Solar Micro Pump Report ME 340 Instructor: Dr.

Lamancusa Team 2G: John Neel, Tyler Quinn, Tyler Thompson

Executive Summary Water is a precious resource. This fact is especially known to farmers living in third world countries who must carry water in buckets for, in some cases, miles just to water their crops. Another major problem with this method of irrigation is the inefficient use of the water; not all of the water provided to the plant will be absorbed by its roots due to run off. This inefficiency is crucial to eliminate because of the dependence on crops for food production both for living and as means of income. A solution to this inefficiency is to implement a new watering method: drip irrigation. For a drip irrigation to operate requires a pump to push water from the source to the plant. The pump to perform such action will be the solar micro-pump. The pump will be powered by solar energy and require no other user input than placing it in the water and turning it on. The centrifugal design of the pump facilitates the suction of water through the inlet whereby it is then spun clockwise by an impeller blade and then discharged through the outlet at 0.8 gallons per minute. Estimated NPV for the solar pump is $3,470,000 at an expected retail price of $20.00.

Table of Contents Executive Summary 1. Introduction 1. Problem Statement 2. Background Information 3. Project Planning 2. Customer Needs and Specifications
1 ME 340.2 Solar Powered Micro-Pump Detailed Design Report

Page 1 Page 3 Page 3 Page 3 Page 3 Page 4

3.

4. 5.

6.

7. 8.

Identification of Customer Needs Design Specifications Concept Development 1. External Search 2. Problem Decomposition 3. Design Concepts 4. Concept Selection System Level Design Detailed Design 1. Modifications to Proposal Sections 2. Theoretical Analysis 3. Component and Material Selection Process 4. Fabrication Processes 5. Industrial Design 6. Detailed Drawings 7. Economic Analysis 7.1. Unit Production Cost 7.2. Business Case Justification 8. Safety 9. Actual Construction Process Testing 1. Test Plan 2. Test Results and Discussion Conclusion References Appendices A. Gantt Chart B. Quality Function Deployment 13 C. Concept Screening Matrix D. AHP Weighting Matrix E. Concept Scoring F. Patent Search
1. 2.

Page 4 Page 4 Page 5 Page 5 Page 6 Page 7 Page 7 Page 7

Page 9 Page 10 Page 12 Page 12 Page Page 14 Page 15 Page 16 Page 17

2 ME 340.2 Solar Powered Micro-Pump Detailed Design Report

1. Introduction
1. Problem Statement Roughly 600 million farmers in least developed countries lack water needed to grow crops using traditional irrigation methods [1]. Yet the majority of these farmers have an abundant source of sunlight energy. The mission of the solar powered micro-pump is to develop a solution to inefficient use of water by designing a pump that will operate solely off the energy from the sun in order to operate a drip irrigation system. Due to the variations in farmer needs in regards to drip irrigation configuration, the project will limit itself in scope to the design of only the micro-pump. 2. Background Information The pump will be powered by a 30W high-efficiency photovoltaic module. It will be designed to be reliant on one user input of turning the pump on or off. A subset condition of this constraint is that the pump will need to be self-priming so as to eliminate pump damage due to the possibility of a low or temporarily nonexistent water level. The pump must be able to push water up an elevation difference of 0.5 meters at a rate of 0.5 gallons per minute. 3. Project Planning Once research on pumps has been completed and customer needs have been identified, the general pump concepts found during research will be evaluated. After screening the concepts they will then be scored using weighted ratings. Task breakdown will be distributed on an as need basis. When tasks are distributed it is up to the individual team members to complete their work and if needed help other members. The project will be completed on time with the guidance of a Gantt chart (Appendix A) that not only illustrates the milestones for project deliverables, but also the flow of tasks and their dependency on one another.

3 ME 340.2 Solar Powered Micro-Pump Detailed Design Report

For resources, the team will use the Reber Instrument Room for the assembly and testing of pump prototypes, SolidWorks for visual models, http://www.jameco.com, http://www.mcmaster.com, and local hardware stores for online material supplies, professors, books, the internet, and lead users as sources of information. Tasks and project deliverables will be completed ahead of schedule to allow for a buffer for further refinement and to provide appropriate time to rectify any unexpected occurrences. Once the customer needs were identified they were translated into design specifications that could easily be used as a basis for choosing a pump design to meet the project requirements. Research was then conducted on the different types of pumps to determine which configuration would best meet the project demands. Once a basic understanding of the different types of pump operations was established, the design problem was decomposed into functional sub-problems. Design concepts were then generated based on the information obtained thus far, after which concept selection followed. Analysis was then conduced on the prototype of the selected concept to determine product specifications and economic viability.

