 Mar 10 3 1 Heat Pipe Build 11 Jan 10 31 Jan 10 3 2 TEG Build 8 Feb 10 14 Feb 10 Cooling Unit Build 11 Jan 10 31 Jan 10 7d 7d ab a a Encasement Build Inverter Build User Interface Build 7d 54 0 Imitial Testing 1 Feb 0 S4 1 HeatPipe Testing 1 Feb 10 7 Feb 10 7d 54 3 Cooling unit Testing 1 Feb 10 7 Feb 10 7d s4 4 EncasementTesting 1 Mar 10 S4 5 Inverter Testing 1 Feb 10 7 Feb 10 7d S4 6 UserinterfaceTest 15 Feb 10 21 Feb 10 7d 55 0 Project Status 9 Feb 10 4 Mar 10 56 0 system Integration 15 Mar 10 1 Apr 10 18d 7 0 1 58 0 user s Manual 13 Apr 10 27 Apr 10 59 0 Final Report 29 Apr 10 23d 7 7 N N w N k e i dT C _ i ST o o C o o N oo __ m MN S ooo oo GP CT oo o I lt ___ _ __ ao_ o eC o I oo mm oo IN Po oo __ _ O MMM I o e oo __ _a_a _ Eee i i i iS o un 16 Network Diagram Fall 2009
5. Wood Burning Generator System Design amp Project Plan Kevin Jensen Drew Messick Jeremy Verzosa Table of Contents System Desigri ir atrio LE AR Ines bd ave ae 3 Background 3m it nia lla Linee 4 System Overview ai lla iaia iaia ani 5 Block KETTEL EE 6 Functional Deseription ofiBlocks astice lai tn 7 Project 9 Organization and Management 10 Estimated ee sss des c s v s ver ara aa ara ve 11 Work Breakdown Structure Fall 20009 12 Work Breakdown Structure Spring 2010 ii 13 Gantt Chart Fall 2009 ono wawa non ene eres et eee eee eee eee aaa aaa et enter 15 Gantt Chart Spring 2010 ananas di di 16 Network Diagram Fall 2009 serrures cua osama mana e kene aannkkaa neo nenen n noo nor nora eee tee eee tere eee 17 Network Diagram Spring 2010 i 18 tele lee et 19 Appendix A Budget References ice 20 Appendix B Requirements SpecificatiOnN ii 22 System Design Background There is a large interest in today s market for sustainable energy Consumers are looking for devices that can provide electricity to their home not only when power is unavailable but also in addition to their normal usage The trouble with most products is that they are complex bulky and expensive Additionally energy sources for these generators are not always available wind solar fossil fuels What is needed is a low cost storable easy to use device that
6. achments such as bolts or screws to be affixed prior to use Harmful Gases The device should not compromise the existing effectiveness of the fireplace to route harmful gases carbon dioxide carbon monoxide nitrogen oxides and aldehydes out from the house Due to the large variety of sensors needed along with the associated costs this will be judged by visually observing if there is a change to the amount of smoke in the room when the device is in use compared to when it is not in use Nature of Fuel The device will work with a fire built with wood logs not wood chippings or sawdust The user will not be required to cut the logs to certain dimensions provided the logs will fit in the fireplace User Intervention The user will be responsible for maintaining the fire An indicator on the device will notify the user if the fire is not hot enough sufficient power is not being produced see Indicators and Controls The device should not require the user to burn more than 25 pounds of wood per hour Indicators and Controls The device will indicate visually e g LED to the user when enough electricity is being generated to run a device Additionally the user will be able to cut off power to the outlet by shutting off the device with a switch Electrical Safety The electrical system must be grounded by a connection to an existing wall outlet s ground All internal wires should be able to handle the maximum amount of current in o
7. any electrical device which uses less than 150W of power to a standard NEMA Type B outlet Special Restrictions The generator must be considered safe with no parts exposed that could cut or burn the user Additionally the electrical aspects should present no risk of fire or shock The NEMA Type B outlet should be properly grounded Input The input of the device is a wood burning fire in an open hearth fireplace The heat from the fire will serve as the energy source for the electric generator Closed stoves and gas burning fireplaces will not be supported 22 Output The generator s output connector will consist of a NEMA Type B electrical outlet The outlet will provide 125 VAC 15 and at least 1 5 A 10 at 60 Hz 0 5 For comparison most normal household electrical outlets in the United States provide approximately 125 Volts and 15 Amps at 60 Hz when connected to the power grid Technical Requirements The following requirements must be met 1 Size The device should be small and light enough to be carried by a single person The generator should be no greater than 0 6 x 0 6 x 0 46 meters 2 x 2 x 1 5 feet This does not include the device for collecting and transporting heat from the fire to the generator Weight The device should not weigh more than 22 7 kg 50 Ibs Installation The generator will sit on the hearth and a device will be extended into the fire for heat collection There will be no permanent att
