FINAL REPORT
SOLAR POWERED SONIC BOOM MICRO PUMPTeam D12 December, 2012
Sean MunckNam PhamNick PinnExecutive SummaryUnderdeveloped
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.Table of Contents
__________________________________________________________________
Executive Summary
1. Introduction..41.1 Problem1.2 Background Information1.3
Project Planning
2. Customer Needs and Specifications.5
3. Concept Development..53.1 External Search3.2 Problem
Dissection3.3 Design Concepts3.4 Concept Combination3.5 Concept
Selection
4. System Level Design..8
5. Detailed Design...........85.1 Changes from Proposal5.2
Theoretical Analysis5.3 Industrial Design5.4 Material Selection5.5
Manufacture and Fabrication5.6 CAD Drawings5.7 Economic Analysis5.8
Addressing Safety
6. Prototype Testing.......136.1 Test Procedure6.2 Test
Results
7. Conclusion and Recommendations.......157.1 Conclusion7.2
Design Improvements7.3 Project Experience
8. References....16
Appendices:
A. Gantt ChartB. Product SpecificationsC. Weighted Customer
NeedsD. Concept GenerationE. Concept GenerationF. Patent Search
ReferencesG. Concept CombinationH. Bill of MaterialsI. Dimensioned
DrawingsJ. 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 SpecificationsThe 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).
NeedWeightDescription
Safety28%Product must pose no electrical or other hazard
Durability24%Product should last for 5 years of irrigation
cycles
Price18%Product should be manufactured for less than $50
Ease of Use/Assembly, Disassembly12%Product components should be
fully accessible, and steps should be universally
understandable
Efficiency9%Pump should operate within solar power limits
Simplicity of Design8%Parts should be common and kept to a
minimum
Compactness1%Product should be easily carried in one hand
Table 1. Concept Specifications and Weights
3. Concept DevelopmentResearch 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. #5076769Filing date: Jul 16, 1990Issue date: Dec 31,
1991Multiple Magnetic [8]
Pat. #4678409Issued July 7, 1987Plastic Gear Housing [9]Pat.
#6325604
Water Well [10]
Pat. #7837450Issued:November 23, 2010Filed: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:
Water
Water Mechanical energy applied to waterConverted to electricity
by solar panelLight Source
Motor converts electricity into mechanical energyTrigger opens
circuitOn/Off Trigger
Heat
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.4. System Level DesignThe 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.Flow Direction Figure 2. Current
Prototype Design
5. Detailed Design5.1 Changes from ProposalAfter 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.
Impeller Housing RingsRubber LinerBarbed Hose AttachmentShaft
CouplerBarb Mounting TubePower SwitchEnd-Cap AdapterInlet
CoverMotorSize 1.5 PipeImpeller2 to 1.5 AdapterPlastic CapRubber
LinerEnd-Cap ScrewPlastic Cap
Figure 3: Exploded View of Pump5.2 Theoretical Analysis
The specification of the pump in production must be the
following requirements:
Flow ()Head ()
0.51.64042
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. 2125528Part 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 ()
1.53250
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.
()2577.732530.32471.012411.73
()32.6325.6216.878.113
()269.94264.97258.76252.56
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
VoltageCurrent ()
120.55
100.43
7.50.30
50.16
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 MotorVoltage ()Current ()Power Input to
Motor ()Head Flow Rate PerformanceEfficiency
@ 1 DIA. 8.920.3793.3811.920.656~72%
@ 1.5 DIA.8.950.3913.4993.601.73~81%
Operating Point @ 10K RPM MotorVoltage ()Current ()Power Input
to Motor ()Head Flow Rate Performance Efficiency
@ 1 DIA. 4.220.4581.9331.880.598~28%
@ 1.5 DIA.4.10.4621.8955.7152.49~26%
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 DesignThe 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
SelectionThe 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 FabricationFabrication 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 DrawingsThe 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 AnalysisBecause 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 2nd year. By the
4th year, the product expected revenue should be around 4.1 million
dollars. For more information, see Appendix H.
Table 3. Bill of Materials5.8 Addressing SafetyAs 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. 6. Prototype Testing6.1 Test
ProcedureName of PrototypeMicro Turbine Pump Floatation/Impact
Test
PurposesSelect material for floats
Confirm suitability of PVC housing for floatation
Confirm housings durability
Level of ApproximationCorrect housing dimensions
Correct weight
Experimental PlanPlace 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
ScheduleNovember 5Complete Alpha Prototype
November 7Perform floatation test
November 14Perform impact test
November 15Analyze 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 motor2.Turn on the
light source (Can use the voltmeter to measure voltage/current of
the circuit3.Submerge pump in water tank4.Set tanks 0.5m
apart5.Turn on pump (Observe flow, head, flow rate)Experiment
Materials:1.Voltmeter2.Pump3.wire clamps4.Two Water Tanks 21x33x18
cm6.2 Test ResultsThe 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
TypeFlow ()Head ()
TurbineInsufficient~ 0.333
Axial Centrifugal0.647~ 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 Recommendations7.1 ConclusionProgress
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 ImprovementsThe 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 ExperienceThe 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. References1) "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 PumpDescription: 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 PumpDescription: 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 PumpDescription: 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 PumpDescription: 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 ReferencesPatent 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 DiagramAppendix H: NPV
Analysis
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
Figure 14. Motor (Part no. 2125528) Output Vs. Pump Input Power
@ 1.5" Dia.
Figure 15. Motor (Part no. 2125528) Output Vs. Pump Input Power
@ 1.5" Dia.
Figure 16. Motor (Part no. 174693) Output Vs. Pump Input Power @
1.0" Dia.
Figure 17. Motor (Part no. 174693) Output Vs. Pump Input Power @
1.5" Dia.
Figure 18. BP SX330 Panel Output Vs. Motor (Part no. 2125528)
Input Power @ 1.0" Dia.
Figure 19. BP SX330 Panel Output Vs. Motor (Part no. 2125528)
Input Power @ 1.5" Dia.
Figure 20. BP SX330 Panel Output Vs. Motor (Part no. 174693)
Input Power @ 1.0" Dia.
Figure 21. BP SX330 Panel Output Vs. Motor (Part no. 174693)
Input Power @ 1.5" Dia.
ME 340.2 Solar Powered Turbine Micro Pump 10/10/201215 |
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