Professional Documents
Culture Documents
Team 5D
Benjamin Clark
Mike Kinney
4 May 2010
Executive Summary
The Fantastic Faucet is a self powered automated sink accessory which can easily be installed on
any existing faucet. The device uses a nozzle which directs the water onto a Pelton water turbine
inside of a transparent housing to drive a small electric generator. The Pelton turbine design was
chosen due to its efficiency with flow characteristics found in a typical faucet. The discharge is
in a vertical downward direction, so the water stream is still usable. The power generated from
the turbine is used to power a motion sensor, which automates the water flow, turning the flow
on when a hand is placed under it. This creates a hands free faucet, perfect for residential use.
The Fantastic Faucet has an attractive, slim profile, hanging only 4 inches below the faucet head,
which allows the faucet to retain all of its functionality. The product is anticipated to retail for
approximately $50 and can produce 0.35 Watts, with an estimated net return of $27 million over
four years.
Modern hydropower plants are incredibly efficient, with some turbines having efficiencies around 95%.
These generators have long life spans as well; some have been in operation for over 100 years and are still
working. Plants now have the ability to store hydropower for peak usage times, where the turbines are
converted to pumps which pump water back up into the reservoirs. This mechanical energy storage
proves to be very efficient and much more effective than electrical energy storage in batteries (Cimbala,
2010).
Hydropower has become more and more popular recently, primarily due to the emergence of the green
movement. The world is becoming more environmentally aware, and people are demanding that we look
for alternative fuels and energy generation systems that produce less carbon emissions and pollution.
Hydropower is such a system. There is no pollution or emissions from generating power from water.
Granted, rivers must be modified by building dams and reservoirs, but this is less taxing on nature than
burning coal and oil. Currently, only 100 GW of power is produced from hydropower in the United
States, but by retrofitting existing dams, we could produce an additional 60 GW of power (Cimbala,
2010).
Many individuals are also attempting to be more environmentally minded in their purchases and
consumption today. With this in mind, it would be appropriate to introduce a personal, small scale,
hydropower generator. This can be used to raise awareness of hydropower and how it works.
The Gantt Chart serves an added purpose in assigning tasks to each group member. We decided to divide
the main elements of the problem dissection up among the team. The turbine, housing, and shaft/gear
assembly are the primary components of the product and were assigned to Mike Ganci, Ben Clark, and
Mike Kinney, respectively. This component will be that member’s primary charge through the external
One major complaint of the ECOlight was its reliability and longevity. Some of the components, like the
threaded connections, are made of plastic and can be easy to damage during installation. The ECOlight
also suffers from a short shelf life; many fail after less than a year in use. Customers are looking for a
quality product that looks and feels like it is robust and can last for many years regardless of water quality
(mineral content of water supply) without any maintenance.
3. Concept Development
Our team used extensive research on water turbines and existing patents when developing The Fantastic
Faucet. Many concepts were developed from this knowledge, and a careful concept selection process was
utilized to ensure that the final design met all of our customers’ needs.
It is apparent that the Francis turbine, Pelton wheel and Kaplan turbine are the simplest and most efficient
turbines to use in these low flow, low head applications. These three main turbine types are summarized
and analyzed below.
The Pelton wheel turbine is an impulse turbine that acts like a water wheel; the
buckets on the wheel collect almost all of the flow’s energy, making it a very
efficient turbine (Bruno, 2004). Due to this high efficiency in the turbine, it is
an appealing design choice for the team. Additionally, the turbine orientation
makes it very easy to attach the generator along the same axis as the turbine. Figure 3: Pelton wheel
The Pelton does pose the added challenge of having the water still flow out
despite losing almost all of its energy at the Pelton stage.
Once the team familiarized itself with the various styles of turbines available, we brainstormed several
different ideas, including some unique design concepts, summarized in Table 3. We did not limit our
concept germination process to only turbine styles optimized for our flow. Rather, we generated ideas
looking at the system as a whole: how the turbine would influence the outer shell design and generator
placement. Fluid flow through the entire system was also an important component during the concept
generation phase, considering that the water entered the device vertically and had to discharge from the
outlet vertically as well.