8. atts are being supplied to the outlet Input 110 VAC 125 VAC greater than 1 5 Amps 50 Hz 60 Hz User controlled switch Output 110 VAC 125 VAC greater than 1 5 Amps 50 HZ 60 Hz Power Indicator Unit Outlet The unit outlet is the standard household outlet NEMA type B that the user will plug their device into For safety reasons the neutral pin will be connected to the metal frame of the device Input 110 VAC 125 VAC greater than 1 5 Amps 50 Hz 60 Hz Output 110 VAC 125 VAC greater than 1 5 Amps 50 Hz 60 Hz Project Plan Organization and Management Our team consists of two mechanical engineering students and one electrical engineering student Project management and design tasks will be broken down into the following responsibilities Kevin Jensen Mechanical Engineering Kevin is the project manager and responsible for the project being completed on time and under budget He will ensure that the Requirements Specification System Design amp Project Plan Final Design Project Status User s Manual and Final Report documents and presentations are completed and turned in on time All parts ordering must go through Kevin to ensure that the budget is adhered to Additionally he is responsible for any design and construction relating to fireplace integration the heat pipe the hot side heat sink and the thermoelectric generator Drew Messick Mechanical Engineering Drew is responsible for th
9. e initial construction of the device as a whole He will oversee the fabrication of the sub functions as well as their preliminary and final integration Drew will be in charge of any CAD drawings that must be done Additionally he is responsible for any design and construction relating to the cold side heat sink the cooling component and device housing He will work closely with Kevin to ensure that the cold side heat sink is compatible with the cold side of the thermoelectric generator Jeremy Verzosa Electrical Engineering Jeremy is responsible for the system analysis and testing of the device This includes the initial testing of individual sub functions as well as the device as a whole Any modifications that are necessary due to these tests are also Jeremy s obligation Additionally he is responsible for any design and construction relating to the battery the inverter the user interface and the unit outlet He will work closely with Kevin to ensure that the inverter and battery interface seamlessly with the thermoelectric generator It is important to note that these individual tasks are not exclusive to each engineer only the responsibility for their completion Every member of the team will be expected to be familiar with each other s systems and to keep their ultimate integration in mind at all times during the design process 10 Estimated Costs Item Possible Vendor Cost Date of Estimate Heat Pipe Copper Tubi
10. e wood to be added to the fire the user will move the heat pipe using the poker or provided tool and add more logs When this is complete the heat pipe will be again positioned on top of the burning logs The heat pipe remains in the fireplace during this entire time but will either be pushed to the back or pulled to the front out of the way of the new logs This will be repeated as necessary When finished using the generator the user will turn off the device and allow it to cool down along with the fire Removing the heat pipe from the fireplace prematurely would present a burn risk The generator will be delivered as the entire unit thermoelectric generators cooling system and electrical components heat pipe etc The device being external will be versatile enough to integrate with most household fireplaces Block Diagram Encasement Boundary Hot Side E Heat Sink artery 220 C lt T lt 230 C 40 x 40 mm pad Thermoelectric Inverter Generator Excess heat 230 C without cooling 120 10 VAC 40 x 40mm pad A gt 1 5 Amps 60 05 Hz 220 C lt T lt 230 C Fireplace 12 VDC 20 Amps Cold Side Heat Sink User Interface Excess heat 230 C without cooling 120 10 VAC A gt 1 5 Amps Cooling Device 60 05 Hz Unit Outlet Functional Description of Blocks Fireplace The user s fireplace will act as the combustion chamber and contain the wood burning fire The fire will be req
11. grate the heat pipe and Working sub Feb 8 K cooling device with the TEGs function meet Feb 14 specifications S3 3 Cooling Unit Build the cooling unit and Working sub Jan 11 D Building ensure that it will cool the function meet Jan 31 TEG sufficiently specifications 3 4 Encasement Build the encasement and Working sub Feb 22 D Building ensure that all sub functions function meet Feb 28 will fit inside specifications S3 5 Inverter Build the inverter and Working sub Jan 11 J Building ensure that is provides the function meet Jan 31 proper output specifications 3 6 UserInterface Integrate the user interface Working sub Feb 8 J Building into the device and ensure it function meet Feb 14 works appropriately specifications 4 0 Sub Test the sub functions for Test results Feb 1 K D J Component input and output modification Mar A Testing recommendations S4 1 HeatPipe Ensure that the heat pipe Test results Feb 1 K Testing transfers heat at the needed modification Feb 7 rate recommendations S4 2 TEG Testing Ensure that the TEG Test results Feb 15 K interfaces with the heat modification Mar A pipe and cooling unit recommendations S4 3 Cooling Unit Ensure that the cooling unit Test results Feb 1 D Testing meets specifications modification Feb 7 recommendations S4 4 Encasement Ensure thatthe encasement Test results Mar 1 D Testing meets specifications modification Mar A 13 recommendations S4 5 S 4 6 S6 0 S 7
