PDF OLAR POWERED BICYCLE MECHANISM DESIGN - Universiti Malaysia Sarawak

OLAR POWERED BICYCLE MECHANISM DESIGN

ATIRAH M N IRAH BT ABD AZ1Z

Universiti Malaysia Sarawak 2000

TL

220

AB72

2000

SOL'\R POWERED BrCYCLE MEcnA. I ~1 DE IGN

•

ATIRAH Ml '1RAll BT ABD AZIZ

Tesis Dlkemukakan Kepada

Fakulti Kejuruteraan, Universiti Malaysia Sarawak Sebagai Memenuhi Sebahagian danpada Syarat

Penganugerahan Sarjana Muda KeJurutcraan

Dcngan Kepujian (Kejuruteraan Mekanikal dan Sistem Pcmbualan )

2000

80rallg J>~nyerab.n T"lIis

•• i"frsili Ma l.ay ia Sarawllk

Rlla BORA G PENYERA.D.AN IT IS

Judul: Solar Powered Bicycle ~'Iechanism Design

SESI PE. GAJIA N 1999/2000

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This project report entitled "SOLAR POWERED BICYCLE MECHANISM DESIGN" was prepared by Ati rah Mu nirah Bt Abd Aziz as a partial fulfillment of the requirement for the degree of Bachelor of Engineering with honours (Mechanical and Manufacturing System) is hereby read and approved by:

Date

God....million ofthanks for the strength and spirit through my heart For Dad and Mum, thank you for YOllr encouragemellt, support and patient

JJ

ACKNOW L EDGEMENT

The author would like to give her special thanks and appreciation to her _up..:rvisor. Mr. Nazcri Abd ul Rahman for his guidance and supportive encouragement tit

making of thi project a reality and obtained the objectives. Through all the ~eme,ter'i.

many p.:ople have helped in the thesis development and the author is grateful for their

valuable suggestions and comment

Pcr,onally, the author would like to thank Mr Masri and Mr Rh leT lOr their helps, ideas, encouragement and support toward fini,hing this thesis project Abo, personal thank is dedicated to Miss Mahshuri Yusoff

A Series of thanks also recorded to beloved parents and families for their supportive respon5ihilities during the making of this project

Lastly, thanks are extended to Yayah, Fauzi, Ismail, Murni alri, Haslina and all of author friends who always around during the author hard limes.

III

ABS T RACT

This project designed new mechanism of solar powered bicycle with the consideration on the aerodynamics and ergono mics. Two main objectives that must be fulfilled are to develop the mechanism of the solar bicycte and to minimize the energy losses and to optimize the energy obtained from the sources. To achieve these objectives some designs consideration on the prototype design has been done and one experimental design has been construct in order to make sure that the design of the new mechanism worked. Recommendation is included [or future development of the milestone solar bicycle mechanism designed.

lV

A S STRAK

Projek rekabentuk mekant~ma baru untuk ba~ikal solar ini bergantung kepada pcnilaian terhadap aerodinamik dan ergonomik. Terdapat dua objektif yang mesH dicapai iaitu membina mekanisma baru basikal solar dan meminimakan tenaga yang hllang sena meningkatkan lenaga yang di perolehi daripada sumber tcnaga. Bagi mencapai i-edua-dua objektif ini,penilaian rekabentk terhadap rekabentuk yang dlcipta telah dilakukan dan :;"tu rekabentuk eksp<::,itnent telah dibina untuk memastikan rekabenluJ.. bani basikal solar ini belja\ a dan dapat digunakan. Beberapa cadangan dl. erlakan bagi kegullaan pel11binaan rekabentuk mekanisma basikal solar ini pada masa akan datang

v

22 Initial Electnc Bicycles and its Development..

.... 15

.,

_ . ..

.

"1 Solar Powered Mechanism Dt:sil,'ll and its Developmen t. . . .... 17

CHAPTER 3 - PROTOTYPE D ESIGN

30

Jntroduct Ion ...

