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Water is among the most valuable resources on Earth. Outdated crop irrigation techniques such as flood irrigation are wasteful of the valuable but scarce water supply in developing countries. Pascal’s Posse has developed a 100% solar powered pump that automatically and efficiently pumps water from a source to allow for the more modern technique of drip irrigation in a cost effective way. The pump harnesses energy from the sun and converts it into electricity that powers the motor. The motor drives a centrifugal pump floating on the surface of the water. As centrifugal forces develop inside the pump due to impeller rotation, water is forced through a tube at high pressure to the desired destination. Retailing at only Pascal’s Posse Detailed Design Report – 12/4/2012 1 MAXWELL PEPPER LIZ DONOFRIO KYLE MOORE

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Page 1: Detailed Design Report

Water is among the most valuable resources on Earth. Outdated crop irrigation techniques such as flood irrigation are wasteful of the valuable but scarce water supply in developing countries. Pascal’s Posse has developed a 100% solar powered pump that automatically and efficiently pumps water from a source to allow for the more modern technique of drip irrigation in a cost effective way.

The pump harnesses energy from the sun and converts it into electricity that powers the motor. The motor drives a centrifugal pump floating on the surface of the water. As centrifugal forces develop inside the pump due to impeller rotation, water is forced through a tube at high pressure to the desired destination. Retailing at only 299 USD, this provides an inexpensive way for farmers in developing countries to utilize modern irrigation techniques.

Pascal’s Posse Detailed Design Report – 12/4/20121

MAXWELL PEPPER

LIZ DONOFRIO

KYLE MOORE

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Table of Contents

Executive Summary...............................................................................................................1

1. Introduction Page...............................................................................................................31.1 Problem Statement...............................................................................................31.2 Background Information......................................................................................41.3 Project Planning...................................................................................................4

2. Customer Needs and Specifications...................................................................................52.1 Identification........................................................................................................52.2 Design Specifications...........................................................................................5

3. Concept Development........................................................................................................63.1 External Search....................................................................................................63.2 Problem Development.........................................................................................63.3 Concept Generation.............................................................................................73.4 Concept Combination..........................................................................................73.5 Concept Selection................................................................................................7

4. System Level Design.........................................................................................................84.1 Overall Description..............................................................................................8

5 Detailed Design...................................................................................................................85.1 Modifications to Proposal Sections.....................................................................85.2 Theoretical Analysis............................................................................................95.3 Component Material Selection............................................................................105.4 Fabrication Process..............................................................................................105.5 Aesthetics and Ergonomics..................................................................................105.6 Detailed Drawings...............................................................................................115.7 Economic Analysis..............................................................................................115.8 Safety...................................................................................................................125.9 Testing Procedure................................................................................................13

6. Conclusion.........................................................................................................................14

7. References..........................................................................................................................15

Appendices.............................................................................................................................18A - Team ContractB - Team Member FunctionsC - Customer Needs MatrixD - External Research (Excerpt)E - QFD, Importance Ratings of Needs and MetricsF - Pro and Con MatrixG - Functional Decomposition Black Box ModelH - CalculationsI - Detailed DrawingsJ - Manufactured Parts EstimationK - Bill of MaterialsL - Economic Analysis

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1. Introduction

1.1 Problem Statement

Despite adequate water supplies in industrial nations, water scarcity poses an imminent threat to the socio-economic stability of developing countries. As an input of agriculture, water plays a crucial role in maintaining food self-sufficiency. Still, there is a lack of investment in water infrastructures throughout impoverished regions around the world. Instead, rural farmers in poverty stricken countries remain highly dependent upon unreliable rain-fed farming irrigation methodologies or even aid packages imported from nations that are more affluent. With unprecedented growth projections of world population surmounting 9 billion people by 2050 [1], subsistent agricultural practices in poor rural regions of the world will no longer suffice human sustainability requirements.

In order to improve the social, economic, and environmental conditions of the rural poor in impoverished countries, Pascal’s Posse recommends that the irrigation industry expand irrigation water accessibility to low-income, small-scale farmers. Currently, the private sector does not offer any small-scale design irrigation systems. Instead, modernized irrigation systems are designed with the large-scale farmer in mind, cutting off the small landholder as a potential client [2]. In fact, with the exception of non-profitable governmental organizations (NGOs), the majority of businesses and investors in the sector do not even acknowledge, never mind target, the small-scale farmer as a customer, because modernized water distribution systems are not affordable to an impoverished farmer. Contrary to prevalent market conceptions, Pascal’s Posse recognizes the significance of the 1.92 billion small-scale landholders living in extreme poverty today [3] and sees their promise as a potential market for micro-irrigation systems.

Pascal Posse’s overall objective is humanitarian. The aim of this project is to aid those in developing nations gain access to a reliable source of water by both designing and manufacturing a beta prototype of the team’s final micro-pump design concept. Pascal’s Posse intends for the beta prototype to be of the highest quality. This entails that the micro-pump be not only the highest performing pump but that it also abides by the set design constraints. It is important to note that the design of the micro-pump irrigation system was restricted by the following design criteria:

1. Pump must be self-priming.2. Power source must be from solar energy.3. Maximum inner diameter of tubing is 3/8 inches; maximum length is 1 meter.4. Motor must be selected from the four given Jameco part numbers. 5. Limited to a total budget of $100 for all charges.6. Allowed a maximum of 3 cubic inches of total material with the RP machine.7. Allowed a maximum of 4 minutes of total cut time with the water jet machine.

After the entire product development process is completed, Pascal’s Posse will have produced a beta prototype that is reflective of the micro-irrigation system that will be entered in a new potential market where the poor rural farmer is the valued customer. Pascal’s Posse assures that its design solution will offer developing nations an affordable, appropriate, and environmentally sustainable solar-powered micro-pump irrigation system as a cost effective application for rural farmers to utilize in the threat of water scarcity.

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1.2 Background Information

Water scarcity is an ongoing problem in developing countries throughout the world. A lack of water and technology makes essential tasks such as farming more complicated and inefficient than anywhere else in the world. The most common technique used to irrigate crops in these countries is the age-old process known as flood irrigation [4]. This process results in a great deal of wasted water and is very inefficient when it comes to growing crops, two things these countries cannot afford. An obstacle to modernizing these farming techniques is the lack of power availability. Electricity is not readily obtainable, which makes using modern equipment next to impossible. Pascal’s Posse along with other small groups of mechanical engineering students was assigned the task of developing a solar powered micro-pump that is both cheap and efficient. The goal of this pump is to allow farmers of developing countries to use drip irrigation, a more modern irrigation technique, to save time, money, and other essential resources. The pump is required to have a minimum flow rate of 1.9 liters per minute and must be able to lift water at least a half of a meter. Its power source will be a photovoltaic array panel that will provide approximately 3.1 watts of power.