12. is unavailable but also in addition to their normal usage The trouble with most products is that they are complex bulky and expensive Additionally energy sources for these generators are not always available wind solar fossil fuels What is needed is a low cost storable easy to use device that provides supplemental energy to the home or emergency electricity if the power is out We believe that a generator using an already built fireplace as the energy source is the natural choice for this request The major benefit of this generator is that the combustion chamber is already available and safe users know how to use it and fuel is readily available The Deliverables There are five deliverables as listed below 1 Working Prototype 2 System Specifications a Design Concept b Block Diagram c CAD Drawing and Analysis 3 Circuit Schematics and Simulation Results 4 User s Manual 5 Bill of Materials Principles of Operation The user will begin by installing the generator to their existing fireplace The device will not be permanent but instead will be installed only when used The actual generator will sit on the hearth outside of the fireplace A device will extend into the fireplace to collect heat and transport it to the generator Once a fire is built and the chamber reaches a sufficient temperature the generator will begin to produce electricity and notify the user that they can plug in a device The user will then be able to plug in
13. led Design Oct 15 D TEG ensures maximum Test Results Nov 5 temperature differential F7 4 Encasement Encases all sub functions Detailed Design Nov 5 D Design except the heat pipe Test Results Nov 12 F 7 5 Inverter Design Converts TEG output to AC Detailed Design Oct 15 J and regulates voltage Test Results Nov 5 F 7 6 Userlnterface User controls and indicators Detailed Design Nov 5 J Design Test Results Nov 12 F8 0 System Design Ensure that individual parts Finalized System Nov 12 K D J Analysis will integrate into the Design Dec 3 system as a whole find parts to order F9 0 Final Design Final system and sub Document Nov 12 KD function design Presentation Dec 10 tF Fall S Spring K Kevin Jensen D Drew Messick J Jeremy Verzosa 12 Work Breakdown Structure Spring 2010 Taskt Activity Description Deliverables Start Stop People S1 0 Project Ensure that the team is on Deadlines Jan 11 K Management schedule and under budget constraints and May 2 specifications met 2 0 Documentation Keep records of all design Documents Jan 11 K D J work research and tests Engineering May 2 Notebooks S3 0 Sub Build the sub functions Working sub Jan 11 K D J Component functions meet Mar A Building specifications S3 1 Heat Pipe Build the heat pipe and Working sub Jan 11 K Building ensure that it will provide function meet Jan 31 the correct range of heat to specifications the TEG S3 2 TEG Building Inte
14. ng Silicone Tubing Tubing Accessoriest Condensing Chamber Copper Hot Side Heat Sink Copper Blocks Thermal Compound TEG Thermoelectric Generators Cold Side Heat Sink Copper Blocks Thermal Compound Cooling Device Copper for Fins Fans Battery Battery Electrical Components Inverter Inverter Electrical Components User Controls Switch LED Electrical Components Unit Outlet NEMA Type B Outlet Electrical Components Device Encasement Hardware Sheet Metal Insulation Miscellaneous Contingency Total Estimated Cost PlumpingSupply com MSC Industrial Supply Co Storm Copper Components Co Storm Copper Components Co Thermal Enterprises Storm Copper Components Co Storm Copper Components Co Newegg com Amazon com Lowe s Lowe s Lowe s Lowe s 200 00 10 00 5 00 30 00 25 00 50 00 5 00 40 00 5 00 3 00 2 00 5 00 10 00 5 00 10 00 20 00 5 00 350 00 850 00 Sept 30 2009 Sept 30 2009 Oct 11 2009 Oct 11 2009 Oct 11 2009 Oct 11 2009 Oct 2 2009 Oct 11 2009 Oct 11 2009 Oct 5 2009 Oct 5 2009 Oct 3 2009 Oct 11 2009 Oct 3 2009 Oct 11 2009 Oct 11 2009 Oct 11 2009 Oct 11 2009 Oct 3 2009 Oct 11 2009 Oct 11 2009 Oct 11 2009 Oct 11 2009 tTubing Accessories refers to any connectors pipe caps valves soldering requirements or other miscellaneous items needed for the construction of the
15. ng from the cold side of the thermoelectric generators 40mm x 40mm each to the cooling device The temperature should remain below 50 C Input Excess heat 230 C without cooling on 10 pads 40mm x 40mm Output Excess heat 230 C without cooling Cooling Device The cooling device will serve to keep the heat sink below 50 C This will be achieved through either natural convection or forced convection by a fan around fins or a tube bank Input Excess heat 230 C without cooling Output None Battery The battery will be charged by excess DC voltage produced by the thermoelectric generator It will serve as a regulator as the output of the thermoelectric generators fluctuates Input 12 Volts and 20 Amps DC 240 Watts Output 12 Volts and 20 Amps DC 240 Watts Inverter The inverter will convert the DC power from the thermoelectric generator or battery into AC power and step up the voltage Input 12 Volts and 20 Amps DC 240 Watts Output 120 10 VAC greater than 1 5 Amps 60 05 Hz User Interface This circuitry will control the flow of power to the outlet as well as indicate to the user when sufficient power is being supplied to the outlet When the user switch is in the on position power will be available and the user can plug in a device using 200 Watts or less When it is in the off position no power will be supplied to the outlet Additionally a single indicator LED will light up when at least 150 W
