Professional Documents
Culture Documents
Executive Summary
The goal of this project is to design a safe, clean, sustainable, and affordable cook stove for the developing region of Nepal. Throughout the semester, the team will evaluate and meet customer needs culturally and performance wise, and conduct external searches to design a sustainable cook stove that reduces harmful emissions, requires less fuel, is longer lasting and durable, and is easy to use and clean. This report will outline the methods taken to select a final concept, the processes carried out to produce the cook stove, and the analysis involved with testing the cook stove. We are looking to achieve a production cost of just over $20 and be able to reduce the current carbon monoxide emissions by at least 30%. The ultimate goal is to obtain a CO emission of less than 30 ppm. However, the lowest recorded emission from the Envirofit G3300 Cook Stove is 86 ppm. Therefore, anything below this value will show that the design is heading in the right direction.
Table of Contents
Executive Summary....................................................................................................................................... 0 1.0 Introduction ............................................................................................................................................ 3 1.1 Initial Problem Statement ................................................................................................................... 3 1.2 Objectives............................................................................................................................................ 3 2.0 Customer Needs Assessment.................................................................................................................. 3 2.1 Gathering Customer Input .................................................................................................................. 3 2.2 Weighing of Customer Needs ............................................................................................................. 5 Table 1: AHP Pairwise Comparison Chart to Determine Weighting for Main Objectives .................... 5 3.0 External Search ....................................................................................................................................... 5 3.1 Patents ................................................................................................................................................ 5 Figure 1: Envirofit Patent US2010/0258104 A16................................................................................... 6 3.2 Existing Products ................................................................................................................................. 7 4.0 Engineering Specifications ...................................................................................................................... 7 4.1 Establishing Target Specifications ....................................................................................................... 7 4.2 Relating Specification to Customer Needs.......................................................................................... 8 Table 2: Needs-Metrics Matrix to relate Specifications to Customer Needs ...................................... 8 5.0 Concept Generation and Selection ......................................................................................................... 8 5.1 Problem Clarification .......................................................................................................................... 8 Table 3: Questions/Solutions Table for Concept Generation ............................................................... 9 5.2 Concept Generation ............................................................................................................................ 9 5.3 Concept Selection ............................................................................................................................. 11 Table 4: Pugh Concept Scoring Matrix ................................................................................................ 11 6.0 System Level Design .............................................................................................................................. 11 Figure 2: 3-D SolidWorks Drawing of Concept 1 ................................................................................. 12 7.0 Special Topics ........................................................................................................................................ 12 7.1 Budget and Vendor Purchase Information ....................................................................................... 12 Table 5: Distribution of Funds ............................................................................................................. 13 7.2 Project Management ........................................................................................................................ 13 7.3 Risk Plan and Safety .......................................................................................................................... 13 Table 6: Risk Management Plan Chart ................................................................................................ 14 7.4 Ethics Statement ............................................................................................................................... 14
2 7.5 Environmental Statement ................................................................................................................. 15 7.6 Community and Coordination with Sponsor .................................................................................... 15 8.0 Detailed Design ..................................................................................................................................... 15 8.1 Manufacturing Process Plan ............................................................................................................. 16 Table 7: Manufacturing Process Plan.................................................................................................. 16 8.2 Analysis ............................................................................................................................................. 17 Figure 3: Output voltage versus Temperature Gradient.................................................................... 17 8.3 Material and Material Selection Process .......................................................................................... 18 8.4 Component and Component Selection Process ............................................................................... 19 8.5 CAD Drawings.................................................................................................................................... 19 Figure 4: Thermo-Shell-Ectric Prototype Design ................................................................................. 19 8.6 Test Procedure .................................................................................................................................. 