The three mechanical engineers of Pascal’s Posse bring both classroom and real world experience to the table. Max Pepper, the project manager, has previously interned at the nuclear power plant run by Pennsylvania Power and Light. Max was also the manager of several design projects including a team tasked with designing and building a remote controlled search and rescue vehicle. Kyle Moore has interned at a nuclear power plant in Limerick, PA for Exelon Generation. Working at these plants gives Max and Kyle a solid understanding of pumps and flow systems. The third member, Liz Donofrio, has completed an internship with Pratt and Whitney working with jet engines. This experience has given her a great knowledge base of fluid dynamics. Along with the internships and past experiences, each member of the team has completed an introduction to engineering design course and is also either enrolled in or finished with the fluid mechanics course at The Pennsylvania State University. This project gives our team the unique and exciting opportunity to apply and combine classroom based knowledge and experience based knowledge to develop a pump that could potentially help thousands of people in developing countries across the globe.

1.3 Project Planning

At the first team meeting each team member’s strengths and weaknesses were identified and included them in our team contract (Appendix A). Max has been appointed the project manager but the team takes an all hands approach when it comes to completing tasks. Every task to be completed involves input from each member in order to integrate everyone’s strengths in each step of the process.

We broke the project down into four stages, Customer Analysis, Brainstorming, Prototype Development, and Final Preparation. These stages are based off of the Engineering Design Process covered in the ME 340 Design class [5]. To keep job distribution fair, equal, and organized, we created a color-coded Gantt chart. This breaks down tasks of each stage of our development process, is color-coded based on who is responsible for every task and includes a schedule of when each task is to be completed. This chart can be found in Appendix B.

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2. Customer Needs and Specifications

2.1 Identification of Customer Needs

The inability to create a high quality information channel directly between the end users of the micro-pump irrigation system and the team due to geographical barriers did not prevent the team from engaging in the art of eliciting customer needs data.

In order to understand the intended end user, Pascal’s Posse interviewed Engineers Without Borders (EWB) organization member Andrew Kreider [6]. Kreider initiated a humanitarian engineering project in Africa with the purpose of establishing a water distribution infrastructure within the village of Sierra Leone. Kreider was able to communicate to the team the emerging needs of the tribal-like community he collaborated with to build a water infrastructure. He also provided Pascal’s Posse with the raw data that he had collected from the team’s intended end user while he was overseas (i.e., customer surveys, pictures of the use environment, meeting minutes from the water committee from its inception, etc.) which can all be found in the organization’s water assessment report [7].

This data later proved to be instrumental to Pascal’s Posse in developing a fact base for use in the concept development phase of the project development process. It also embedded a deep sense of commitment to the team initiatives at an early stage of the project. Furthermore, a good source of customer needs came from a Lowe’s employee who was characterized as an intended lead user of our pump set [8]. The employee specialized in pipe flow systems and was able to articulate the latent needs of the team’s customers and stakeholders, which otherwise would not have been acknowledged in advance.

From the raw data, Pascal’s Posse was able to translate customer statements into customer needs with confidence. After identifying the customer needs from the research generated in the study of the market, Pascal’s Posse used numerical importance weighting in order to establish the subset of customer needs with greatest relative importance. This task was accomplished by relying on the consensus of team members, who based their perception of the relative importance of a customer need on the information they obtained from Kreider and the Lowe’s expert. The customer needs matrix (Appendix C) adequately identifies the following needs as the top five most important: ‘Reliable,’ ‘Easy to repair,’ ‘Environmentally friendly,’ ‘Easy to install,’ and ‘Easy to use.’ Reliability is ranked as the most important for our target market for two crucial reasons. The micro-pump would be the end user’s primary access point to a water resource and therefore must remain operational when needed. Also, it is essential that one’s investment not only remunerates but multiplies in value. An archival record of the customer needs phase can be found in Appendix D.

2.2 Design Specifications

After identifying the customer needs but before generating any product concepts, Pascal’s Posse established the target specifications for its micro-pump. Consequently, the team engaged in a four-step process.

The first step entailed preparing a list of metrics. To generate this list of metrics, Pascal’s Posse had to map each customer need to a specific, measurable set of specifications. This mapping was

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performed for each of the customer needs by identifying a measurable characteristic associated with the respective customer need [5].

Pascal’s Posse then graphically represented this translation between customer needs and their associated metrics in a Quality Function Deployment (QFD) chart, as depicted in Appendix E Chart E1. The team saw that the relation between customer needs and their associated set of metrics is nearly one-to-one. Using this functional relationship as a model, Pascal’s Posse was able to derive the importance rating of each metric from the importance ratings of its associated customer needs. When a metric was exactly one-to-one with a customer need, Pascal’s Posse assigned it the same importance value as the associated customer need had. For incidences where a metric corresponded to two customer needs, Pascal’s Posse had to contemplate the relative importance of each customer need before assessing the importance rating of the metric. The importance ratings of the customer needs and the importance ratings of the metrics can be seen in Charts E2 and E3 of Appendix E, respectively. The importance ratings are based on a scale ranging from zero to five, with a low-spectrum rating of zero being equivalent to ‘Having no importance’ and a high-spectrum rating of five being equivalent to ‘Having critical importance.’

3. Concept development

Utilizing effective research, an exhaustive concept generation process, and a solid prior knowledge of pumps, Pascal’s Posse was able to explore all feasible pump options in order to select the most promising concepts to refine and develop further.

3.1 External Search

At the beginning of the external search process, Pascal’s Posse believed the most important and time consuming part of the search would be researching existing pump types and determining which pump would be ideal. Once all of the research was completed, the group created a Pros and Cons table as seen in Appendix F. This breaks down the research done for each pump type, and the pros and cons of each based on the pump location relative to the water.

Another important step in the external search process was benchmarking the competition. During the search process, the team came across the solar products company Solar Powered Solutions that currently manufactures pumps for gardening and landscaping purposes [9]. The specific pump that the team chose to benchmark retails at $329. It has a flow rate of 11 liters per minute and can lift water 2.75 meters. Although these performance specifications are significantly higher than those required by the project description, Pascal’s Posse chose this pump as its main competitor because of the similarity in price.

3.2 Problem Decomposition

When breaking the problem down into subsystems, the team created a black-box model (Appendix G). Pascal’s Posse used the model to break the pump into three categories:

Energy: how the pump system will receive, harness, convert and transport energy. Material: in this instance water, how it is introduced, transported, and used in our pump system. Controls: how the pump system is activated.

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3.3 Design Concepts

Pascal’s Posse began generating pump concepts immediately after completing the team contract. Prior pump knowledge allowed the team to establish the initial concepts very early in the design process through brainstorming. Nearly all feasible pump types were identified before the majority of market research was conducted. This technique was utilized in order to get an early start on the project because of the short amount of time given to complete it. It was also advantageous because of the tremendous progress the team was able to display in the first project presentation. Later, the team conducted an extensive internal and external research gathering period. The knowledge and information gained allowed Pascal’s Posse to narrow down concept selection to the most promising pump designs for this specific application. Internet research also yielded one additional concept (the screw pump) that the team was able to consider [10].