16. provides supplemental energy to the home or emergency electricity if the power is out We believe that a generator utilizing a wood fire in an existing fireplace as the energy source is the natural solution The major benefit of this generator is that the combustion chamber is already available and safe users know how to use it and fuel is readily available Our device will fill these requirements by being relatively inexpensive when compared to other sustainable energy products small enough to easily store and transport and simple to use If the user already burns fires in the home for heating or otherwise this device s fuel will come at no extra cost The energy will simply come from the excess heat that is generally lost during wood burning The generator will only be able to run or charge electrical devices that require less than 200 watts of power Devices that require more power will not be supported System Overview Our project will provide power to a standard household outlet NEMA Type B utilizing a wood burning fireplace The device will consist of a main generator box which will sit on the hearth outside of the fireplace along with a heat pipe that extends into the fire The main generator will fit into a rectangular space no larger than 0 6 x 0 6 x 0 46 meters approximately the size of a laundry basket and weight less than 22 7 kg 50 Ib These dimensions will allow the device to be easily transportable and storable by a single per
17. rder to prevent electrical fires Wire that is at least an AWG gage 10 nonmetallic insulated wire will provide this safety General Safety Any exposed outside of the fireplace surface of the device should not exceed 43 degrees Celsius 110 F in order to prevent burning the user 23
18. son The main generator will also house the user interface consisting of an on off switch a power indicator and the power outlet The power indicator will let the user know when the device is generating enough electricity for the outlet to be used When in use the main generator will collect heat from the fire via a gravity return heat pipe sometimes known as a thermosyphon This heat pipe will transport the heat away from the fire and to the main generator sitting on the hearth Inside the main generator several thermoelectric generators will utilize the temperature differential between the provided heat and a cooling device These thermoelectric generators will provide a DC voltage which will be sent to an inverter to convert it to the required output The power indicator will analyze this output and if it is sufficient notify the user A backup battery will also be charged using the DC voltage in order to supplement the output as the temperature of the fire fluctuates gr In order to set up and use the generator the user will first place the device on the hearth to the right of the fireplace aligning the turn in the heat pipe with the right edge of the fireplace and build a fire Using their poker or a provided tool the heat pipe will then be positioned on top of the burning wood The user will then wait until the power indicator lights up Once this has happened the user may turn on the switch and plug in a device When it is time for mor
19. uired to provide a temperature of at least 250 C 482 F Input Wood Output Temperatures above 250 C Heat Pipe The heat pipe will gather heat from the fire and transport at a rate sufficient to keep the hot side heat sink at a temperature between 220 C and 230 C provided that the fire temperature is above 250 C If the fire falls below 250 C then the hot side heat sink will fall below 250 C Input Temperatures above 250 C Output Temperatures between 220 C and 230 C Hot Side Heat Sink The hot side heat sink will transfer the heat from the heat pipe and distribute it to the hot side of 10 thermoelectric generators 40mm x 40mm each It will maintain a temperature of 220 C to 230 C Input Temperature between 220 C and 230 C Output Temperature between 220 C and 230 C on 10 pads 40mm x 40mm Thermoelectric Generator The thermoelectric generator will use the temperature differential that exists between the hot side heat sink and the cold side heat sink to produce approximately 12 Volts and 20 Amps DC or 240 Watts 10 individual thermoelectric generators providing 8 volts and 4 amps each 2 sets in series of 5 in parallel Input Temperature between 220 C and 230 C on 10 pads 40mm x 40mm Output 12 Volts and 20 Amps DC 240 Watts Excess heat 230 C without cooling on 10 pads 40mm x 40mm Cold Side Heat Sink The cold side heat sink will transfer excess heat 230 C without cooli
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