3 J Purpose of thc Project.. _. ^--'

"

3. J I Shortcoming of the Existing Design ... . . . .^.,~ _J

32 Design Criteria ... .. 24

3.2. I Body Frame, 'eat and Paddle ... . __ .. .. :!5 .. 26

(a) fire Characteristic, . . .... . 29

(b) Tire Constructions ... .... ... . · ... . 19

(c) TIre Threads Patte rn .

30

,

., ^,

-'._. J Gear Selections .. .. 3 I

3.2.4 Steering ... 32

(a) Rack and Pinion. .. .. ... .. .. ... ... 32

3 2 5 Batteri es · .. . . 34

3.26 DC Motor.. 36

3.2.7 Photo\'oltaic (P V) . . .37

3.1.8 Bearing.. · .... 38

(a) Bearing Support ... ... . . ... 39

(b) Wheel Spindles .. ... ... ... . .. .40 32 9 Chain . .... ... . .... ...41

3.3 Operation of the c\\ Mechamsm ... .... .. ... __ 42

VII

CHAPTER 4 - EXPERIMENTAL D ESIGN

-10 General ... . _....-14

-I.I Purpose of the Experiment ... ... . ... 45

Theoretical Consideration .. ..45

4.2.1 Angular Velocity and Angular Acceleration. _{. "0}

4.2.2 Velocity, Acceleration and Power .. ... 46

-13 Apparatus. _{. .... 50}

" 3.1 DC Motor .... 51

-1 .3:2 Batte ry . ... 51

Solar PV ... ... 52

4.3.4 Bicycle Tire ... ... "''''

4.3.5 SWltche . . ^.

. . .

^.

..

.. ^. ..

..

^{. .... ~ , ...}

~ .3.6 Chain. ... ... _.... S3

4 3 7 Tire Holder .. ... 5·1

43.8 Analyzer. Tachometer and Multimeter ... .5-1

·\3.9 Wlrc>Crocodiie Cllp~ Battery harger .. .. .... .... .. ... ... 55

4.4 Expen men t Procedures ... .. ..

56

CHAPTER 5 - RESU LTS AND DISCUSSIONS

5.0 Introduction .. .. 58

5. 1 Changi ng Experi ment Design . . .. .. ... .. ... 59

52 Battery Charger Damage ... ' .. ... " . ... . ...59

5.3 DC Motor Fai lure . " .... . .. 61

54 Concentration of <;unl ight .. fi2

\III

55 Rubber at tht: \I1otor Shaft..

. . . 62

5.6 FITeCI of Voltage produce by PV... . ... 63

j 7 _{EfTeer of} urrent produced b) PV.. .. 66

5.8 Velo ity .. (i9

_ 9

Solar I'ower ...69

C H APTE R 6 - CONCLUSIONS AN D RECOMMENDATIONS 6. 1 ConciuslOJlS ...

n

6~ Recommendations ... .. 73

(a) Solar ell (PV) .. .... 73

(b)

Dc

^{MotoL .} ... ... ... . 74

(e) ^{Battery ..} .74

(d) Regularor .. . .... ... 74

(e) Breaking System.. .. 75

(f) rearing y tern , . 75 BIBLIOGRAPHy... ... ... .. .. ... ... ... ... 76

APPEN DIX

A . ... ... ... ... ... ....80

A P P E NDIX

B ... ... ... ... ... ... . 83

APPEN D IX

C ... ... ... ... ... .... .. .. , .... 85

IX

Figure 1.1 Figure 1.2

Figure 2.1 Figure 2.2 Figure 3.1 Figure 3.2 Figure 3.3

Figure 3.4 Figure 3.5 Figure 3.6 Figure 3.7 Figure 3.8 Figure 3.9 Figure 3.10 .Figure 3.11

Figure 3.12 Figure 3.13 Figure 3.14 Figure 3,15

I NDEX OF F IGURES

Solar Panel on the roof ... ... .5

Solar Cell ... ... 7

Example of Electric Bicycle ... 21

Example of Solar Powered Bicycle ... . ... 22

Paddle, Seat and Steering Connection ...25

Direction of Load on the Tire ... ... ... " ... .. ' ... ... , ., .... 26

Maximum Vector Forces Possible during a turn (a) Large Lateral Force while making a Sharp turn ...27