Before the team began the concept selection process, there were ten potential concepts. The general pump types the team considered were radial centrifugal (figure 1), positive displacement (figure 2), axial centrifugal (figure 3), and screw (figure 4). For all but the screw pump, the team considered a submerged, floating, and dry (outside of the basin) pump. The radial pump utilizes centrifugal force to propel fluid tangentially to the circumference of the impeller. Axial pumps work like boat or airplane propellers and impel water along the axis of the pump. Positive displacement pumps are slightly more complicated and transport fluid using an expanding and collapsing cavity. When the cavity expands, fluid is drawn in through the intake. Then the fluid is compressed and forced through the outlet. The specific type of positive displacement pump Pascal’s Posse is considering uses two meshed gears to create the cavity. The last type is a screw pump which uses a large inclined auger that carries fluid up along its threads as it rotates.

Fig. 1: Radial Pump [11] Fig. 2: Positive Displacement [12] Fig. 3: Axial Pump [13] Fig. 4: Screw Pump [14]

3.4 Concept Combination

Initially, Pascal’s Posse generated four preliminary concepts. These concepts were a submerged axial pump, a floating radial pump, a dry positive displacement pump, and a screw pump. It was determined that radial, axial, and positive displacement pumps were all feasible as either a submerged, floating, or dry pump. Three types of pumps with three location options each plus the screw pump yielded ten total concepts.

3.5 Concept Selection

Upon completing the concept generation and internal/external market research phases, the team initiated the concept selection phase. The first technique utilized to select the most promising concept was a pro and con matrix for all ten pump concepts (Appendix F). After discussing and refining the matrix, the team began to select the most promising concept through a multi-voting process. Concepts were selected based upon how well they met customer needs and if they could

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be feasibly designed and built in the allotted time. First, the team voted on which type of pumping mechanism to use. Each member was given six votes; however, no more than three of these votes could be cast for a single concept. The two most popular selections were the radial centrifugal pump and the positive displacement pump. Appendix F contains the complete results of the team multi-vote. Centrifugal pumps are feasible to build and are ideal for high flow rate applications. Positive displacement pumps are more suited towards lifting fluids and are self-priming but require very tight tolerances. Motivation to choose the centrifugal pump came from its simple design and good overall performance.

The next step was to choose location of the pump. Since the location of the pump is heavily dependent upon the type of pump, this multi-vote was done after the pump mechanism was selected. For the centrifugal pump, the most popular selection was a floating pump. The floating design is oriented vertically and only the pump impeller and housing should ever contact the water. Ordinary pool noodle material will serve as the floatation device. The main advantages for the floating pump are that it does not require the self-priming mechanism that a dry pump would need and is more accessible and less prone to water damage than a submerged pump. See Appendix F for more information.

For the solar panel, basin, and tubing, the final selection had already been made for the team by the professor. Options for the pump motor included parts 174693, 238473, 2125528, and 206949. The final decision was made based on motor maximum power and efficiency. Pascal’s Posse quickly reached a unanimous decision because motor number 2125528 was the capable of generating the most power and consumed the least amount of energy [15].

4. System Level Design

At this stage in the project, most design aspects of the pump have been finalized. Only noncritical attributes of the pump are still being developed. The motor, solar panel, and tubing are already in the possession of the team and all necessary pump components have been manufactured. Any further changes made to the design will be minor and based upon the results of the beta prototype testing.

4.1 Overall Description

The broad attributes of the pump have been extensively research and decided upon. The team chose a floating centrifugal pump as the ideal concept. Although the design is nearly complete, some aspects of the pump are still subject to change. See section 5.6 for the final design of the beta prototype. Once testing of the beta prototype is complete, the team will determine if any final revisions to the pump are necessary. If the testing is a complete success, Pascal’s Posse will be ready to begin producing the pump on a larger scale once all appropriate resources are allocated.

5 Detailed Design

5.1 Modifications to Proposal Sections

Since the submission of the initial proposal, there have not been any major changes to the schedule. The Gantt chart has been a useful tool to the group and all dates and deadlines have been met and all future deadlines are on track to be met. There has only been one minor design

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change to the prototype. Since the prototype will be tested in a small bin, Pascal’s Posse has added a hooking mechanism to the beta prototype to attach it to the side of the bin. The group had to make this modification to the prototype because of the threat that the weight of the hose may pose a threat to tipping the pump over if the floating support did not cover enough surface area. Due to the small size of the bin, the group felt as though it would not be possible to create a floating mechanism small enough while still providing the proper support. The hooking mechanism is not intended to be part of the manufacturing process, only a part of the prototype. However, the floating mechanism will be a part of the final design to be manufactured.

5.2 Theoretical Analysis

Because the pump’s power is limited to solar energy, it must be determined if the solar panel and motor are capable of fulfilling the requirements established in the project description. A very conservative approach was taken in the following analysis. The solar panel that will be used to power the pump motor is capable of generating up to 30 watts of power [16]. It was assumed that solar conditions are not ideal and only 10% of the solar panel’s maximum power output can be achieved. The motor the team selected is known to have an efficiency of 62.5% [15]. From personal experience, typical centrifugal pump efficiency is known to be around 70% to 80%. The efficiency of Pascal’s Posse’s pump was chosen to be a conservative 50%. The overall useful power that is available to pump water is calculated in Appendix H.

Even with very conservative estimates, the system will have over 5 times the power necessary to fulfill the project requirements provided that the pump is at least 50% efficient.

Because the project was determined to be feasible under the set circumstances, Pascal’s Posse moved forward and continued with designing the pump. The team recognizes that although the available power is ample, it is also known that it must be effectively utilized in order to design a successful pump. The team based the pump design on a preexisting pump that had been purchased by team Legion for benchmarking and educational purposes. Pascal’s Posse’s pump is proportional to Legion’s pump and contains only a few minor alterations in order to better suit the pump for the specified application. While nearly all of the relative dimensions were determined by the purchased pump, the actual size (diameter) of the pump impeller was yet to be finalized.

In order to establish the ideal size of the impeller, pump affinity laws were utilized. First, the specifications of the purchased pump were needed. The pump affinity relating power to impeller

diameter is written as follows.PB

P A

=( ρB

ρA)( ωB

ωA)

3

( DB

DA)

5

Variables with a “B” subscript represent parameters that describe the pump Pascal’s Posse is designing while the “A” subscripted variables are parameters related to the purchased pump. Because both pumps are designed to transport water, the density term will be neglected since ρB and ρA are identical. Also, since there with no realistic way to determine an accurate value for the angular velocity of either pump (ω A, B), the assumption was made that the velocity of the two pumps will be approximately equal, so the angular velocity term may be neglected. The power of the designed pump was previously calculated to be 0.94 W and the diameter of the purchased

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[17]

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pump is known to be 1 inch. The power of the purchased pump was not specified, so it was determined through the analysis described in Appendix H.

Team Legion had already determined the pump performance curve and that it follows the linear relationship. With permission, the team utilized this information to determine the power output. Using the knowledge gained from both the Fluid Mechanics class and Team Legion, the ideal impeller size of 1.11 inches was determined for Pascal’s Posse’s pump. See Appendix H for the pump sizing calculations.