20 8.7 Economic Analyses Budget and Vendor Purchase Information..................................................... 20 Table 8: Current Spending on Project ................................................................................................. 21 9.0 Final Discussion ..................................................................................................................................... 21 9.1 Construction Process ........................................................................................................................ 21 9.2 Test Results and Discussion .............................................................................................................. 22 Table 9: Testing Results of Prototype ................................................................................................. 22 Table 10: Testing Result of the Two Thermoelectric Devices ............................................................. 22 10.0 Conclusions and Recommendations ................................................................................................... 23 11.0 Self-Assessment (Design Criteria Satisfaction) ................................................................................... 24 11.1 Customer Needs Assessment.......................................................................................................... 24 11.2 Global and Societal Needs Assessment .......................................................................................... 25 References .................................................................................................................................................. 27 Appendix ..................................................................................................................................................... 28
1.0 Introduction
1.1 Initial Problem Statement
Nearly half of the worlds population cooks their daily meals by burning biomass fuel (wood, animal dung or agricultural waste). Most meals are cooked on open fires or rudimentary, inefficient stoves that release high levels of toxic emissions into peoples homes. The World Health Organization estimates that this Indoor Air Pollution (IAP) kills over 2 million people annually, where over half (56%) of these deaths are children under the age of 5. Additionally, in many regions the gathering of wood causes deforestation (leading to increased erosion, landslides and habitat destruction) and is often dangerous for the gatherers (primarily women and children). In areas where fuel is not readily available to gather, households must purchase their wood at great cost that is a substantial portion of the household budget. Technical solutions are available to address both the health, environmental and economic effects of IAP; however they need to be implemented on a large enough scale to make a difference. The world-wide IAP problem is too large to be tackled via subsidy or give-away programs. A true market based solution is needed.
1.2 Objectives
The objective of this design is to develop a clean sustainable cooking stove for developing world countries. The targeted audience for this design is the country of Nepal, specifically the region of Chitwan. The current cook stoves provide a way for low-income families in developing world countries to cook food in their home by means other than an open fire. However, the carbon monoxide emissions off of these cook stoves have been reported up to 86 ppm.1 The current Occupational Safety and Health Administration (OSHA) permissible exposure limit is 50 ppm.2 The design will aim to lower these emissions while keeping the cost and weight of the cook stove about the same.
information was also gathered from various journals and articles regarding their cooking methods. The region of Chitwan is about 150 kilometers from the capital of Nepal, Kathamandu.5 It is in the middle of Terrai which is a vast, flat, fertile area that borders India and stretches across southern Nepal. The people in Chitwan region are from mixed tribes but primarily thareu people.5 The average family size comprises of four people.5 There primary work is farming because of the vast, fertile land. The farming provides their primary income therefore; the people of Chitwan have a very low income. The current cooking methods in Nepal are a traditional cooking stove which involves a dugout fire pit that uses cord wood, agro residue, and cow dung as fuel. Also, the newly introduced sustainable cooking stoves have modified features to enhance efficiency with respect to fuel wood consumption. The traditional cook stoves have a very low efficiency of about 10% (energy stored in the wood). Most of the smoke stays in the kitchen because of the absence of any type of chimney or ventilation system. This smoke can be very harmful and has claimed mostly the lives of women and children in Nepal. The smoke can cause diseases ranging from acute respiratory infection, pneumonia, lung cancer, and many other harmful diseases. Not only do traditional cooking stoves pose a medical threat to the people in Nepal, but they also contribute to house fires There have been reports of children falling into the open flame and causing serious burns. Not to mention there are serious environmental effects of these traditional cooking stoves. Therefore, a more efficient, safe cooking stove is needed. The main fuel source in Nepal is woody biomass accounting for almost 80% of the countrys energy demands.3 The woman and children in Nepal are responsible for collecting the wood. Since fuel wood accounts for most of the energy needs in Nepal, it exerts immense pressure on the forest resources within the country. Therefore, it is important for the improved cook stoves to reduce the amount of fuel consumption. Most of the meals that are prepared in Nepal are curry vegetables, rice, meat curry, and potatoes.4 The main dish that is served in Nepal is called dal bhat which comprises of at least one dish of rice (bhat), lentil soup (dal), and a vegetable curry (tarkari).4 They do eat meat curry (maseu) but only on certain occasions. They also eat a small amount of pickle sauce (achar) as a side dish. The cooking methods that are involved include stewing, frying, steaming, and simmering. For the serving of an average family, (4 people) the average cooking time is about 30-35 minutes for rice, 1060 minutes for lentil, 20 minutes for the vegetable curry, 25 minutes for meat curry, and about 10 minutes for the pickle sauce.4 Therefore, it is important for the improved cook stoves to be able to perform all of these cooking functions. One of the main goals for designing this cook stove is to ensure this stove can be produced in Chitwan, Nepal. From research, it was found that there is an industrial site in Hetauda which is a small city about 45 miles from Chitwan. The industrial park comprises of many industries like steel factories, textiles, chemical plants, and mining plants. Therefore, it was determined that the cook stove can be produced in Nepal. Along with knowledge obtained from Sambharant, information was gained from various journals and articles online. The weighing of the customer needs was then ranked based on the groups knowledge obtained from Sambharant and the online articles.