2. Customer Needs and Specifications

2.1 Identification of Customer Needs Customer needs were determined from the project outline and from thinking of needs as a third world farmer. From the project outline it was determined that the pump needs to be selfpriming, capable of a water elevation change of 0.5 meters, have a minimum flow rate of 0.5 gallons/min, and powered only by solar energy. Because of the pumps targeted application to third world farmers it should be easily maintained, durable, safe, and easy to use. These needs were determined with the intent that third world farmers will use the pump with a drip irrigation crop watering system. With the aforementioned needs satisfied the farmer would not have to worry about maintaining, fixing, or adjusting the pump. Additionally, the price will need to be kept low relative to the farmers income so that they do not dismiss the product as unnecessary. 2.2 Design Specifications
The design specifications were determined by quantifying the customer needs. For the customer need ease of use the corresponding design specification was user input is one on/off switch. As another example, safety had multiple corresponding design specifications to include electrical components will be exposed to no water, will have no exposed electrical connections, and will have no exposed mechanical parts. For the entire Quality Function Deployment (QFD) see Appendix B. Concepts for the pump were determined based on the customer needs and the design specifications. Online research of the various types of pumps provided a list of concepts that were screen based on needs and metrics. Once the concepts were screened (Appendix C), the best among them were then scored using weighted ratings determined from the needs and metrics (Appendix D). The resulting concept scoring matrix using weighted ratings determined the best concept (Appendix E).

4 ME 340.2 Solar Powered Micro-Pump Detailed Design Report

Table : Weighted Needs Weights (%) 20 Safe Customer Needs 15 SelfPriming 10 can create a change in elevation high flow rate ease of use durability easily maintained 5 can be used in water cost effective provides a constant water supply

3. Concept Development
3.1 External Search
To design the pump the team performed research on how a pump works, and basic fluid dynamics. A patent search (Appendix F) was also completed to reference inventions that have already been designed; see Table 3 for a summary of the patents. Websites dedicated to pumps were the teams best source of information when learning about the functional description of a pump. The two main websites used for external research were www.pumpscout.com for basic information on the types of pumps and their functions, and www.pumpfundamentals.com for computational analysis. These two sites provided the information needed to create different pump concepts. From these two websites the team discovered that most of the pumps were broken down into two types: positive displacement and centrifugal. The purpose of this research was to determine the advantages and disadvantage of each type of pump, and how their traits fit into the constraints of the project application. For the positive displacement pumps the biggest challenge would be how precise the rotating element was housed, and how fast the element was rotating. For the centrifugal pump the biggest challenge is the design of the geometry and speed of the impeller. Other external searches were performed on how-to blogs and online videos to gain an understanding of how other small homemade pumps have been built. The team also dissected a fish tank filter pump to observe the motor housing and the impeller in regard to preventing water leakage. This dissection also provided a better understanding of how the pump worked and the scale of the pump.

5 ME 340.2 Solar Powered Micro-Pump Detailed Design Report

Advantages

Disadvantages

Table 2: Advantages and Disadvantages between pump types Positive Displacement Centrifugal -self priming -simple -consistent output -output varies depending on the pressure at the outlet; this prevents damage to the pump -smaller -higher maintenance costs -use rotation instead of suction to move water -can develop cavitation -not self-priming -cannot develop high pressure Table 3: Patent Descriptions

Axial Flow Pump and Gear Pump: This Magnetically Submersible pump water circulating pump is a gear pump driven axial-flow with plastic housing: apparatus: This is an that is made up of pump: This pump is This product is a pump axial flow pump that is two gears, made of a made up of an that can go under made up of a motor, and ceramic material, electromagnet that water. The case is a rotor that acts as an enclosed in a is surrounding a made to house single axial flow blade. Both housing. The gears rotor that is fitted or multiple impellers. are in a casing made are driven by a motor with permanent The casing is made of from a resin. The rotor that is only driving magnets. The inside two halves connected is held by a bearing that one of the gears. of the rotor is fitted together which reduces is integrated into the When rotated the with a spiral vane leakage and casing. The input and gear force the water that when rotated manufacturing cost. output ports are built to by pumped from moves water into the casing. the inlet to the outlet. through it Analysis: This design is Analysis: This Analysis: This Analysis: This idea simple and can be design is simple but design is similar to could be implemented constructed with little manufacturing the the axial flow pump in our pump and be parts. The only variable gears very precisely except building the easily manufactured on that would change the could end up being a electromagnet will the rapid prototype 6 ME 340.2 Solar Powered Micro-Pump Detailed Design Report

flow process is the shape of the impeller.

challenge.

take time away from machine. other design aspects

3.2 Problem Decomposition

Housing: Plastic or metal held together with epoxy, screws, or clips. It cannot allow water to damage the motor. Motor: The motor is provided for the project. Pump start position: Outside of water, on top of water, or in the water. Impeller: Number of impellers. Size, shape, and number of fins on impeller. Tubing: Size set at 1m long max, and 3/8 inner diameter. Power Source: Pump will be powered by a solar panel.