5.3 Component and Material Selection

As previously stated, the team was very limited as to which components could be used in the beta prototype currently being developed. The solar panel and piping were preselected for the project, and only four different motor options were available for the prototype. It has been determined that these components will be adequately suited to meet the requirements of the project. However, upon completing the beta prototype testing, Pascal’s Posse will determine if alternate components would improve the pump’s performance or reduce the cost for the final design.

Since the pump impeller and housing are the only parts of the system that will need to machined, they are the only parts whose material is of concern to the team’s design. For the beta prototype, all parts were built using the Dimension 1200 rapid prototyping machine in order to obtain the necessary pump elements as quickly as possible. Currently, the solar panel represents the largest cost of producing the pump. Because all other costs are small compared to the solar panel, the team decided to use high quality pump materials for the final product since any additional costs would not significantly affect the total pump price. The machined parts for the final product will be constructed from 316 stainless steel. This material was chosen because it is very high strength and easily formable. It is also one of the most corrosion resistant ductile metals and is considered marine grade stainless steel, so it is ideal for parts that will remain in the water for the duration of their use [18].

5.4 Fabrication Process

Stainless steel casting will be utilized to construct the mass production unit. Because the shapes of the impeller and housing are relatively complex, casting will be a much more efficient process than other metal forming processes such as milling or forging. Once the impeller and both sides of the housing are cast, the housing will be welded together and the motor will be welded to the rear housing (see section 5.6 for a complete description of each part). Finally, the motor and impeller shaft will be welded together. The only remaining step is to solder the positive and negative leads from the solar panel to the motor terminals. The fabrication process was designed to maximize simplicity and efficiency in order to maintain a low price and high durability in the final product.

5.5 Aesthetics and Ergonomics

To compete and succeed in the market place, Pascal’s Posse incorporated both aesthetics and ergonomics into its design of the micro-pump irrigation system while still paying heed to feasibility constraints.

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The ergonomic design of the micro-pump irrigation system enables poverty stricken rural farmers in developing countries to employ modern agricultural techniques for extensive periods without physical exhaustion. Using human labor to collectively obtain, transfer, and deliver water from a remote water source is inefficient. Moreover, to irrigate even a small plot of land takes several thousand liters [19]. Therefore, Pascal Posse’s ergonomic small-scale irrigation pump is paramount for the sustainable growth of developing nations.

Firstly, the SSX 330 Solar Power panel eliminates the need of the micro-pump system to be near an electrical source allowing the design to work in versatile applications on a variety of terrains. Without the need of electrical outlets for power, the system is lightweight and promotes transportability. The flexible 3/8” plastic tubing can draw water from a relatively faraway water source and deliver it a specified distance with adequate pressure. Meanwhile, Pascal’s Posse sized the impeller to 1.11” via the affinity laws in order to promote adequate flow [17]. Together, these components allow the operation of the system to realize negligible expenditure of human labor. That is, the only manual labor requirements involved in pump operation are controlling pump irrigation times and rotating the panel to the sun’s angle of incidence. For this, Pascal’s Posse’s small-scale irrigation system is easy-to-use and encourages the rural farmer to expand their growth of agricultural products.

In addition to designing for functionality, Pascal’s Posse employed aesthetics into the product design of its micro-pump irrigation system. Due to the capabilities of SolidWorks, Pascal’s Posse was able to specify the perfect form of parts and mating surfaces in the user interface. The virtual CAD program enabled Pascal’s Posse to create a code for rapid prototyping. Rapid prototyping allowed the team to manufacture their micro-pump so that the functionality of their design was sleek. The housing of the micro-pump system allows the entire system to appear as one integrated entity. Surface finishing eliminates the presence of any surface deformities giving the design a sleek, cool finish.

5.6 Detailed Drawings

The necessary manufactured parts for the pump will be the impeller and housing. Critical dimensions and drawings as well as a representation of the final assembly can be found in Appendix I.

5.7 Economic Analysis

As specified, Pascal’s Posse is required to manufacture 100,000 units per year; this breaks down to 25,000 units per quarter. The cost of development was calculated based on the average salary of an engineering intern. This was done because all members of Pascal’s Posse have yet to complete the mechanical engineering program and are not subject to the full time pay of the average engineer. If the three Pascal’s Posse engineers spend approximately 20 hours per quarter developing the pump at a rate of $20 per hour, then the development cost comes out to $1,200 per quarter.

For Pascal’s Posse, the goal of this project is to help developing countries in need. This is why there will be no commercial marketing involved for selling the pump. This saves money on commercials and advertisements. The pump will be marketed and sold through contact with

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humanitarian companies across the world. This keeps marketing costs at a relatively low $10,000 per quarter.

Pascal’s Posse has analyzed the currently available resources and determined that the completed pump will cost approximately 254.70 USD. Since the pump, motor, and solar panel will be sold as one unit, the vast majority of this cost is due to the solar panel which is 209.40 USD at ecodirect.com. After completing our beta prototype testing, it will be determined if a lower cost solar panel can be used in order to reduce the cost of the pump. The prices for the tubing, wires, and pool noodle were determined by a typical price found online. The motor price was found on Jameco.com. All other pump components will be manufactured. The impeller and housing prices in Appendices J and K represent the cost to create these parts with 316 stainless steel casting using the CustomPartNet cost estimator [20]. A complete description of the cost estimate can be found in Appendix J. A bill of materials can be found in Appendix K. All part costs include the associated labor fees.

Since the team was provided a solar panel, motor, and tubing, the only cost to build the prototype was use of the rapid prototyping machine. With a 2.93 cubic inch prototype (including support material) and a cost of $8 per cubic inch of material used, the total cost was $23.44.

Since the goal of Pascal’s Posse is to aide developing countries, the group applied an approximately 20% markup as opposed to the normal 33% markup suggested by class lecture. This brings the unit price to $299 a pump. With intent to sell 25,000 pumps per quarter, this brings the revenue to $7,475,000 per quarter.

The net present value of this product at interest rates of 10 and 15% is $12,513,147 and $11,356,078 respectively. The NPV was calculated using the following formula.

Net Present Value= Period Cash Flow

(1+ Interest Rate )Quarter Number−1[5]

The interest rate must be the quarterly interest rate. For instance, if the desired interest rate is 10% per year, then one would need to use 2.5% per quarter in the formula. A cash flow table for the pump project can be found in Appendix L.

The calculated net present value shows that this product is not only a great investment to make a profit but will be inexpensive enough for developing countries and humanitarian organizations to buy and distribute to local farmers.

5.8 Safety

Pascal’s Posse’s micro-pump irrigation system meets or exceeds all relevant government consumer product safety regulations for sale in North America and European markets. The micro-pump abides by the Standard for Motor-Operated Pumps, UL 778 [21]. The pump is formed and assembled with the strength and rigidity necessary to resist the abuses to which it is subjected to under normal operation (UL 778 Requirement10.2). The components of the final product are all made from materials which are acceptable for their intended application (UL 778 Requirement 5.1). All parts of the pump in contact with water are nontoxic and corrosion resistant (UL 778 Requirement 8) [21].