(b) Less Lateral Force wbile making a wild turn ... . ... 28

Twist in the Tire Thread within the Footprint causing Slip Angle .. 28

Different Part of typical tire .. ... 30

All Season Radial Pattern Thread. ... 30

Top View of Typical Rack and Pinion Steering Gear ... . ... 33

Operation of Rack and Pinion Steering Gear ... .. . . ... 33

Typical Manual Rack and Pinion Steering Gear ... ... 34

Pictorial Diagram of Series Wound Motor .. ... . , .... ... .... . , .. 36

Ball Bearing Contact ... ... 38

Ball bearing can Support Axial, Side Loads and Radial Loads .... .49

Wheel Bearing Movement to Minimize Fatigue ... . ... .40

.42 Front View of the Solar Bicycle with Dimension ... . Top View of the Solar Bicycle with Dimension. ...,.... ... .43

x

Fig.... e 4.1 Motion of Point P of the Tire ... . . ... ... ...48

Figure .:1.2 Proposed Design for Expe riment AnaJysis . ^{... ... ..} ... .. . ... ... ... ... ... ... 50

Figure .:1.3 Actual Design for Experiment Analysis ... 50

Figure 5.1 Voltage (V) against Time (hour) ... . ... ' " " ... 65

Figure 5.2 Voltage (V) against Rotation Per Minute (RPM) ... .65

Figure 5.3 Current (A) aga inst Time (hour) ... . ... 67

Figure 5.4 Current (A) aga inst Rotation Per Minute (RPM) ... ... .. ... 67

l'igure 5.5 Current (A) against Voltage (V) ... . ... . ... 68

Figure 5.6 Velocity (m/s) against Rotation Per Minute (RPM) ... . . ... ... . ...70

Figure 5.7 Solar Power (Watt) against Rotation Per Minute ... ... . ...70

Figure 5.8 Solar Power (Watt) against Velocity (m/s) ... '" ... ... 71

Xl

I NDE X OF T ABLE

Table 4.1 Specificalion~ of Ihe Solar Panel ... ... ... ... ... ... ... .54

XII

N O TATION

ex An gular ccel eration

dEl Ch ange in angle

OJ An gu lar elocity

dco hange in Angular VeloCIty

dt Change in lime

V VelocilY

r Radius

a, Acceleration in tangential direction an Acceleration in normal di rectio n

P Power Generated

Current Produced by PV V Voltage produced by PV

XlIJ

C HAPTE R 1 INTRODUCTION

1.0 Renewahle Energy

The technologies of renewable energy now produce an energy that can be marketed by converting natural phenomenon into useful energy forms. Massive energy potential of this source will greatly exceed the poten tial of fossil fuel reso urces. The renewable energy is a technology, which play an important role in achieving the community goals for sustainable economic development and environmental protection.

Renewable energy is a domestic resource. [t has the potential to contribute or provide complete security supply. It also can be Llsed fOi multiple applications, which meets practically every type of final energy demand.

Resources of the renewable energy technologies are with the exception of wood fuel and large hydro electricity. Part of specific renewahle energy sources that has prospect for the year 2000 are wind energy, pholovoJtaics, biomass, g<.:olhermal, solar, tidal and ocean thermal.

1

Clrupler I Inrrt1fiucrifJIt

1.1 Ellergy Comparison

Ac ording to Hislop Drummond

r

I 992], for most developing countries the interest in renewable t!nergy technologies was originally a response to the energy shortages and price increases fuel in the arly and late 1970s. However, by mid 1990, mternational world prices were back to levels as low as in the late 19605.

Demand for energy in developing countries i~ ,.,creasing as the population

IS increasing and the economic development growth and stable. This pr cess happened for per capita of the energy. BIOmass energy provides electricity fot many years using steam turbine power generation 1\ i~ in the form of industrial and agriculture residues. Existing steam turbine conversion technology is cost competiti\e in the South East Asia region. It is due to the low cost of biomass fuels available. These technologies are comparati ely inefficient for the small size requirement for biomass electricity production. Howe'ver. biomass encrgv is more attractive feedstock at is easier to gasify and very low in sulfur content.