3.3 Design Concepts

During the early stages of the project the team decided that learning and developing design concepts independently was best. Each member was responsible for educating themselves about pumps and to develop two to three concepts based on their research. Once the individual research and concept generation was completed the team met to discuss concepts. Instead of focusing on the whole of the pump as one problem the pump was decomposed into functional subsystems. Concepts were created based on impeller position, pump orientation, and pump type. These concepts focused on making the particular subsystem in question the most important part of that design and all other systems were built around it. In total 10 concepts were generated in the concept generation phase and can be seen in Appendix G.

3.4 Concept Selection

To make the concept screening process manageable the 10 concepts were categorized into 5 major design types. The concept types screened included: gear, centrifugal, piston, vane, and magnet driven pumps. A detailed concept screening matrix to find the most desirable concepts to score is found in Appendix B. From the screening matrix it was clear that our concepts within the centrifugal and magnetic driven design types were going to be scored to find the best individual design. From the centrifugal pumps there were three designs to score, and from the magnetic driven pump type there was one design to score. This gave the team four designs to score to find the most favorable design. The full scoring matrix and results is in Appendix D. The most important consideration is housing the motor and the impeller design. Although the results proved that the axial driven pump was the best, the team felt the snail shell design was the best solution.

4. System Level Design

7 ME 340.2 Solar Powered Micro-Pump Detailed Design Report

The design that was chosen was made to be simple, durable, and require little to no maintenance. Since the team picked a centrifugal design for the pump it will need to be primed prior to operation. Therefore, the pump must be waterproof. This meant that the pump needed parts that would not wear when exposed to water and still be strong enough to operate for a long period of time. Water will be drawn axially in through the front plate by a centrifugal impeller. The water is then accelerated out of a tube on the top of the impeller housing. The motor will be housed in behind the pump housing in a piece of PVC piping. The whole pump is connected together using four bolts.

5. Detailed Design
5.1 Modifications to Proposal Sections The new design uses the same type of pump but is more detailed than in the proposal. Three major design changes were: impeller design, pump housing, and motor selection. The impeller was modified from a configuration that had five straight fins extruded from a flat, circular backing to a configuration that uses five curved blades extruded from a similar backing. This change was made after alpha prototype testing revealed that the flat fins did not push water as well as expected. The pump housing will still use PVC for the motor housing and a custom injection molded housing for the impeller. Now, however, three plates, one on each end and one included in the injection mold, and in conjunction with 4 bolts, act to clamp the unit together. Selection of the motor was changed to take advantage of a faster no load speed in order to ensure the motor operated with as little resistance as possible when loaded by the impeller and the force of the fluid. A more detailed pump performance analysis was computed and can be seen in section 5.2. 5.2 Theoretical Analysis For the pump analysis three graphs were constructed to find the operating points. The first of these graphs was Head vs. Flow Rate (Figure H1) and this graph can be seen in Appendix H. The pump curves (blue, red, and green) were made by using data from the Little Giant Model 1-42 pump, along with similarity laws to scale the pump. The original pump operated at 3250 RPM, and had a 1.5 inch diameter impeller with 0.25 inch tall blades. The pump to be build will only have a 1 inch diameter impeller so scaling laws were used at 2400 RPM, 3000 RPM, and 3500 RPM to create the pump curve. The system curve (purple) was made from using the Darcy Weisbach equation for head loss (H=fLD[QA22g] added to the change in height (h). The f value (friction factor) was found using a Moody diagram. The points where the three pump curve crossed the system curves were used to find the input torque. These points for flow rate and corresponding head at each speed can be seen below in Table 4.
Table 4: Flow rate and head values 2400 3000 9.65602 GPH Q 34.7444 GPH Q