Table 1: AHP Pairwise Comparison Chart to Determine Weighting for Main Objectives
Safe Safe Ease of Use Ease of Mfg Cost Efficient Durable Portable 1.00 0.50 1.00 1.00 1.00 0.33 0.33 Ease of Use Ease of Mfg Cost 2.00 1.00 1.00 1.00 1.00 1.00 1.50 1.00 2.00 1.00 1.50 0.50 1.00 0.50 1.00 0.67 1.00 1.00 1.00 0.50 0.50 Efficient Durable Portable Total Weight Percent 1.00 3.00 3.00 12.00 0.21 20.63% 0.50 0.67 1.00 5.33 0.09 9.17% 1.00 2.00 2.00 9.00 0.15 15.47% 1.00 2.00 2.00 9.50 0.16 16.33% 1.00 2.00 3.00 11.00 0.19 18.91% 0.50 1.00 3.00 7.33 0.13 12.61% 0.33 0.33 1.00 4.00 0.07 6.88%
These criteria are the 7 most important features gathered from our data with customer needs. After all of the specifications were ranked and weighted according to the Table 1 above. We developed specific characteristics that our final design will have to follow. The top three criteria that received the highest percent of importance were safety, efficiency, and cost. All of these criterias will be considered heavily when producing our final product design.
The best patent to meet most of our design specifications was Patent No: US 2010/0258104 A1, shown below in Figure 1.
The next step in the external search was to benchmark the competition to see what products are currently being sold. This is useful to see what designs customers prefer and what they dislike. This stage of the external search was done by searching through cook stove patents to determine the market value. The single-most mentioned comment was the need for a better air to fuel ratio to increase the efficiency of our product.
Surface Finish/Color
Thermal Efficiency
Production Cost
1 2 3 4 5 6 7
Needs Safety Ease of Use Ease Of Mfg Cost Efficiency Durability Portability
x x x x x x x x x x x x x x x x
Table 2 indicates that which customer need is related to the engineering specification. As you can see only one of the engineering specifications cannot be met by a certain customer need. This chart explains which engineering specifications are supported by customer needs.