Our brainstorming session arrived at a variety of interesting designs. We looked at how to best direct the
water flow so as to maximize outlet flow while keeping a vertical downward exit stream. One design we
considered was the experimental Tesla turbine. Boundary layer friction can be problematic in smaller
turbines. A turbine style that works specifically off of friction could operate effectively on a small scale.
The concept scoring matrix determined that the Pelton turbine design was the best option. Reflecting on
these results, the group decided that the Pelton design is the best option. It does not require a change in
the flow direction, and finished product should be compact. The generator can be isolated from the water
flow as well.
The Pelton wheel design was selected for this product because it
works well with a high head and low flow that is available from a
household faucet at standard pressure. The housing allows plenty
of space to allow the water to flow away from the turbine. The
generator is attached directly to the turbine via a coupling shaft that
is supported by bushings. This strategy provides for the lowest
manufacturing cost while accurately locating the turbine.
Figure 5: The Fantastic Faucet, Concept
Rendering, side view
4.1 Preliminary Tests
In order to estimate the efficiency of the given electric generator and the power available from the faucet,
the team conducted a series of preliminary tests. These tests aided the team in properly designing an
appropriate system to incorporate the given faucet and generator.
1. Generator Test
A weight was dropped, causing a shaft connected to the generator to spin. The output voltage of the
generator was measured and compared to the power generated by the falling weight. A complete test
procedure and test data can be found in Appendix I. The data was used to compute the efficiency of the
generator, summarized below in Figure 6. We determined the overall efficiency of the generator to be
approximately 28%.
2. Faucet Test
We tested the volumetric flow rate and pressure from the faucet in room 239 Reber, the competition
faucet. The flow rate was measured across a range of pressures. A complete test procedure and test data
can be found in Appendix I. The resulting data is summarized below in Figure 7.
Because power is directly proportional to the product of volumetric flow rate and pressure, it is necessary
to run the system somewhere around 30 psi and 0.07 gal/sec (shown on graph) in order to maximize the
area under the curve, the power delivered from the faucet. It is also necessary to run the system at a
reasonably high volumetric flow rate because the faucet should still be able to be used for general kitchen
purposes.
Figure 7
For the remaining five parts, the team used all standard or stock parts in order to minimize the price per
part. For the shaft, the team minimized costs by buying aluminum stock of 8 foot rods. Judging how
many shafts could be produced per rod, we determined the number needed to accommodate 100,000
units, and found the price per unit. The Electrical Connector, Generator, Marine Grease, and Bearing
were all standard or given parts that the team found cheapest at the listed vendors. These standard parts
are summarized in Table 5.
Finally, the unit price must include the overhead and assembly cost of the product. Given the eight parts,
including two press fits and assembly orientations, the team estimated the cost per unit of assembly to be
$1.60.
Summing all of the estimated prices per part, per unit and the estimated cost due to assembly per unit, the
unit price of the product is determined to be $14.79. Consequently, our net profit over four years is
estimated to be $27 million, as calculated in Appendix K.
Nozzle (molded
Electrical into housing)
Connector
Back Cover
Shaft
Generator
Main Housing
Pelton Wheel
Body
Turbine
Front Cover
5.1 Housing
The housing of the turbine will be plastic injection molded, allowing for tabs to align internal parts and
the housing covers while retaining a transparent outer shell. The front and back covers will be attached
via ultrasonic welding, which will effectively seal the unit so that it is waterproof. Internal threads at the
outlet and external threads at the inlet will be molded directly into the casing, reducing the number of
required parts and decreasing assembly time. The housing is molded into separate compartments, a wet
compartment for the turbine and water flow, and a dry compartment for the generator and electronics.
5.4 Turbine
The Pelton wheel turbine will be plastic injection molded with a glass filled
nylon, due to the strength of this material. This strength is needed due to the
long term force from the water stream on this part. It will receive high
Figure 10: The Fantastic torques compared to other parts in the design. Since the torque is delivered
Faucet, Final Design via the impulse of the water against the bucket, the buckets have been design
Rendering, side view to maximize this impulse. The water enters the bucket and is direct 174
degrees back on itself. This angle prevents the water stream from hitting the
next bucket but maximizes the impulse received. There is also a notch cut into each bucket to allow for a
better contact angle between the bucket and the stream.