3500 48.7375

8 ME 340.2 Solar Powered Micro-Pump Detailed Design Report

1.646427 m

1.750292 m

GPH 2.69815 m

The equation T=gHQ was used to solve for torque at each angular speed. These three data points were graphed on the Torque vs. Angular Speed graph (Figure H2 in Appendix H) to create the pump torque line (black line). The other four lines on this graph (purple, green, red, and blue) were created from the specification for the motor. The motor used was model number 2125528.These lines represent motor torque at varying voltages. Using no-load and stall data from the manufacture the values for Kt/Ke, Tloss, and Ra were found. These values were plugged into TLoad-Tloss=Kt/Ra[V-KE]. The straight lines were made by changing the values for voltage. The values used for the graph we 12, 10, 7.5, and 5 Volts. The points where the pump torque line crossed the four motor torque lines were used to find the current using equation IV=T. These points for torque and corresponding angular velocity at each voltage can be seen below in Table 5. Torques are in mN-m and is in RPM. Table 5: Torque and angular velocity values 12V 10V 7.5V 5V 9.93404 5.35302 T 14.011529 T 8 T 8 T 1.682782 6592.31 5830.72 4752.9 3452.98 The four points for current and voltage were plotted on the Electrical Power graph (Figure H3 in Appendix H). These four points made the pump output line (red). The other line (blue) plotted on this graph voltage and current data from the unregulated solar panel. Where these points crossed is the operating point, and the voltage and current from this point were 7.85 Volts and 0.396 Amps. Now a new motor torque line was created on the Torque vs. Angular Speed graph at 7.85 Volts. This graph (Figure H4) can be seen in Appendix H with only the torque line at 7.85 Volts (red) and the pump torque (black). These lines crossed at a torque of 5.95 mN-m and a speed of 4900 RPM. Since the operating speed was 4900 RPM a new pump curve on the Head vs. Flow Rate graph was made at this speed. A graph (Figure H5) with only the system curve and pump curve at 4900 RPM can be seen in Appendix H. These lines crossed at an operating head of 2.34 feet, and flow rate of 81 GPH. The total results of the analysis can be seen below in Table 6. Table 6: Results Final Results Q 1.35 GPM H 0.713 meters w 4900 RPM T 5.95 mN-m i 0.3964 Amps V 7.85 Volts

9 ME 340.2 Solar Powered Micro-Pump Detailed Design Report

Using the pump curve at 4900 RPM it is seen that the pump will operate at 87 GPH or 1.45 GPM at a head of 0.5 meters. These are the operating conditions that the pump will be tested at. 5.3 Component and Material Selection Process for Mass Production Unit Due to its relatively simple shape the housing will be injection molded to save on costs and time. Injection molding requires no machining; therefore reduces cost due to labor. Since the pump will be in contact with water, plastic is the best option to prevent rust or any other type of water wear. The motor housing will be a simple off the shelf cut of PVC piping. This piping provides the necessary waterproofing that is needed. The piping is sold in lengths of 10 feet, which allows for roughly 30 units to be assembled from one length of piping. The only machining required is a cut on the band saw. PVC will also be used because of electrical connections being housed inside; there will be reduced risk of a short circuit because PVC does not conduct electricity. The impeller is designed specifically to work well with the choice of pump housing. Injection molding will be used to create parts in bulk. This molding will allow easy reproduction of the impeller with minimal labor hours. The impeller will also be made from plastic to avoid corrosion from water contact. Plastic also offers a better resistance to bending on the impeller blades. The front and back plates will both be machined from quarter inch clear chemical resistant plastic. Plastic again will be used due to it being in contact with water as well as it not being able to conduct electricity. The plastic plates will be milled to size. This is the same process for an aluminum or steel plate, but the plastic stock is cheaper and more resistant to deformation. All electrical components will be purchased from Jameco Electronics in bulk. A waterproof switch will be used to avoid a short circuit. Standard solder will be used to secure electrical connections. The bolts holding the entire pump together will be four inch long, -20 steel cap screws and secured with nylon wing nuts. The wing nuts will be nylon to avoid corrosion from water. These components will be purchased in bulk from McMaster-Carr. 5.4 Fabrication Processes for the Mass Production Unit Injection molding will be used to manufacture both the impeller housing and the impeller. All other components are standard parts that will be purchased from suppliers. Jameco Electronics will be the supplier of the motor, wires, toggle switch, waterproof boot, and PV panel connection. McMaster-Carr will be the supplier of the o-ring for the motor shaft, hosing fittings, and PVC.