Learning Curve
Total Weight
Part Count
Lifetime
Metrics
Table 3: Questions/Solutions Table for Concept Generation Problem Potential Solution Biomass (wood) Kerosene Solar What will the fuel source for the stove be? Gas Propane Charcoal Fan add-on How will carbon monoxide emissions be lowered? Holes in side of cook stove Fuel feeding system What add-ons will make the cook stove easier to use? Quick start kerosene system Pull out tray $0-10 $10-20 How much will the stove cost? $20-30 $30-40 Aluminum Steel What materials will be used to make the stove? Powder Coated Steel Iron Thermoelectric Device Battery How will the fan be powered? Hand Powered Spring Powered Solar Funnel Shaped How will the combustion chamber look? Doubled Cylindrical
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closely-related groups. Each group was given a name that would clearly identify the theme of the group. The groups included, fuel source, combustion chambers, air to fuel ratio, and add-on parts. Using the design concept brainstorming session we also looked at our sponsors specifications as well as our customers needs. We had the option to either modify the Envirofit G-3300 Cook Stove or come up with a brand new design incorporating the ideas generated above. The group decided to design a brand new prototype. The concepts discussed below are original ideas developed by the group. These ideas resulted from the information that was found during the external search, the gathering of customer needs, and the generation of specifications. Many ideas were tossed around about a possible different fuel source. However, as shown in the graph in the Appendix A, fuel wood accounts for almost 75% of the fuel consumption in Nepal. Using any other fuel besides that would put the design at an economic disadvantage. However, due to fuel wood being the main source, Nepal is under immense pressure with deforestation issues. Therefore, it is important that we take into account how much fuel is consumed in our generation. Another idea that was tossed around was the use of a fan to enhance the air to fuel ratio. Currently, in most cook stoves, a fuel rich reaction occurs. Basically, there is not enough air for all the fuel to burn. If we could incorporate a fan that could increase the amount of air in the combustion chamber then it would result in an increase of efficiency. The last thing to take into consideration was the combustion chamber itself. We generated several ways to make the combustion chamber different to possibly result in complete combustion or efficiency. All these ideas are expressed in the four concepts generated below. The first concept (Appendix C-I) had a fan at the bottom of the cook stove with spacing along the side of the combustion chamber to force air into the reaction to allow for complete combustion. The fan is powered using a thermoelectric device which will be placed below the ceramic plate which is below the combustion chamber. The thermoelectric device and fan are relatively low cost of production and have a significant impact on lowering emissions therefore the extra cost in production is necessary. The combustion chamber in this concept was also changed to a double combustion chamber to decrease the smoke due to partial combustion. A picture of this design can be found in the Appendix C-I. The second concept (Appendix C-II) that was generated made modifications to the Envirofit G-3300. The Envirofit G-3300 is an acceptable cook stove because it is very simple, light weight, and low part count. Therefore, making small changes that resulted in lower emissions it would be beneficial to the already existing manufacturing process. Our concept idea included a funnel shaped combustion chamber instead of the existing cylindrical chamber. This would allow for more air to access the flame and result in more complete combustion by decreasing the air to fuel ratio. A drawing of this design can also be found in the Appendix C-II. The third concept (Appendix C-III) was almost the same idea as the first concept but with a different method of powering the fan. In this concept, we decided to power the fan by means of a hand crank. This would be the same type of technology that is used in emergency flash lights. Two different air flow locations where considered in this concept. The first was forcing air on top of the combustion reaction and the second was forcing air on the sides of the combustion reaction. A drawing of this design can be found in the Appendix C-III.
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The last concept (located in Appendix C-IV) was looking at the current cook stoves they use in Nepal. This design is more a rectangular prism design with a chimney stack coming out the back and two burners. This was appealing due to the two burners because most cooking involves more than one pot. The idea was to add fans and holes in the stove to allow for an increase in air flow to reduce emissions and increase efficiency. The downside to this design was that it would not be portable like the other three concepts. A drawing of this design can be found in Appendix C-IV.
In conclusion, our scoring matrix has indicated that our first design is the most feasible for this market region. Concept 1 will now be further tested with developing and alpha and beta prototypes. These prototypes will be generated using the Penn State Learning Factory and materials that we have purchased.
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the combustion chamber (D). The combustion chamber is set up into two stages (Appendix C-I), the first combustion chamber burns the woody biomass with the increased air flow. The second combustion chamber recirculates the unburned exhaust gases back into the first combustion chamber. The flat top cooking surface (C) allows for direct heat from the flame to reach the bottom of the cooking pot. The bottom compartment (E) is responsible for the storage of the thermoelectric device and the fan. The thermoelectric device is mounted in between the first combustion chamber and the fan. Since the thermoelectric device generates the most electricity when the temperature gradient is the largest, the placement of this device is significant. Our SolidWorks drawing cannot feature all the key components of our cook stove, refer to Appendix C-I for a hand sketch.
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sponsor and the low manufacturing abilities of our region of Nepal, roughly under $30 USD. Future purchases include powder coated steel, insulation, and aluminum.