5.5 Testing
We will construct a prototype of this design for initial testing. The unit will be built as specified, and the
voltage will be measured across a 10ohm resistor with a digital multimeter. We should be able to
calculate all necessary information from this data. The prototype will use a gear train so that we can
make adjustments. The gear train will not be used in the final design; this is only for testing purposes.
6. Alpha Prototype
Once we completed our preliminary designs of the
Fantastic Faucet, our team developed an alpha
prototype for initial testing. While this prototype was
not constructed from the final materials or
manufacturing processes, it provided a means to test
turbine efficiency, generator output, and water flow
through the casing. Some modifications were made
during the build time, including the use of
subassemblies to aid in easy assembly and disassembly
for modification. Once all modifications were
complete, the device was sealed completely.
GENERATOR
MODULE
The turbine module was made from three cuts of ½in material capped on each end with a piece of 1/8in
material. The gear train module was made from one cut of ½in material and one cut of 1/8in material,
and the generator module was made from four cuts of ½in material and one cut of 1/8in material. All
modules were assembled with epoxy for a watertight seal. Additional holes were cut for the inlet valve
and outlet valve, shaft, and electrical connection.
6.4 Conclusions
The casing proved to be the most time consuming part of the prototyping process. This was mainly due
to us having to cut each part by hand. The production run housing will be injection molded, significantly
cutting down on the assembly time. We must also ensure that the casing allows for quick and easy
assembly of all parts with self locating components. Pins will need to be used to align the different parts
7. Test Results
The Fantastic Faucet performed within the estimated performance characteristics. We estimated that our
turbine would output 1.9 volts, and the actual output was 1.85 volts. We were only 3% off of our initial
estimates. With such conservative calculations, we were hoping that the turbine would perform above our
estimates, but this was not the case. With the information learned from the alpha prototype though, we
feel that we could significantly increase our efficiency in the beta prototype.
We did find that our output voltage dropped by nearly 50% on the day of the competition when it was
producing 1.85 volts the night before. We eventually traced the problem to the seal on the faucet.
Drilling a ventilation hole in the top of the casing restored our output. Apparently the leak at the faucet
allowed the turbine to breathe, which prevented water from backing up in the casing. This was a very
important design component that we did not find in initial testing, primarily because we were not testing
under the same conditions present for the competition day.
The biggest hurdle for the product is efficiency—the product cannot be produced if it does not supply
enough voltage for the electrical hands-free sensor accessory. However, after researching similar
products, it is apparent that the industry standard is either a 6-Volt DC power supply or four AA batteries
in series, also producing 6 Volts (Air Delights 2010). We are confident that our water turbine can
produce this voltage with improvements to the design and removing losses due to poor manufacturing of
the alpha prototype.
Another design constraint is the volumetric flow rate out of the faucet. Significantly restricting the
outflow will render the product useless. We had been having some problems with our volumetric
outflow, but after switching to a larger nozzle and putting an airflow inlet into our prototype, it became
apparent that the outflow of the turbine produced more than enough flow to be usable by the customer.
The final constraint is that of product size. Our product is relatively large (around four inches by four
inches by four inches). Consequently, this is the biggest room for improvement in our product. However,
the team believes it can be made smaller with the proper manufacturing, without losing any efficiency.
Additionally, even at this size, it will still fit most faucets without being an obstruction.
In learning from our peers, it is apparent that the most successful turbines used small Pelton wheels, a
small nozzle, and a direct drive. Implementing these ideas to the Fantastic Faucet will make it a better
product.
We also learned about how to produce professional and aesthetically impressive technical reports and
project posters. These are very important skills for both the senior design class and also for employment
down the road. Finally, we learned the importance of working together in a team. For all of the parts of
the project, we had very good coordination between group members in communicating between CAD
drawings, tests and calculations, and the writing of reports. All of these things resulted in successful
projects.