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In addition, the motor used in the design fulfills the requirements set in the Standard for Electric Motors, UL 1004 [22]. In addition, the motor meets the Standard for Overheating Protection for Motors, UL 2111 [23]. Short-circuit live parts are secured by the proper adhesives and satisfy the Standard for Polymeric Materials- Use in Electric Equipment Evaluations, UL 746C [24]. The terminal compartment containing the wire-to-wire connections to the power supply are in compliance with the safety standards set in UL 778 Requirement13.2 [21].

Furthermore, the SSX 330 solar panel is defined in accordance with the Standard of Solar Energy, ISO 9488, and compliant with the international standard of Crystalline Silicon Terrestrial Photovoltaic (PV) Modules, IEC 6125 [25, 26]. The panel satisfies UL 1703, the Standard of Flat-Plate Photovoltaic Modules and Panels [27] and is in compliance by the EU Restriction of the Use of Certain Hazardous Substances in Electrical Equipment (RoHS) Directive [28].

In ensuring the safety of its customers, Pascal’s Posse recommends that the users of the product employ all relevant Occupational Safety and Health Administration (OSHA) regulations [29].

5.9 Testing Procedure

Pascal’s Posse completed construction of the alpha prototype on November 16th, 2012. This prototype was stationary and nonfunctional. The prototype was intended to show the team on an enlarged scale how the pump and its various parts will come together and if the positioning of different elements is as expected (inlet, outlet, blade positioning, number of blades, etc.).

The beta prototype will be a full scale, working model of the final product intended to be manufactured. However, instead of stainless steel it will be made of plastic for easier rapid prototyping. Also, this prototype will not be floating on the surface of the water. Due to the small size of the competition tank and the heaviness of the hose compared to the light weight pump, a sufficiently supported floating mechanism was not able to be developed without the threat of tipping. Thus, Pascal’s Posse created an innovative hooking mechanism to attach to the side of the competition tank. The hooking mechanism will not be used in the final pump design meant for production; the floating mechanism, however, will.

From the beta prototype prototype, Pascal’s Posse intends to discover the actual flow rate at the intended elevation head (0.5m). The group also intends to find any weaknesses or flaws in the design such as, but not limited to, leaks, part interference, part sturdiness, etc. The purpose of this prototype is to test the pump at production specifications to determine flow rate and elevation head. The size of the impeller, the size of the casing, and the motor-impeller connection are all critical aspects of the final design and were manufactured to the planned production specifications. The aesthetics and material are different from the final design because the prototype was made from more accessible materials in order to save time. The prototype is still an excellent representation of the final product and will be used to collect valuable and accurate data.

The experimental plan will be simple in procedure. Pascal’s Posse will use two 9-volt batteries to power the motor. The pump will then be placed in a bin full of water. The team will run a hose from the pump to an empty 500 mL container. The time it takes to fill the 500 mL container will be recorded as well as of the height of tube. This will give the group data on what flow rate is achieved at various elevation heads.

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The pump parts to be rapid prototyped were completed on December 3, 2012. On this date, the team conducted an initial “smoke test.” This smoke test determined that the pump is functional and able to move water very well. When the pump is working to expected performance, Pascal’s Posse will conduct tests and record data on December 5th, 2012 so the actual working condition of the pump is known by the due date of the beta prototype. On this date, the pump will be formally tested using strictly solar power.

6. Conclusion

From the beginning of this assignment, Pascal’s Posse has worked diligently through the design process to achieve the goal of developing a cheap, solar-powered micro-pump intended to improve the quality of life in developing countries. Through rigorous customer and expert analysis, multiple brain storming efforts and pump dissections, and hours in front of the SolidWorks program, Pascal’s Posse is proud to report that the chief goal has been achieved. The team has developed a simple pump design that consists of just 4 parts, the motor, front pump casing, rear house casing, and impeller. There are no screws or bolts, making for easier assembly, maintenance and trouble shooting. Along with the simple design, Pascal’s Posse has designed the pump to be durable. Having the pump made out of 316 stainless steel will make it resistant to corrosion and rust so it will have a much longer life span.

Pascal’s Posse’s pump also makes sense from a business prospective. After performing a four year economic analysis selling 100,000 units a year at interest rates of 10% and 15% with a 20% price markup from production cost to unit price, the pump will have a Net Present Value of $12,513,147 and $11,356,078 respectively.

The intent of this pump has always been to benefit countries lagging behind in technological advances necessary to sustain a good quality of life. Pascal’s Posse has been successful in developing a simple, durable, and most importantly, working pump that will allow farmers to update their irrigation practices. Not only does this pump make sense from a technical prospective, it also makes sense from a business perspective. Turning a profit by the third quarter with a very reasonable markup price, this pump has met every expectation Pascal’s Posse has set out to achieve and would be a wise investment for any humanitarian organization looking to make a difference.

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7. References [1] United Nations. Economic and Social Affairs. Population Division. World Population to

2300. By United Nations. New York: United Nations Publications, 2004. Web. 26 Nov. 2012. <http://www.un.org/esa/population/publications/longrange2/WorldPop2300final.pdf>

[2] Frausto, Keith. "Assessment of Irrigation Options." Developing Irrigation Options for Small Farmers (2005): n. pag. Web. 26 Nov. 2012.

[3] World Bank. "Poverty & Equity Data." Poverty & Equity Data. World Bank, n.d. Web. 26Nov. 2012. <http://povertydata.worldbank.org/poverty/home/>

[4] "Irrigation Techniques." Irrigation: USGS Water-Science School. N.p., n.d. Web. 26 Nov. 2012. <http://ga.water.usgs.gov/edu/irmethods.html>.

[5] Ulrich, Karl T., and Steven D. Eppinger. Product Design and Development. 5th ed. NewYork: McGraw-Hill/Irwin, 2012. Print.

[6] Kreider, Andrew. Personal interview. 30 September 2012.

[7] Engineers Without Borders- Penn State Chapter. "Community Water Source and Governance Evaluation." Engineers Without Borders, n.d. Web. <http://www.engr.psu.edu/ewb/Projects/SL-Water-2012-522-FINAL.pdf>.

[8] Lowes. Personal interview. 30 September 2012.

[9] "Solar Powered Water Pump System for Irrigation." Solar Power Solutions. Zen Cart, 1 Dec. 2010. Web. 21 Nov. 2012. <http://free-water-lawn-garden.com/index.php?main_page=product_info&cPath=65&products_id=180>.

[10] "Archimedean Screw Pumps." Screw Pumps and Archimedean Screw Pumps. N.p., n.d. Web. 25 Sept. 2012. <http://www.spaansbabcock.com/products_en_applications/screw_pumps.aspx>.

[11] "Home | Smartpond." Home. N.p., n.d. Web. 1 Oct. 2012. <http://www.smart-pond.com/>.

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[12] "Mechanical Engineering." Mechanical Engineering. N.p., n.d. Web. 1 Oct. 2012. <http://www.mech-engineer.blogspot.com/>.