Table 5: Distribution of Funds
Distribution of funds Equipment Quantity Amount in dollar(USD) Envirofit Cook Stove 1 $116.00 CO Detector 1 $230.00 Cord Wood 1 $5.00 Thermoelectric Device 1 $5.00 Fan 1 $8.00 Total $364.00
Level
Moderate
Schedule delays
Low
Delays in order placements or delivery Product does not function as predicted Customer not satisfied
Moderate
Actions to Minimize *Research customer needs and make adjustments *Track time and have good management on due dates *Expedite shipping *Make sure you have all the shipping information so you can track it
Fall Back Strategy *Add time to schedule for that particular task *Additional budget required *Build in safety time *Re-allocate resources
Low
Moderate
*Test early and often *Research customer needs and make adjustments
*Build it by yourself *Alternative design *Different material, technology, etc *Discuss ways to fix the problems
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of the safety requirements deal with the allowed voltage of the power supply and other electrical components. Safety requirements will continue to be reviewed throughout the continuation of the design and building process at every step. The construction process brings about many small changes that will each have to be approved in a safety mindset. As we finish with the final prototype, safety checks will be of the highest priority. At the current phase, we foresee no issues concerning meeting these safety requirements.
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additional added cost to buy our product, but will receive this investment back in the amount of fuel they will save with the increase in efficiency.
MATERIAL TYPE 6061-T6 Aluminium 6061-T6 Aluminium 6061-T6 Aluminium 6061-T6 Aluminium
RAW STOCK SIZE 2' x 4' x .064" sheet 2' x 4' x .064" sheet 2' x 4' x .064" sheet 2' x 4' x .024" sheet
OPERATIONS Cut to size on cutter Debur edges using flap wheel Rolled to a 10 Diameter with roller Cut to size on wet jet (10 diameter) with (3) 1 x 1 tabs for construction Cut to size on wet jet (10 diameter) with (3) 1 x 1 tabs for construction Cut to size on cutter Debur edges using flap wheel Rolled to a 8 Diameter with roller
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Combustion Chamber Part 2 Combustion Chamber Part 3 Thermoelectric Assembly Base Assembly
Cut to shape and size using wet jet Rolled to final cone shape Cut to shape and size using wet jet Rolled to final cone shape Devices will be mounted on the Inside Base using brackets to slide piece in place Inside Base will be riveted together and Housing Base will be bolted in place on Housing TIG weld together
8.2 Analysis
We will predict the system performance of the cook stove by using equations to solve for air flow rate, thermoelectric generations voltage output, internal & external temperatures and emissions output. The voltage output can be determined from the specification report on the TEC112706 thermoelectric cooler. The graph shown below is a graph from the specification report that displays output voltage as a function of temperature gradient.
Figure 3: Output voltage versus Temperature Gradient
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The graph above is not completely accurate when describing our thermoelectric device because it assumes a Th of 25 degrees Celsius. In reality, the Th of our thermoelectric device will be closer to 100 degrees Celsius. However, the graph does provide us a decent estimate of what kind of temperature gradient we should expect for the desired voltage. The purchased fan which we wish to power runs at a current of 0.8A and at a voltage of at least 4.5V. Using the graph above, it shows we cannot realistically get the desired voltage from 1 thermoelectric device. Therefore, we decided to go with 2 thermoelectric devices in series. By using 2, we will be able to obtain about 2.5 volts per device thus giving us the voltage necessary to power the fan. Another important calculation needed was the heat transfer rate from the thermoelectric device. The thermoelectric device has a maximum operating temperature of 138 degrees Celsius before it becomes mechanically unstable. Although this may be hard to achieve due to the environment in which it will be in. The aluminum fins and the convective flow of air should keep the device below this maximum temperature. The calculation for the heat transfer rate to the thermoelectric device was calculated to be 252 W with efficiency of 60% (Appendix J). The calculation for the pin fin heat transfer rate from the combustion chamber to the thermoelectric device is 6.714 W with efficiency of 77.6% (Appendix J). Heat sink performance usually is specified in terms of thermal resistance (s): Ts - Ta s = --------------Q where: s = Thermal Resistance in Degrees C per Watt Ts = Heat Sink Temperature in Degrees C Ta = Ambient or Coolant Temperature in Degrees C Q = Heat Input to Heat Sink in Watts
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made up of this material as well. The fan is made up of high tempered plastic allowing it to work close to high temperatures and not dysfunction.