Ultimately, this project was a very useful learning experience that cannot be replaced by other classes;
there is no substitute for projects like this with trial and error when it comes to the ―art of engineering.‖
8.4 Recommendations
While we enjoyed this project very much, and the end result was relatively successful, we do have some
recommendations.
1. We think it would have helped us to make the report submissions due at midnight of the due date.
We would frequently not be able to meet on the weekends to work on the report, due to other
commitments, and most of our time to work as a full team on the project was from the end of
class until submission. I think we could have produced better reports if we had those extra two
hours.
2. One difficulty with the project came from writing the detail design report while simultaneously
machining the prototype. It was hard for us to specify things in our detail design that we weren’t
really decided on yet, because it required some help from building and testing our prototype.
3. In terms of our turbine, we need to make a smaller turbine for the beta prototype while decreasing
the overall size of the unit. We will eliminate the gearing and revert back to a direct drive
system.
Bruno, Leonard. ―Turbine.‖ Gale Virtual Reference Library. The Gale Encyclopedia of Science.
Ed. K. Lee Lerner and Brenda Wilmoth Lerner. Vol. 6. 3rd ed. Detroit: Gale, 2004.
p4135-4138.
Cengel, Yunus A., and John M. Cimbala. Fluid Mechanics: Fundamentals and Applications.
Boston: McGraw-Hill Higher Education, 2010. Print.
Cimbala, John M. ―Hydropower.‖ 022 Deike Building, The Pennsylvania State University. 1 April 2010.
Holden, Joseph. ―Hydro Turbine.‖ U.S. Patent 6309179. Filed Nov 23, 1999. Issued Oct 30,
2001
―Hydropower.‖ Wikipedia: The Free Encyclopedia. 14 April 2010. Web. 14 April 2010.
Kaisha, Kyowa. ―Water Turbine and Brush Head using the water turbine for cleaning pipes.‖
U.S. Patent 4531250. Filed Jun 6, 1983. Issued Jul 30, 1985
Lamont, John. ―Hydro Turbine.‖ U.S. Patent 6409466. Filed Aug 25, 2000. Issued Jun 25, 2002.
McKenzie, T. ―Floating Water Turbine.‖ U.S. Patent 4849647. Filed Nov 10, 1987. Issued Jul
18, 1989
Sturm, Zeynab. ―Home Power Station.‖ U.S. Patent 4122381. Filed May 4, 1977. Issued Oct
24, 1978
Ulrich, Karl T., and Steven D. Eppinger. Product Design and Development. New York: McGraw-Hill
Higher Education, 2008. Print.
ME 340.5
home faucets
Needs
X
The product will secure to a standard faucet (will fit a standard 3/8-18 NPS pipe thread)
Appendix D – Needs Metrics Matrix
X
The product will attach with no additional tools
X
X
The product will discharge water in a vertical, downward direction
5/4/2010
X
The product will retail for $50 or less
X
X
X
The product will isolate the generator and electrical connections from moisture
X
X
The product will be contained in a sealed, decorative casing
X
The product will generate a minimum of 0.225 watts
X
X
X
The product will be designed to maximize ergonomics of the outer casing
X
X
The product will terminate in a standard 3/8-18 NPS internal pipe thread
X
X
The product will be designed with materials not suseptible to water damage
X
The product casing will be constructed with windows or some form of transparent material
Page 23 of 36