[13] "Axial  Flow Pumps." Axial Flow Pumps. N.p., n.d. Web. 1 Oct. 2012. <http://nuclearpowertraining.tpub.com/h1018v1/css/h1018v1_99.htm>.

[14] "General Pump and Machinery." General Pump and Machinery. N.p., n.d. Web. 1 Oct. 2012. <http://netpumps.com/>.

[15] "RS-385SH Data Sheet." Jameco. N.p., n.d. Web. 21 Nov. 2012. <http://jameco.com/webapp/wcs/stores/servlet/ProductDisplay?freeText=2125528>.

[16] "SX 330." BP Solar. BP, n.d. Web. Oct. 2012. <http://www.bp.com/liveassets/bp_internet/solar/bp_solar_usa/STAGING/local_assets/downloads_pdfs/pq/SX330J_9-09.pdf>.

[17] Cengel, Yunus A., and John M. Cimbala. "Turbomachinery." Fluid Mechanics: Fundamentals and Applications. 2nd ed. Boston: McGraw-Hill Higher Education, 2010. Print.

[18] "Stainless Steel - Grade 316 - Properties, Fabrication and Applications." AZoM. AZo Journal of Materials Online, n.d. Web. 02 Dec. 2012. <http://www.azom.com/article.aspx?ArticleID=863>.

[19] Development Technology Unit. The Treadle Pump. Working paper no. 34. Warwick, UK: Department of Engineering University of Warwick, 1991. North East Arid Zone Programme. Web. 04 Dec. 2012. <http://www.watersanitationhygiene.org/References/EH_KEY_REFERENCES/WATER/Handpumps/Handpump%20Specific%20Types/The%20Treadle%20Pump%20%28Warwick%20Uni%29.pdf>.

[20] "Manufacturing Cost Estimation." Manufacturing Cost Estimation. N.p., n.d. Web. 04 Dec.2012. <http://www.custompartnet.com/>.

[21] Underwriters Laboratories Inc. UL Standard for Safety for Motor-Operated Water Pumps, UL 778. Underwriters Laboratories Inc., 27 Aug. 2002. Web. 04 Dec. 2012. <http://bbs.dianyuan.com/bbs/u/54/1070201182761263.pdf>.

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[22] Underwriters Laboratories Inc. Electric Motors, UL 1004. Underwriters Laboratories Inc., 24 Nov 1999. Web. 04 Dec. 2012. <http://bbs.dianyuan.com/bbs/u/36/1134777354.pdf>

[23] Underwriters Laboratories Inc. Overheating Protection for Motors, UL 2111. Underwriters Laboratories Inc., 28 March 1997. Web. 04 Dec. 2012. <http://ulstandardsinfonet.ul.com/scopes/1703.html>.

[24] "Scope for UL 746C." Scope for UL 746C. N.p., n.d. Web. 04 Dec. 2012. <http://ulstandardsinfonet.ul.com/scopes/scopes.asp?fn=0746C.html>.

[25] "CRYSTALLINE SILICON TERRESTRIAL." Iec.ch. International Electrotechnical Commission, 2005. Web. 4 Dec. 2012. <http://webstore.iec.ch/preview/info_iec61215%7Bed2.0%7Den_d.pdf>.

[26] "Home." ISO. N.p., n.d. Web. 04 Dec. 2012. <http://www.iso.org/iso/home/standards_development/list_of_iso_technical_committees/iso_technical_committee.htm?commid=54018>.

[27] Underwriters Laboratories Inc. Flat-Plate Photovoltaic Modules and Panels UL 1703. Underwriters Laboratories Inc., 03 Dec. 2003. Web. 04 Dec. 2012. <http://ulstandardsinfonet.ul.com/scopes/1703.html>.

[28] United Kingdom. Department For Business and Innovation Skills. ROHS Regulations. Bis.gov.uk, Feb. 2011. Web. 4 Dec. 2012. <http://www.bis.gov.uk/assets/biscore/business-sectors/docs/r/11-526-rohs-regulations-government-guidance-notes>.

[29] "Highlights." Occupational Safety and Health Administration. N.p., n.d. Web. 04 Dec. 2012. <http://www.osha.gov/>.

[30] Munson, Bruce Roy, T. H. Okiishi, Wade W. Huebsch, and Alric P. Rothmayer. Fundamentals of Fluid Mechanics. 7th ed. Hoboken, NJ: John Wiley & Sons, 2013. Print.

[31] "Team Legion Benchmark Pump Discussion." Personal interview. 25 Nov. 2012.

Pascal’s Posse Detailed Design Report – 12/4/201217

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Appendix A - Team Contract

“As a team we intend to face the assigned challenge by staying focused, staying on schedule, and keeping a productive work environment. Throughout this process we intend to follow

the engineering process and develop furthers as engineers. It is our goal to develop the most successful project in the class and receive A’s as a result of excellent teamwork.”

I. Contact Informationa. Kyle Moore

i. Phone: 610-764-8358ii. E-mail: [email protected]

b. Max Pepperi. Phone: 610-428-2007

ii. E-mail: [email protected]. Liz Donofrio

i. Phone: 978-500-2209ii. E-mail: [email protected]

II. Team Meetingsa. Location

i. Schreyer Grandfather Clock Room/Computer Labb. Time and Day

i. Fridays at 12:30 PMii. Sundays at 7 PM depending on work load

c. Attendance Policyi. 3 Excused absences max

ii. 2 Hours of unexcused absence time1. Time will be determined from the meeting start time to when

an individual shows upiii. 48 Hour notice of absence required to be considered excused

1. Emergency situations with proper communication void 48 hours requirement

a. Sudden injury or illness, family emergency, weather conditions, etc.

d. Excusesi. Transportation Problems

ii. Serious Illness/Hospitalizationiii. Death in the familyiv. Job Interviews

e. Behaviori. Maintain a positive atmosphere

ii. Constructive criticism onlyiii. Focus is expected during team meetings

1. Breaks may be agreed upon by team during team meetingsiv. No swearing, screaming, or intimidation of another teammate will be

tolerated III. Performance Expectations

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a. Assignments expected to be completed on timeb. Team agreement on work distribution

i. At the end of each meeting, tasks to be completed for the next meeting will be determined. At this point team members will be allowed to volunteer to complete a task.