The air flow in the cook stove works initially by sucking in the air by the fan which is located on the bottom of the stove. Next, it pushes the air from outside into the tube. The thermoelectric devices are located a bit to the right with multiple fins attached to its bottom for increased cooling. As the air gets pushed from the fan, it goes through the fins and upwards towards the first combustion chamber. Since the diameter for both
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the tubes are equal, we predict equal flow rate will be divided into the first and second combustion chamber. The pipes are relatively close to the combustion chamber therefore as the chamber gets hot; the temperature inside the pipe will also increase. The incoming hot air to the second combustion chamber creates a downward push causing the smoke to re-combust ultimately lowering the CO emission.
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the addition of a fan and power source to lower the carbon monoxide emissions and increase the overall efficiency of the cook stove. We will be using the Aluminum 6061-T6 sheets along with other miscellaneous materials that the Learning Factor provides for the production of this prototype. As of now we have made all the other purchases such as the thermoelectric device, 5-volt DC fan, toggle switch, and testing equipment. The table 6 below shows the current spending on the Shell 3 cook stove project.
Table 8: Current Spending on Project Date Vendor Item Cost Purchased Comments (USD) By 9/27/2012 Lowe's CO Detector/Wood $47.86 Colby Petty Cash Fund 9/28/2012 Amazon.com Envirofit Cook $50.00 Louis Petty Cash Stove Fund 10/2/2012 Sensorcon CO Tester $203.36 Colby Material Request 10/23/2012 Amazon.com Thermo Device, $21.38 Colby Petty Cash Fan, Toggle Switch Fund 10/30/2012 Lowe's IR Temperature $48.00 Louis Petty Cash Reader Fund 10/30/2012 eBay Fan and Heat Sink $29.50 Louis Petty Cash Fund 10/30/2012 Amazon.com 2 Thermo Devices $25.44 Louis Petty Cash Fund Rolling Total (USD) $952.14 $902.14 $698.78 $677.40 $629.40 $599.90 $574.46
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assembly was the placement of the thermo electric devices and fan. The fan was mounded onto the bottom of the bottom 10 plate located on the main housing body. An airflow hole was drilled into the plate. The air ran through a PVC pipe that was mounted in between the bottom 10 plate and the 10 bottom combustion chamber plate. The thermoelectric devices where located in between the 10 combustion plate the PVC pipe, the PVC pipe had 1.5 x1.5 slits cut outs so that the bottom of the thermoelectric device where the fins where located could sit inside the pipe and be cooled by the air flowing through while the hot side was exposed to the bottom of the 10 bottom combustion chamber plate. The final step of assembly was to run the air flow pipes from the opposite end of the PVC pipe where the fan was mounted to the two separate combustion chambers.
Test Parameters Without Fan With Fan (15 CFM) 2nd Combustion Chamber
addition of a fan significantly decreased the CO emissions by 40% when testing our own prototype. Also we devised a simple test to see if the second combustion chamber had any effect on the CO emissions. To do this test, we plugged the air flow from the fan into the main combustion chamber and tested the CO emissions from the cook stove to see if this result was different than without the fan running. From Table 9, the addition and design of the second combustion chamber resulted in a 6% decrease in overall emissions. Even though this is a minor decrease in emissions, this proves that the second combustion chamber did have an effect on the overall carbon monoxide emissions. Also, the overall 44% decrease in carbon monoxide emissions shows a great improvement from the existing model. Graphs and tests tables are located in Appendix K. Another test which we had to preform was the voltage our thermoelectric devices were producing. As the cook stove was running, we hooked up the thermoelectric device to a multimeter to record the voltage output. From Table 10 below you can see the lack of voltage these produced. These result indicate the lack of a large temperature gradient,
Table 10: Testing Result of the Two Thermoelectric Devices
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4.49
which can be overcome by increasing the temperature of the hot side or decreasing the temperature of the cool side. For our prototype to produce the necessary voltage to power the fan, a voltage about 4 volts is required. In order to fix our design flaw, the thermoelectric devices will be place directly below the bottom combustion plate in order to have the maximum allowable heat transfer from the fire. By making this simple switch this will allow a more direct air flow from the fan into the combustion chamber and reduce the cost by eliminating the heat sinks and PVC piping.