Appendix E – AHP Weighting Matrix (Lamancusa)
Visibility of Mechanics
Unobtrusive/Compact
Aesthetically Pleasing
Ease of Installation
Waterproof
Easy to Use
DFM/DFA
WEIGHT
TOTAL
Cost
Ease of Installation 1 1 1/3 1 2 1/4 1 1 1/2 2 10.083 0.07
Aesthetically Pleasing 1 1 1/3 1/2 3 1/4 1/2 1 1 2 10.583 0.07
Unobtrusive/Compact 1 1 1/3 1/2 2 1/3 1 2 2 1 11.167 0.08
Reliability/Robustness 3 3 3 2 3 1 2 1 3 2 23.000 0.16
Compatible with Home Faucet 1 2 2 1/2 2 1/2 1 1 2 1 13.000 0.09
Visiblity of Mechanics 1/2 1/3 1/2 1/3 1/2 1/4 1/3 1/3 1/3 1/3 3.750 0.03
Maximizes Power Production 4 4 3 1 2 4 3 3 4 2 30.000 0.21
Waterproof 1 2 1 1/2 1 3 1/3 1 2 1 11.830 0.08
Easy to Use 1 1 1/2 1 1 3 1/3 1 2 1 11.833 0.08
Cost 2 1 1/2 1/3 1/2 3 1/4 1/2 1/2 2 10.583 0.07
DFM/DFA 1/2 1/2 1 1/2 1 3 1/2 1 1 1/2 9.500 0.07
*Based on a scale of relative importance; 1=equal, 2=slightly important, 3=moderately important, 4=extremely
important
Generator Efficiency
Time Mass Voltage Height mass Torque Power in power out efficiency Current
(s) (g) (V) (m) (Kg) rad/sec (Nm) (hp) (hp) n (A)
6.42 50 0.87 2.7432 0.05 109.9505 0.0019 0.000281 0.0001015 0.3614567 0.07569
6.42 50 0.83 2.7432 0.05 109.9505 0.0019 0.000281 9.2383E-05 0.3289834 0.06889
2.72 100 1.77 2.7432 0.1 259.5156 0.00381 0.001326 0.00042013 0.3169335 0.31329
2.72 100 1.77 2.7432 0.1 259.5156 0.00381 0.001326 0.00042013 0.3169335 0.31329
1.25 200 3.00 2.7432 0.2 564.7059 0.00762 0.005769 0.00120692 0.2092065 0.9
1.25 200 3.10 2.7432 0.2 564.7059 0.00762 0.005769 0.00128872 0.2233861 0.961
1.23 240 3.00 2.7432 0.24 573.8881 0.00914 0.007035 0.00120692 0.1715494 0.9
𝑚𝑟 𝑉 2
𝐹= (2)
2𝑡
where r = radius
and V = linear velocity of the wheel
𝑚
= mass flow rate = υδ = (volume flow rate)(density of Water)
𝑡
1 𝑚𝑖𝑛 .0038 𝑚 3 1000 𝑘𝑔
= 2.5𝑔𝑝𝑚
60 sec 𝑔𝑎𝑙 𝑚3
𝑚 𝟎.𝟏𝟓𝟖𝐤𝐠
=
𝑡 𝐬
Note: use 4gpm as volume flow rate. This is where the team specified optimum operating flow and is a
realistic point on the graph of pressure versus υ. After testing many nozzles, the team found that a
threaded 4mm nozzle gives a flow of 4gpm.
To find the torque on the wheel, T=Fr=(0.086)(1 inch)(0.0254 m/in)=.002 N-m(0.737 ft-lb/N-m)=.0017
ft-lb
To find rpm, use the plot of rpm versus Torque, and find that 3000 rpm corresponds to the Torque.
Converting this rpm to rad/s and then to linear velocity of the wheel, we find u=0.471 m/s
Going back to Equation 1, using Vi=V=20.2 m/s and u=0.471 m/s
4u Vi −u 4∗0.471 ∗ 10.2−0.471
ηturbine = = = .017
Vi 2 10.2 2
η = efficiency
p = pressure (psi) = 15 psi
υ = volume flow rate (GPM) = 2.5 gal/min
1
P = power (HP) = υ*p*η* (3)
1713
However, this result does not include viscous losses, bearing friction, etc.
Additionally, the Pelton wheel efficiency means this is at steady state, once the wheel has fully
accelerated, since ηturbine is proportional to the speed of the wheel. Therefore, this is a very generous
estimate.
𝑣2 1.5 2
P= = = 𝟎. 𝟐𝟐𝟓 𝐖𝐚𝐭𝐭𝐬 (7)
𝑅 10
Comparing the results of the 2 calculations, we see that given this pressure and volume flow rate of the
faucet, it is possible to attain the power required by the project.
As a result, it is apparent that we have more than enough power coming from the faucet, even with an
overall efficiency of 4.97%, as specified in the project constraints.