5.5 Industrial Design

The pumps motor and impeller will be sealed inside a plastic housing. This housing will be made up of two parts, the casing for the motor and the impeller housing. The motor casing will be waterproof so that the wires and motor cannot be damaged by water. The seal will be created by mounting the motor in a plastic pipe and pressing a back plate against the back of the pipe and pressing the front of the pipe against the plate on the impeller housing. The two plates will be held together by four bolts. Gaskets or o-rings will be used at the mating 10 ME 340.2 Solar Powered Micro-Pump Detailed Design Report

surfaces to hold the seal. This seal will insure that the electrical connections are safe and the user can easily access the motor and impeller by taking off the bolts. There will also be a switch mounted on the motor casing back plate so that the pump can easily be switched on and off. The switch will also be protected from water by using a rubber cover and a gasket on the mating surfaces of the switch and the back plate.

5.6 Detailed Drawings

Figure 1: Isometric view of pump

5.7 Economic Analysis 5.7.1 Unit Production Cost

# 1 2 3 4 5 6 7 8 9 1 0 1 1 Part PVC Motor Housing Impeller (IM) Pump Housing (IM) Front Plate End Plate Rubber Gaskets Steel Bolts Pipe Fitting Wing Nuts Electrical Switch Motor Table 7: Bill of materials Vendor Info Bulk (100,000) unit cost ($) McMaster Carr 48925K14 0.76 Xcentric Molding 0.30 Xcentric Molding 0.47 McMaster Carr 8733K18 0.07 McMaster Carr 8733K18 0.07 McMaster Carr 9774K43 0.23 McMaster Carr 91251A089 1.70 McMaster Carr 5346K18 1.10 McMaster Carr 98143A015 0.16 Jameco 76523 1.25 Jameco 2125528 1.95

11 ME 340.2 Solar Powered Micro-Pump Detailed Design Report

5.7.2 Business Case Justification

The product will be sold at $20.00 per unit. This yields an $8.25 profit per unit. Selling 100,000 units per year will create a profit of $825,000 per year. An assumed $200,000 a year for overhead which includes, salaries, marketing and ramp up is included in this NPV calculation. The NPV for this product is estimated at $3,470,000. The calculation of this number can be found in Appendix I. With the NPV in mind, there is good justification to invest in this business venture. 5.8 Safety Because the pump is designed to be operated underwater and autonomously there are inherently reduced risks to the end user. All electrical components are well sealed and insulated within a non-conductive enclosure. The impeller is enclosed within a housing that helps eliminate injury due to misuse. This enclosure also eliminates user harm due to impeller failure that could otherwise throw the failed impeller pieces. Additionally, the impeller can be removed so as to eliminate user harm caused by accidental or inadvertent motor activation during repair; though the power source should be disconnected prior to service.

5.9 Actual Construction Process of Beta Prototype Construction of the beta prototype began with the creation of the impeller and impeller housing from the rapid prototyping machine. A center hole was then drilled into the back of the impeller housing for the motor shaft. Two end plates were milled from Plexiglas. Four holes were then drill into both end pieces, and the impeller housing, to be used with four 20 cap screws and their complementary wing nuts to clamp and seal the pump body. A center hole was also drilled and tapped into the front end plate to serve as the inlet when a fitting was fastened into the hole; Teflon tape was wrapped around the fitting thread to prevent leakage. This front end plate was also milled to allow the impeller housing to mate perfectly. Once the wires were soldered to the motor terminals, a small hole was drilled into the back end plate, for the wires, which was waterproofed with silicon sealant. Later it was decided that the motor should be secured with mounting screws. In order to achieve this safer design it was necessary to mill the surface of the impeller housing where the motor engaged with the shaft hole because the lengths of motor mounting screws available were too short. In addition, two holes for the mounting screws were drilled into the impeller housing. Once the impeller housing was milled and mated with the motor the set screws were used to fasten the motor to the impeller housing. A piece of PVC was also cut to serve as the motor and electrical housing. With all pieces made the entire assembly was then secured with the four aforementioned cap screws and wing nuts. Figure 2: Assembled Pump 12 ME 340.2 Solar Powered Micro-Pump Detailed Design Report

Figure 3: Front end plate with inlet fitting

removed

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6. Testing
6.1 Test Procedure The test that will be conducted on the motor will be a dynamometer test. The materials required for this test will be an electric motor, a variable voltage input, a string, weights with known masses, a stopwatch, and a tape measure. To do this test a string will be put on the motor and a weight will be hung from the string. When the motor is turned on the weight will be lifted. The time for the weight to reach a certain distance will be recorded. This will be done for multiple weights at a constant voltage. With the data know torque, velocity, and force can be solved for. This will lead to angular velocity values. This test will be used to compare the motors performance to the specifications given by the manufacturer.
The second test the will be conducted is to test the pumps performance. This will be done using the prototype pump, a voltage source, a container with marks for volume, a stopwatch, and a tape measure. To test the pump a constant voltage supply will be used to power the pump. The flow rate will be tested by taking the time it takes to fill the container to a certain volume. Then the flow rate will be tested at different pressure head heights by raising the outlet. This will be done at multiple head heights to create a pump curve. This test will show how the analysis compares to the actual performance of the pump.