1. In the event of nobody volunteers for a task or two or more members want to complete a task, a team vote will be conducted after each teammate gets to voice their opinion on the matter.

c. At least one team member checks and signs off on another team members work before the beginning of the scheduled team meeting the work is due

d. Input from every team member is expected with each task regardless of who was determined lead of the task

IV. Communication:a. Phone: quick and/or urgent communicationb. Email: technical and formal discussions/questions

V. Policy and Proceduresa. Excused absence notification

i. Failure to communicate an excused absence to the group will be count towards unexcused absence time.

ii. For every excused absence after the allotted 3 it will become an unexcused absence and time will be deducted accordingly. (see “V.b”)

b. Unexcused absence deduction policyi. For every hour of unexcused absence time an individual accumulates

a deduction of 5% which will be taken from the individuals gradec. Late work violation

i. There will be a warning given for a first offense of work turned in late. For each subsequent violation a 5% deduction will be taken from an individual’s grade

d. Behavior violationi. It is the responsibility of the team members to keep each other in line

shall one violate any of the behavior policies of “II.e”ii. If an individual does not comply with the behavior guidelines they will

be kicked out of the meeting and lost time will count as unexcused absence

iii. A meeting with the professor will be made if necessary.1. Depending on outcome of “iii.d” a teammate may be subject to

additional loss of points and/or removal from the group

VI. Strengths and Weakness

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Administrative Roles:Project Manager (Max Pepper): Makes sure project is on track and time is

being used valuably, efficiently, and effectively. Facilitator (Kyle Moore): Keeps a neutral outlook on all things related to

the project regarding the decision making process and all other areas where disagreement may be an issue.

Customer Focus (Liz Donofrio): Leads market research and continually keeps an outlook/focus on the customer voice throughout the duration of the project

Pascal’s Posse Detailed Design Report – 12/4/201220

Max(Project Manager)

Strengths WeaknessesHard Working Busy ScheduleLeadership experience PickyCommunication Skills Conservative

Kyle Moore(Facilitator)

Strengths WeaknessesDiligent CADHard Working Second GuessingEfficient Impatient

Liz D(Customer Focus)

Strengths WeaknessesPeople-Oriented Easily DistractedTechnical Writing IndecisiveCreative Machinery Inexperience

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Appendix B - Team Member Functions

Table B.1: Team Gantt Chart

Pascal’s Posse Detailed Design Report – 12/4/201221

Table B.2: Individual team member roles

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Appendix C - Customer Needs Matrix

Table C: Final customer needs matrix

Customer Lead Users Gerneral Public SumInexpensive 5 0 0 15Reliable 5 4 4 27Effi cient 3 2 1 14Environmentally Friendly 4 4 4 24Simple Design 3 4 0 17High Flow Rate 3 3 0 15Instills Pride 2 3 3 15Safe 2 5 2 18Light Weight 1 3 0 9Compact 2 3 3 15Easy to Install 4 4 0 20Easy to Repair 4 5 2 24Easy to Use 5 5 0 25Looks Good 1 2 3 10Runs Quietly 4 4 3 23Vandal Resistant 4 4 2 22

*Ratings range from 0 to 5 with 5 being the highest prioritySum = 3×(Customer) + 2×(Lead User) + General Public. Project judging criteria are shaded.

Priority*

Pascal's PosseCustomer Needs Matix

Need

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Appendix D - External Research (Excerpt)

Site #1 Date/Time: 1/2/12 @ 9:37am

Interviewee: Haragetu Jalloh (Mother), Age 29, Female, has been in community for 3 years

Interviewers: Kyle Palmeter, Rich Kercher, and Pastor Martin Simbo

Needs: Water (they do not have running water)

Electricity (specifically said she needs “light”)

Water: -Gets water from Garden Spring (usually a long wait) and sometimes from the

-Family uses about 10 buckets (5 gal) a day for general purpose and another 5 for cooking

-Uses chlorine solution (also had ammonia smell) to purify water. She got a small bottle from a friend who deals with water treatment about 5 months ago and is still using same bottle. She squirts a small about from a syringe into her drinking water bucket every time she adds more water to it.

-Uses ½ cc for 5 gallon bucket

Site #2 Date/Time: 1/2/12 @ 10:26 am

Interviewee: Mohamed Kai, Age 52, Male

Interviewers: Kyle Palmeter, Rich Kercher, and Pastor Martin Simbo

Needs: Clean Water, Latrines, Schools, A Market, A Health Center

Water: -They take water from the dam (spring box) because the street tap is broken

-The know the water isn’t pure but they drink it anyway because they have no choice

-They help to clean the spring box when called to do so by the elders -If the dam runs dry, they will go to the garden spring

-Usually have to wait to get water -One family (2 adults, 3-5 kids) will use about 10 buckets (5 gals) a day

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Appendix E - QFD

Table E1: Quality Function Deployment matrix

Table E2: Importance Ratings of Target Specifications

Pascal’s Posse Detailed Design Report – 12/4/201224

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Table E3: Importance Ratings of Target Specifications

Pascal’s Posse Detailed Design Report – 12/4/201225

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Appendix F - Pro and Con Matrix

Table F1: Concept selection matrix

Pump Concepts Submerged Floating Outside Basin

Radial Centrifugal [11]

Pros:-Fairly simple to build-High flow rate-Common for small pumps

Cons:-Needs waterproofing-Difficult to service-Relatively low discharge pressure

Pros:-Fairly simple to build-High flow rate-Needs less waterproofing than floating pump

Cons:-Relatively low discharge pressure

Pros:-Fairly simple to build-High flow rate-Needs minimal water proofing

Cons:-Low disch. pressure-Difficult to service-Needs self-priming mechanism

Axial Centrifugal [13]

Pros:-Very simple to build-High flow rate

Cons:-Needs waterproofing-Difficult to service-Very low discharge pressure-Does not lift fluids well

Pros:-Very simple to build-High flow rate-Needs less waterproofing than floating pump

Cons:-Very low discharge pressure-Does not lift fluids well

Pros:-Very simple to build-High flow rate-Needs minimal water proofing

Cons:-Very low disch. pressure -Does not lift fluids well-Needs self-priming mechanism

Positive Displacement [12]

Pros:-High discharge pressure-Ideal for lifting fluids-Prefabricated parts may be available

Cons:-Needs waterproofing-Difficult to service-Difficult to machine

Pros:-High discharge pressure-Ideal for lifting fluids-Prefabricated parts may be available-Needs less waterproofing than floating pump

Cons:-Difficult to machine

Pros:-High discharge pressure-Ideal for lifting fluids-Prefabricated parts may be available-Needs minimal waterproofing-Self-priming

Cons:-Difficult to machine

Screw [14]

Pros:-Very simple concept-Designed specifically to lift fluids-Unique concept

Cons:-Very large and heavy-Expensive to produce-Inefficient

Table F2: Concept selection multi-vote outcome

Pump Concept Votes Location Concept VotesRadial Centrifugal 8 Submerged 6Axial Centrifugal 3 Floating 9Positive Displacement 5 Dry 4Screw 2

Pascal’s Posse Detailed Design Report – 12/4/201226

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Appendix G - Functional Decomposition Black Box Model

Table G: Subsystem breakdown of pump

Pascal’s Posse Detailed Design Report – 12/4/201227

Water/Air

On/Off Switch

Page 28: Detailed Design Report

Appendix H – Calculations

Power Requirements:

Ppump = Ppanel × epanel × emotor × epump

Ppump = (30 W)(0.10)(0.625)(0.50) = 0.94 W

Next, the theoretical required power was calculated and compared to the available power above. The values used were those specified by the project description.