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For the next team to take this over we recommend that our design be examined and tested with altering the angle of the air flow into the combustion chambers, different air flows into the fire to see the change in carbon monoxide emissions, and looking into other low cost ways to power a 5 volt DC fan. With our time constraints, our team was not able to go back and redesign and test these different factors. Also, adding a simple front hood to the combustion chamber opening can reduce the soot that accumulated on the cook stove when testing. Overall our concept reduced the carbon monoxide emissions of the existing product, which can reduce deaths caused by indoor air pollution.
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for the thermoelectric devices. This ended up raising our cost to the said price. However, the carbon monoxide emissions that resulted from this additional cost could make the stove competitive due to the safety of it compared to other cooking methods currently used in Nepal. The ease of manufacturing need was determined based on if the stove could potentially be built in Nepal. Ideally, the stove would be able to be fully constructed in Nepal as opposed to being constructed in the US and then being shipped over. This would add additional unwanted cost to the cook stove. It was concluded that this stove would be able to be constructed in Nepal. It was determined that there are steel industries in Nepal close to the region of Chitwan which was our specific area of interest. There is nothing that was put in our cook stove that would not be able to be produced in Nepal therefore the ease of manufacturing need was met. The customer need of durability had to do with how long the stove would be able to last before it would no longer work. We believed that the stove should be able to run about as long as the Envirofit G-3300 can which is about 5 years. The concerns with our stove in terms of durability would be how resistant the material is that it is made out of, how long the thermoelectric devices would work for, and how long the fan would work for. Although our prototype was made out of aluminum, the stove ideally would be made out of powder coated steel. This would improve durability greatly over the use of aluminum for the stove. The thermoelectric devices have a maximum operating temperature of 125 degrees Celsius. In testing, we determined that the thermoelectric devices would not get to that temperature. Therefore, the thermoelectric devices would not cause an issue in terms of durability. Lastly, there were some concerns regarding how hot the fan would get and if that would affect its operation. During testing, it was determined the fan would not get very hot and thus would not affect the fans operation. Therefore, the stove succeeds in the customer need of durability. The customer need ease of use was judged based on how difficult it would be for the average person to figure out how to use the stove. We specified a learning curve of 1 day as a reasonable time frame to figure out how to operate the stove properly. Our stove essentially has the same design as the Envirofit G-3300 when it comes to wood feeding and overall use. Therefore, our stove is about as easy to use as the Envirofit G-3300. There is no additional user operation required with the fan as it generates its power from the thermoelectric devices which generate power from the heat of combustion. The customer need of portability referred to how reasonable it would be to physically move the cooking stove. It is known that in Nepal, the people prefer to cook both indoors and outdoors. Therefore, we wanted to make it so the stove would be light enough that they could easily carry it from one spot to another. The aim was for the stove to be no more than 15 pounds. Our stove ended up weighing approximately 12 pounds. This is lower than our 15 pound limit we had set. From our research 12 pounds is a reasonable weight for someone to carry outside or inside without having any trouble with it. Therefore, the customer need of portability was met sufficiently.
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to Envirofits model. Incorporating thermoelectric device as a mean to power the fan and integrating the second combustion chamber into the model to re-combust the smoke has greatly helped further lower the CO emission. But because indoor air pollution is not considered to be a problem by the customers, higher costs or radical changes to the current design would not be fully accepted or more over would be disregarded by the costumers. Since the customer needs were not fully met it deserves a 6 in this category. This design is a bit more complicated from the ordinary, but it would inherently enhance cooking and lowering CO emission thus an improvement overall.