6.2 Test Results After testing was completed the results revealed that the motors worked as expected by the manufactures specifications (efficiency 60%-70%). The data was plotted on a Torque vs. Angular Velocity graph and this can be seen in Appendix J. The blue line was the one found from the torque equation with a voltage of 6 Volts, and the red is from the testing. At stall the calculation says the motor should make 19.44mN-m, and the experiment showed that at the same voltage the torque was 12.909mN-m. With this data it can be shown that the motor made 66% (12.909/19.44) of the power that was expected by at the same input power. This means that the manufactures specifications of efficiency between 60%-70% are correct and the motors are performing as expected. After testing flow rates at different outlet heights, the performance curve for our pump was found and can be seen Appendix J. This graph can now show the flow rate at any height between 0 to 1.14 meters. At 0.5 meters of head the pump will have a flow rate of 0.825 GPM. When compared to the analysis there is a 43% error. 14 ME 340.2 Solar Powered Micro-Pump Detailed Design Report

This is from the fact that the analysis it is assumed that when changing the impellers size that it is scaled perfectly. So when the diameter drops from 1.5 inches to 1 inch the height of the impeller blades at 0.25 inches should drop to 0.167 inches. The impeller that we used is only 0.1 inches. For this analysis it is assumed that the size dropped by only 33% when in reality the impeller implemented in the design was scaled normally on diameter and by 60%. This is almost twice the size scaled down from where it was assumed. Since the flow rate is directly proportional to the impeller size the true expected flow rate can be found from setting up a proportion: 1.45GPM0.167inches=expected flow0.1inches Solving this shows that the expected flow rate from the analysis should be 0.868 GPM based on the impeller that was used. This is only a 5.5% error from the actual flow rate of 0.82 GPM

7. Conclusion
This pump is the most viable option for a third world drip irrigation system as it is affordable and provides the necessities to operate said system. Key features include easy disassembly for maintenance and complete set and forget operation. Utilizing specific materials such as plastics and nylons makes this pump completely recyclable when it has reached the end of its life. Economically this pump is perfect for the third world farmer as well as the company producing it. It is affordable at $20.00 per pump while still yielding an $8.25 profit on each pump sold. Referencing the NPV, which is $3,470,000, indicates that this is a worthwhile investment. Assuming 100,000 units sold each year an $825,000 profit per year can be expected. Testing has highlighted problems which were unknown and could be improved upon. The length of the impeller blades could have been doubled as this would have allowed more water to be pushed and therefor increasing the overall flow rate of the pump. The set screws for the motor were not recessed enough into the motor housing to provide necessary motor support. This lack of support caused shifting of the motor leading to a rubbing of the shaft during operation. A nut or washer could have been used to prevent the wing nuts from being over tightened and eventually leading to a motor lock via shaft friction which was experienced during pump testing. These improvements can potentially lead to a better performing and longer living pump. This project was a great way to gain experience and actually learn, hands on, what an engineers job consists of. The team learned how to conduct research and gain knowledge that was then used to come up with viable initial designs. We also learned how to take a SolidWorks drawing and then turn that drawing into an actual item through the machine shop. This project could be improved to better aid in learning and reduce stress. There should be fewer projects assigned during the semester as to not distract teams from the final project. A more detailed and involved class in the machine shop to develop machining skills would greatly reduce the total time spent outside of class learning how to use certain machines.

8. References
1. Vallabh Rao. Driptech: How affordable irrigation can transform small-plot farms. dowser.com. Dowser Media. 11 Oct. 2011. Web. 25 Sept. 2012. 2. "Jameco Part no. 238473." Jameco Electronics. Jameco, 2012. Web. 6 Oct 2012.