Pneeded = m × g × h + Ploss = ρ × q × g × h + Ploss = Phead + Ploss [30]

Phead = (103 kg/m3)(1.9 l/min)(0.001 m3/l)(0.0167 s/min)(9.8 m/s2)(0.5 m)(Ws3/kgm2) = 0.16 W

ℜ=VDv

=(1.9 l /min)(61.0¿ .3/l)(0.0167 min /s)¿¿ [17]

Since the Reynolds number is above 4000, the flow through the inlet and outlet pipe is turbulent, so the following analysis can be used to determine our losses. The Darcy friction factor was obtained using a Moody chart and a relative roughness of 0 [17].

Ploss=( fLD

+∑ K L) q3 ρ2 A2=(0.04

39.5∈.0.375∈.

+0.03+0.04)[(1.9 l /min)(0.001 m3/ l)(0.0167 min/s) ]3(1000

kg

m3)

2[ π (0.188∈.[0.0254m¿ .])

2

]2

= 0.0132 W [17]

Ppump/Pneeded = 0.94 W/(0.16 W + 0.0132 W) = 5.4

Size Requirements:

h = (-8.117q + 9.7) m [31]

PA = m × g × h = ρ × q × g × h [30]

PA = (103 kg/m3)(q l/min)(0.001 m3/l)(0.0167 s/min)(9.8 m/s2)[(-8.117q + 9.7) m](1 Ws3/kgm2)

PA = (-1.33q2 + 1.59q) W

dPA

dq = -2.66q + 1.59 = 0 (at PMAX); q = 0.598

Pascal’s Posse Detailed Design Report – 12/4/201228

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PMAX = PA(q = 0.598) = (103 kg/m3)(0.598 l/min)(0.001 m3/l)(0.0167 s/min)(9.8 m/s2)×[(-8.117×0.598 + 9.7) m](1 Ws3/kgm2) = 0.547 W

Using the obtained purchased pump power, the diameter of the designed pump was computed using the pump affinity law.

PB

P A

=( ρB

ρA)( ωB

ωA)

3

( DB

DA)

5

; DB=( 5√ PB

PA)DA

DB=( 5√ 0.940.547 )(1 inch )=1.11 inches

Pascal’s Posse Detailed Design Report – 12/4/201229

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Appendix I – Detailed Drawings

Pascal’s Posse Detailed Design Report – 12/4/201230

Figure H1: Pump impeller Figure H2: Rear housing

Page 31: Detailed Design Report

Pascal’s Posse Detailed Design Report – 12/4/201231

Figure H3: Front housing

Figure H4: Impeller and housing assembly with cutaway views

Page 32: Detailed Design Report

Appendix J – Manufactured Parts Cost Estimation

General

Quantity:

Defect rate (%): Run quantity: 1,000

Number of cavities:

Material

Pascal’s Posse Detailed Design Report – 12/4/201232

Miscellaneous

1000

0

8

Page 33: Detailed Design Report

Material: Browse...

Metal price ($/lb): Density (lb/in³):

Part volume (in³): Part weight (lb): 0.432

Feed system volume (in³):Material yield

(%):

Sand per mold (lb): Mold sand price ($/lb):

Material markup (%):

Metal: $5,979 ($5.979/part)

Mold sand: $125 ($0.125/part)

Material: $6,104 ($6.104/part)

Production

Melt loss (%):Melting price

($/lb):

Mold-making rate (molds/hr):

Mold-making labor ($/hr):

Pouring labor ($/lb):

Cleaning labor ($/lb):

Plant efficiency (%):

Production markup (%):

Melting: $4,737 ($4.737/part)

Mold-making: $2,500 ($2.500/part)

Core-making: $0 ($0.000/part)

Core-setting: $0 ($0.000/part)

Pouring: $4,500 ($4.500/part)

Cleaning: $21,600 ($21.600/part)

Markup: $3,334 ($3.334/part)

Production: $36,671 ($36.671/part)

Appendix K – Bill of Materials

Table J: Preliminary Cost Analysis

Item Cost per item (USD) Vendor Quantity Total (USD)Front Housing (0.18 in.3) 4.52 - 1 4.52Impeller (0.27 in.3) 6.78 - 1 6.78

Pascal’s Posse Detailed Design Report – 12/4/201233

Impeller and housing pieces combined

316 Steel

13.84 0.288

1.46

.5 96.00

.1 10

0

5 10

5

100

10

50

100

10

Page 34: Detailed Design Report

Rear Housing (1.01 in.3) 25.38 - 1 25.382125528 Motor 1.95 Jameco 1 1.95SX 330 Solar Panel 209.40 ecoDirect 1 209.403/8" ID Clear Tube (1 m) 0.485 (per foot) Amazon 3.28 ft. 1.610 AWG Wire (6 ft.) 0.387 (per foot) Amazon 6 ft. 2.32Pool Noodle 2.75 Amazon 1 2.75

Total 254.70

Pascal’s Posse Detailed Design Report – 12/4/201234

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Appendix L – Economic Analysis

Table K: Cash flow for the pump project over four years

Pascal’s Posse Detailed Design Report – 12/4/201235

($ values in ones)Q1

Q2Q3

Q4Q1

Q2Q3

Q4Q1

Q2Q3

Q4Q1

Q2Q3

Q4Quarter Num

ber1

23

45

67

89

1011

1213

1415

16Developm

ent Cost-1200

-1200Ram

p-up cost-1200

-1200M

arketing & Support Cost-10000

-10000-10000

-10000-10000

-10000-10000

-10000-10000

-10000-10000

-10000-10000

-10000Prouction Cost

-6367500-6367500

-6367500-6367500

-6367500-6367500

-6367500-6367500

-6367500-6367500

-6367500-6367500

-6367500-6367500

Prouction volume

2500025000

2500025000

2500025000

2500025000

2500025000

2500025000

2500025000

Unit Production Cost-254.7

-254.7-254.7

-254.7-254.7

-254.7-254.7

-254.7-254.7

-254.7-254.7

-254.7-254.7

-254.7Sales Revenue

74750007475000

74750007475000

74750007475000

74750007475000

74750007475000

74750007475000

74750007475000

Sales Volume

2500025000

2500025000

2500025000

2500025000

2500025000

2500025000

2500025000

Unit Price299

299299

299299

299299

299299

299299

299299

299

Period Cash Flow-1200

-24001096300

10975001097500

10975001097500

10975001097500

10975001097500

10975001097500

10975001097500

1097500

PV Year 1, r= 10%-1200

-2341.461043474

1019138994280.8

970030.1946370.8

923288.6900769.4

878799.4857365.2

836453.9816052.6

796148.9776730.6

757785.9PV Year 1, r= 15%

-1200-2313.25

1018482982743.6

947222.7912985.8

879986.3848179.5

817522.4787973.4

759492.5732040.9

705581.6680078.7

655497.5631804.8

PV Year 1, r= 20%-1200

-1600487244.4

325185.2216790.1

144526.796351.17

64234.1142822.74

28548.4919032.33

12688.228458.813

5639.2093759.472

2506.315

Project NPV (10)12513147

Project NPV (15)11356078

Project NPV (20)1454987

Interest0.025

Year 1Year 2

Year 3Year 4