WInd eneryy generating capacity now IS about 2000 MVv': [Burnham, 199']. The value of wind electricity depends on the characteristics of the utility system into which it is integrated.

Solar thermal generation system use sunlight to heat fluids that drive turbines. These systems typically concentrate sunlight with mirrors A state of the art solar thermal electric system would produce electricity for about 9.3 cents per kWh [Burnham, 1993]. This cost is higher than the cost of base load electricity In

most regions. The value of the solar thermal electric power dcpcnd~ n sunlighl

2

ChapUT I IlIfrmiuct;f}fl

and often correlates well with peak electricity demands in wal lfl areas wtth heavy conditioning loads.

Ph(}lOl'o/talc modules are solid state devices. II converts sunlight directly into electricity with no rotating equipment. Photovoltaic system can be built in any size, highly reliable and need only little maintenance. These systems are cost effective in many remote areas where alternative sources of power are impractical or costly. Photovoltaic electricity is produced during periods of peak unlighL It is closed to the sites where it is consumed, thereby reducing the need for costly conventional peaking capacity.

RlOma.'s energy has provided electricity for many years suall , it is in the form of industrial and agricultural residues. According to Burnham [1993], United States currently has more than 8000MW of generating capacity, fueled with such feedstock.

1.2 Introductioll to Solar Energy Power

Energy that comes directly from the sunlight is called sO/lIr ellergy. It is a type of energy sources for fuels and electricity. In general terms, solar enerj:,'Y means that all the energy that reaches the earth from the sun. The em:rgy prOVIdes daylight, makes the earth hot and it is the source ofenergy for the plants to grow.

Without sun, nothing could exist on the earth and earth would be as lifeless as the moon. The sun is our greatest and most basic source of energy. Ileat and light derived from the sun. The rain and the winds are resultant from heat and li ght

3

Chapter I IlIlrod"ct;ulI

force from the sun. Plants use solar energy to flourish. Solar energy can be harvested both directly and indirectly

The energy sources are all around liS. Before usmg this energy, one must learn how to control it. When energy is control, the process is called power Power is used to move automobiles, airplanes and all other means of transportation devices. Solar energy power is defined as a process of conlrol for encf!,'Y that comes directly from the sun. Solar energy can be collected and put mto work. Supposingly that all the energy arriving from the sun each day could be collected and controlled most of earth energy problems are solved. Ways of collecting and controlling solar energy are inefficient and expensive. Furthermore, it is impossible to collect solar energy at night or during cloudy \\·cather Nevertheless it is harder to store solar energy. However, some progress has b~en

made in utilizing soJar energy collectlve and usage ln the past several years. If research and development continues, solar energy could become an important direct energy source

Solar Energy can provide both heat and electricity. Solar panels (refer to Figure 1. t) are devices that collect solar energy to heat water We can al so control solar energy with mirrors. Mirrors concentrate the sunrays on a small area and this heat can be used to produce steam for electncal generaLlrs operations.

4

Chapter J r"rrodllcnolt

Figure 1. \ Solar panel on the roof[McDonalds. et aI, 19861

Solar Energy is one of important energy sources. McDonald, et al [1986J, indicate that the sun provides 500 times more energy than the energy used ev ry day. By capturing only one-tenth of thts energy the need~ of nit ed States every day demands can be satisfied. This sufficient energy could be captured wtth collectors of only two percents of our nation swfacc [McDonald, et aI, 1986j.

Thus, solar energy has a very great potential

5

Clwpter 1 InlrmlucrifJlt

1.2.1 Electricity from Solar

Two common u es for solar energy are heating and electrici ty. Usually for heating it is used to heat both water and buildings. It is over one quarter of domestic energy usage for these purposes. Therefore, this is an important area to be rl.:vr,l'lped for solar energy. Electricity is the most important u es of thIs solar energy. This energy can be converted directly into electricity. It is usually use to generate steam, which can drive turbine toward electricity genera1ion.