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3. Lowes. N.p., n.d. Web. 07 Oct. 2012. <http://www.lowes.com>. The Lowes online store was used to price materials. 4. "Jameco Electronics." Electronic Components Distributor. N.p., n.d. Web. 07 Oct. 2012. <http://www.jameco.com/webapp/wcs/stores/servlet/StoreCatalogDisplay? storeId=10001>. The Jameco Electronics online store was used to choose the pump motor. 5. "McMaster-Carr." McMaster-Carr. N.p., n.d. Web. 07 Oct. 2012. <http://www.mcmaster.com/>. The online McMaster Carr store was used to price materials. 6. Postel, Sandra. "Drip Irrigation Expanding Worldwide." National Geographic. N.p., 25 June 2012. Web. 06 Oct. 2012. <http://newswatch.nationalgeographic.com/2012/06/25/drip-irrigation-expandingworldwide/>. 7. Manda, Takahike, Yoshifumi Tanabe, and Kazunori Murakami. Axial Flow Pump and Fluid Circulating Apperatus. 7,168,926 B2. Jan. 30, 2007. 8. Post, Johannes. Gear Pump. 6,158,997. Dec. 12, 2000. 9. Noda, Hiroyuki. Magnetically Driven Axial Flow Pump. 6,527,521 B2. Mar. 4, 2003. 10. Zimmer, John. Submersible Pump with Plastic Housing. 4,923,367. May 8, 1990. 11. Fox, Robert W., Philip J. Pritchard, and Alan T. McDonald. Introduction to Fluid Mechanics. 7th ed. Hoboken, N.J.: Wiley, 2009. 12. Hyman, Barry. Fundamentals of Engineering Design. 2. Prentice Hall, 2002. 374. Web.

Appendix A Gantt Chart 16 ME 340.2 Solar Powered Micro-Pump Detailed Design Report

17 ME 340.2 Solar Powered Micro-Pump Detailed Design Report

18 ME 340.2 Solar Powered Micro-Pump Detailed Design Report

Appendix B Quality Function Deployment

19 ME 340.2 Solar Powered Micro-Pump Detailed Design Report

Can create a change in elevation High flow rate Can be used in water Self priming Ease of use Durability Cost effective Safe Easily maintained Provides a constant water supply Easily repairable Metrics Change in elevation of atleast 0.5 m Flow rate of atleast 0.5 gpm X

Appendix C Concept Screening Matrix

X X X X X X X X X X Electrical components will be exposed to no water No priming of the pump is required User input is one on/off switch Parts will resist most damage fromenvironment Tubing inner diameter of 3/8" Will cost 30 dollars or less X X Will have no exposed electrical connections X Will have no exposed mechanical parts X X Will have no surge in water X X X Can be opened without tools X X

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Selection Criteria can create a change in elevation high flow rate can be used in water Self-priming ease of use durability cost effective safe easily maintained provides a constant water supply Total

Gear 3 2 5 5 3 3 1 3 3 2 30

Impeller Centrifug al 3 5 5 3 3 3 4 3 4 5 38

Piston Pump 3 1 5 5 3 2 2 3 2 2 28

Vane Pump 3 2 5 5 3 3 2 3 3 2 31

Electroma gnet Pump 3 4 5 3 3 5 3 3 4 5 38

Based on score of performance: 1-Poor, 2-Below Average, 3-Average, 4-Above Average, 5Excellent

Appendix D AHP Weighting Matrix

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can create a change in elevation

high flow rate

can be used in water

Self priming

ease of use

durability

cost effective

safe

easily maintained

provides a constant water supply

Totals

Weights

can create a change in elevation high flow rate can be used in water Self priming ease of use durability cost effective safe easily maintained provides a constant water supply 2 1 2 1 1/2 1/2 3 1 1/2 2 3 1 1/2 1/2 3 1 1 2 1 3 1 3 2 1/2 1 1 1/3 2 1/2 1/3 1 1/2 3 1 1/3 1/3 3 1 1/2 4 3 2 1/4 1/3 1/3

1/2

1 1/2

1/2 1/3 1/2

1 1 1 1

2 2 1/3 1 1

2 2 1 3 2 3

1/3 1/3 1/3 1/2 1/3 1/3 1/4

1 1 1/2 2 1 1 1/3 4

101/3 101/6 8 2/3 171/2 111/3 121/3 41/4 28 12 3/4 55/6 Total 121 1/6

2 1 2 3 3 2 1/2 3 3

8.528198 8.390646 7.152682 14.44292 9.353508 10.17882 3.507565 23.10867 10.5227 4.814305

22 ME 340.2 Solar Powered Micro-Pump Detailed Design Report

Based on a scale of relative importance: 1-equals, 2-slighlty important, 3-moderately important, 4-extremely important