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References
1. Emissions and Performance Report G-3300 Envirofit Cook Stove. Department of Mechanical Engineering Colorado State University. Fort Collins, CO. 2011. 2. Occupational Safety and Health Administration. Occupational Safety and Health Guidelines for Carbon Monoxide. United States Department of Labor. Washington D.C. 2012. 3. Basnyat, Madan. Government Policy and Strategies of Improved Cook Stove for Dissemination in Nepal. 2003. 4. Food-Nepal. DesiGrub. 2009. 5. Nepal Tourism. Indo Vacations. Kathmandu, Nepal. 2012. 6. Patent: http://www.google.com/patents/US20100258104?pg=PA14&dq=wood+cookstove&hl =en&sa=X&ei=SM5gUPCYH9KL0QGd8YGYBQ&ved=0CEYQ6AEwBw#v=onepa ge&q=wood%20cookstove&f=false
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Appendix
A. Graph of Fuel Consumption in Nepal
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II.
Concept 2
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III.
Concept 3
IV.
Concept 4
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E. Gantt Chart
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F. Bill of Materials
Current Cook Stove Bill Of Materials Component Aluminum Cylindrical Body 11.3 x 26.1 x 27.5 inches Aluminum Handle Aluminum Front Piece Feet Inside Steel Grate Outside Steel Grate Cast Iron Top Burner Top Mount Screws Screw Brackets Front Plate Screw Front Plate Nut Metal Alloy Combution Chamber Rivets Insulation Quality 1 2 1 4 1 1 1 6 3 1 1 2 8 1 Unit Production Cost ($) Overhead Total Cost ($) Variable Cost($) 1 0.25 0.35 0.1 0.5 0.6 1 0.2 0.2 0.2 0.2 1 0.2 1 Labor ($) 0.2 0.1 0.35 0.05 0.4 0.5 0.5 0.5 0.1 0.5 0.2 1.5 0.5 1 Total ($) 1.2 0.6 0.7 0.45 0.9 1.1 1.5 1.7 0.7 0.7 0.4 3.5 2.1 2 17.55 2 19.55
33 Final Concept Cook Stove Bill Of Materials Component Aluminum Cylindrical Body Aluminum Handle Aluminum Front Piece Feet Inside Steel Grate Outside Steel Grate Top Burner Top Mount Screws Screw Brackets Front Plate Screw Front Plate Nut Metal Alloy Combution Chamber Rivets Insulation 5V DC fan CPU Thermoelectric Device Quality 1 2 1 4 1 1 1 6 3 1 1 2 8 1 1 2 Unit Production Cost ($) Overhead Total Cost ($) Variable Cost($) 1 0.25 0.35 0.1 0.5 0.6 0.5 0.2 0.2 0.2 0.2 1 0.2 1 2 4 Labor Total ($) ($) 0.2 1.2 0.1 0.6 0.35 0.7 0.05 0.45 0.4 0.9 0.5 1.1 0.5 1 0.5 1.7 0.1 0.7 0.5 0.7 0.2 0.4 1.5 3.5 0.5 2.1 1 2 2 4 1.5 9.5 30.55 2 32.55
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G. Shop Drawings
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39
40
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42
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H. CO Inspector Specifications
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J. Hand Calculations
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K. Testing Results
With Fan 2nd Combustion Chamber Test Without Fan Time (min) CO Emissions (ppm) Time (min) CO Emissions (ppm) Time (min) CO Emissions (ppm) 0 55 0 82 0 86 0.5 57 0.5 80 0.5 81 1 60 1 76 1 83 1.5 51 1.5 79 1.5 85 2 48 2 82 2 110 2.5 51 2.5 88 2.5 121 3 53 3 93 3 130 3.5 49 3.5 97 3.5 85 4 53 4 106 4 91 4.5 56 4.5 111 4.5 90 5 59 5 121 5 85 5.5 66 5.5 115 5.5 84 6 69 6 126 6 101 6.5 51 6.5 110 6.5 109 7 55 7 103 7 121 7.5 53 7.5 98 7.5 126 8 50 8 91 8 131 8.5 56 8.5 86 8.5 121 9 59 9 96 9 110 9.5 51 9.5 101 9.5 91 10 57 10 95 10 95
Min Max 81 131
Min Max
48 69
Min Max
76 126
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