I he generation of electricity from solar energy has been poSSible since the nineteenth century For the early generating devices, it is only produced only a small amount of electricity and this solar energy was only limited to certain specia l uses.

For recent years, way of converting la,ge amount of solar energy into electricity has been improved. Many projects on electricity generation from this energy had been tried. The most successful projects on this energy generation of electricity arc for dome. tic usage, such as water heater, pumps, turbine and also for transportation needs sLlch as electric car and soJar bie c1e.

1.3 Introduction 10 Sohir Cells (PV) aDd Batteries

Solar cells (see Figure 1.2) are devices that convert sunlight to electricity directly. It is al so called photovo!taic cells (I'V) Solar cells lIsed photon~ III convert

6

Chapler I fniroduNion

this sunlight into electricity. By putting a number of solar cells together it will increase the electric output

Figure 1.2 Solar Ccll (Hislop, 1992]

Nowdays, photovoltaic system is used to provide powcr for water pumping, refrigeration, water treatment, cathodic protection, vaccine refrigeration and many others applications.

The majority of the population in developing countries Jives in dispersed community in rural area. The provision of an electriCity supply to this area is difficult and costly, extension of the main gnd is difficult for varied terrain and it is generally not economical for smaJi power loads. Photovoltaic model is more suited for remote or In acce~sible location for power !,rrid can also provide an independent and reliable electrical power source. PV system component such as inverter is the

7

Clwpler I IlItrfH/UC{;un

second most essential component after the solar generator for the AC power generation. Although, the inverter represents a conventional component but there is effort on the development to improved its ef lcicncy.

"When th,J conventIOnal inverter operated in the partial load r~.r:lon the efficiency of /he CUllvelllional Inverters a\'auged over longer lillie ^{.Iptll/I· IS} low.

t haI is typically about 70% to 80%. 171<'.\'c convelltional inv('rters used Ihl 'rtSlors switched (/{ low ji-(!quencles, exhihit decreased conver.lion elfie/ellelf!" (- YO",,) and 11I1I./JI!r lo.\\r!s when use in Ihe parl/alload r.:gion [Wrixon W.T. et ai, 19931".

Performance of thl.! systi:m has shown that the problem of the system maybe tim: 10.

t. Hardware design that is not-optimized

II. Power Management that is not-optimiz d especially the banerics lit. Sizing of component is incorrect-particularly the inverter

IV. The changes in load demand v Changes in load profi Ie

vt. In adequate hardware backup and spare paT1~,hartlware failures (cracked modules, inverter problems and short baneries life)

The batteri s are used to store electricity generate during dayltght hours for later usage. lt is because during the night day and bad weather, solar photovoltaic is not functiomng and rechargeable banencs arc reqUIred for thl~

pLlrpo~e of supplying electricity. Usually, for solar electric system a lead-acid

banerie~ is used for storage. Rechargeable battery is a type of batteries that can be

8

ClIO/ller / IntrfJtluction

recharged up from the direct current source and can be reused mulliplc~.

Electrochemical or wet cell is the simplest operating unit of batteries.

A particular voltage will be produced by the battery depending on the ma1crials it used. Ratteries mean a group of cells that is connected in series to achieve a higher voltage. This is similar for the solar cell as it is connected in series to fonn a solar module.

OfMati on of the battery, used by the solar PV can be group into two types of c\. ·;Ies. These cycles are as fo llow:

I. A shallow cycle each day

II. Deep cycles over seycral days or weeks during cloudy weather and

winte r.

When the charging of the battery is not enough to supply (he amount of energy used by the appliances, a deep cycle will occur. This will makl! the statc of charge is reduced slightly and further builds up to a deeper cyclc over a period of time. The state of extra charging will improve the cycle gradua lly. For the batteries to perform well in a solar PV system some characteristics must be considered. The characteristics are:

I. High li fe cycle for deep cycle

II . Low maintenance requirement

Ill. High efficiencies charging

9