Rounded Weights 10 10 5 15 10 10 5 20 10 5

Appendix E Concept Scoring

Selection Criterial Can create a change in elevation High flow rate Can be used in water Self priming Ease of use Durability Cost effective Safe Easily maintained Provides a constant water supply Weighted Total Weights 0.10 0.10 0.05 0.15 0.10 0.10 0.05 0.2 0.1 0.05 Concepts Axial Driven Snail Flat Orientaiton Magnetic Driven Rating Score Rating Score Rating Score Rating Score 4 0.4 3 0.3 3 0.3 3 0.3 3 0.3 3 0.3 2 0.2 3 0.3 4 0.2 4 0.2 3 0.15 5 0.25 3 0.45 2 0.3 4 0.6 4 0.6 3 0.3 3 0.3 4 0.4 4 0.4 3 0.3 3 0.3 2 0.2 2 0.2 3 0.15 3 0.15 4 0.2 2 0.1 4 0.8 4 0.8 3 0.6 2 0.4 3 0.3 3 0.3 3 0.3 3 0.3 4 0.2 4 0.2 4 0.2 4 0.2 3.4 3.15 3.15 3.05

Appendix F Patent Search Patent 1: Axial Flow Pump 23 ME 340.2 Solar Powered Micro-Pump Detailed Design Report

Patent 2: Gear Pump 24 ME 340.2 Solar Powered Micro-Pump Detailed Design Report

25 ME 340.2 Solar Powered Micro-Pump Detailed Design Report

Patent 3: Magnetically Driven Flow Pump

26 ME 340.2 Solar Powered Micro-Pump Detailed Design Report

27 ME 340.2 Solar Powered Micro-Pump Detailed Design Report

Patent 4: Submersible Pump with Plastic Housing

28 ME 340.2 Solar Powered Micro-Pump Detailed Design Report

29 ME 340.2 Solar Powered Micro-Pump Detailed Design Report

Appendix G Design Concepts Figure G1- Initial design concepts

30 ME 340.2 Solar Powered Micro-Pump Detailed Design Report

Appendix H Theoretical Analysis

Figure H1 Figure H2 Figure H3

Figure H4 Figure H5

Appendix I NPV

31 ME 340.2 Solar Powered Micro-Pump Detailed Design Report

($valuesinthousands) Development Cost Ramp-Upcost marketingandsupport productcost Productvolume Unit productioncost salesrevenue salesvolume unit price PeriodCashFlow PVYear1,r=10% ProjectNPV -45 -45 3470

Year1 Q1 0 Q3 -45 1 Q4 Year2 -45 2 Q1 -45 3 Q2 -45 4 Q3 5 Q4 Year3 -5 6 Q1 -5 -2.5 7 Q2 -2.5 8 Q3 -73.4375 -2.5 9 Q4 Year4 10 Q1 250 0 -73.4375 -2.5 -73.4375 -2.5 -0.0 294 250 0 1 Q2 -73.4375 -2.5 -0.0 29 12 Q3 50 4 250 0 -73.43 -45 7 13 Q4 250 0 50 -0.0 294 250 0 5 -2.5 -73.4375 -2.5 -4 -45 14 250 -0.0 294 250 0 -50 0.02 0 50 -0.0 294 250 -73.4375 -2 -43 15 0 .5 250 0 -46 -7.5 4 0.02 50 -0.0 294 250 0 -73.4375 -2.5 24.0625 250 0 50 -7 424.062 0.02 250 -0.0 294 250 0 -73.4375 -2.5 5 0.02 0 50 -73 375 424.0625 0.02 250 0 50 -0.0 294 250 0 .4375 -2.5 -73 36 424.0625 0.02 250 0 50 -0.0 294 250 0 .4375 357 424.0625 0.02 250 0 50 -0.0 294 250 0 348 424.0625 0.02 250 0 50 -0.0 294 340 424.0625 0.02 250 0 50 31 424.0625 0.02 250 0 323 424.0625 0.02 315 424.0625 308 424.0625 30 293 Q2

Appendix J Testing Results 32 ME 340.2 Solar Powered Micro-Pump Detailed Design Report

Figure J1: Motor Test Results Figure J2: Pump Curve from Test

Appendix K Part Drawings

33 ME 340.2 Solar Powered Micro-Pump Detailed Design Report

Figure K1: Impeller Figure K2: Housing 34 ME 340.2 Solar Powered Micro-Pump Detailed Design Report

35 ME 340.2 Solar Powered Micro-Pump Detailed Design Report

Fig

ure K3: Motor Housing 36 ME 340.2 Solar Powered Micro-Pump Detailed Design Report

Figure K4: Front plate

37 ME 340.2 Solar Powered Micro-Pump Detailed Design Report

Figure K5: Back Plate

38 ME 340.2 Solar Powered Micro-Pump Detailed Design Report

39 ME 340.2 Solar Powered Micro-Pump Detailed Design Report