Sunday, May 11, 2014

Final Project: The Puzzle of How It All Ended...

Today, my partner Christina and I finished our final product and got to show it off in the science center.

For the most part, it worked very well. The user simply had to pedal the bike to create energy. The back wheel was raised off the ground using a bike stand. A permanent-magnet motor was braced against the back wheel and another smaller wheel was connect to the motor's axle. This second wheel was in contact with the bike wheel and transferred the mechanical energy from the spinning to the motor, where it was transformed into electrical energy to power the light bulbs and various other appliances.The board held the bulbs, wires, circuit and other appliances in place, as well as featured some fun facts about the country's energy consumption and how the Energy Bike's output compares the average household's needs.

At the Presentation!




We even made a video of how the energy bike works so that, should anything go wrong, users would still be able to see what our project outlines and how it functions.


Overall, we were very pleased with the outcome of our Energy Bike Project, though the final days leading up to it were quite a scramble to check last minute details.

We had to paint the motor brace and stands for the board:


We also needed to find a creative way to attach the two legs to the back of the board, as simply nailing them directly on was not working. In the end, we nailed them to smaller pieces of wood and then screwed the wood flush against the back of the board. 


Because the wood was so thin, a few of the nails did stick out in places, we managed to hammer enough directly into it to keep it stable.We also added a simple voltmeter, so the user could see how much energy they were producing and be able to keep their output between 12 and 15 volts (that is the range that the inverter could handle).

Voltmeter


Finally, all that was left to do was glue our fact sheets on and make the front of the board aesthetically pleasing. We carefully planned how it would look prior to permanently gluing everything into place.

Organizing Information

Making Everything Fit Nicely

Final Taped version

Final Product


We managed to finish the entire project early the night before the presentation. We even found a hairdryer with a low enough power requirement to be powered by our bike.

Finally, we had to test everything to make sure it worked properly.

Testing

Then, after a good night's sleep, it was time to show the world what we had made.

Overall, the presentation went well. Unfortunately, about twenty minutes in, the small wheel attached to the motor fell off and never quite stayed on correctly. Originally, we had thought that the glue was melting under the heat caused by the friction and resistance between the motor wheel and the bike wheel. However, the glue we had used the night before was heat resistant. That meant it was the tape that could not endure the heat. We tried fixing the problem with aluminum tape, but the glue did not have sufficient time to dry before we used it. In the end, we used duct tape and a small object to brace a small piece of wood to the other side of the brace to keep the wheel from falling off. It worked for a while. The wood pushed back against the wheel as it tried to fall off and kept it in place. Eventually, though, the glue and tape between the axle and the wheel could not withstand the heat and stopped holding the two together. Though the wheel was staying in place, it was not turning the axle, so nothing was powering the lights. If we had more time, I would have liked to explore other wheel options. Though it may have worn down, perhaps if we had made a Delrin wheel and directly glued it to the axle, the motor wheel might not have fallen off.

Overall, though, we had fun and our users did learn about the importance of energy efficiency. The ones that got a chance to pedal felt the difference between powering the incandescent and powering the fluorescent lights. I think we really delivered our message to our users, and I am very proud of what we accomplished in such a short amount of time, whether or not it worked perfectly every time.

I had a lot of fun working on this project. I was extremely difficult, and though I went into it nervous, I ended up learning a lot about circuitry that I never knew before. Christina and I got along quite well, and I think I will always remember our late nights together in the lab. 

Here ends the story of the construction of the Wellesley Energy Bike. We hope you've enjoyed the ride as much as we have.

Team Wellesley Energy Bike! (Christina left, Kat right)



For our references about the country's energy consumption, please see:
 
http://www.eia.gov/tools/faqs/faq.cfm?id=97&t=3

For the Wellesley Energy Bike Official Site, see

<http://wellesleyenergybike.blogspot.com/>

For Christina's Blog, see

<http://christinaholman-engrportfolio.blogspot.com/>

Monday, May 5, 2014

Final Project: The Puzzle of Editing the Prototype

Today, my partner Christina and I worked to improve our first model of the Energy Bike set up. We had a lot to do.

We started by addressing several of the problems we noticed from our previous work day. The motor tended to bob up and down when the bike wheel was pressed flush against its axle. I built an arch onto the motor stand and brace to counteract the force of the bike wheel and keep the motor steady and in place.

Brace with Attached Arch


This held the motor quite well, and the friction between the wood and the motor itself was an unexpected bonus that kept the bike wheel from accidentally turning the motor itself if the wheel happened to brush it.

Next, we turned our attention to the wheel. The wheel we had originally attached to the motor axle was too big, and the user could not generate the needed RPM to reach 12 volts (without being Lance Armstrong, that is). We needed a smaller wheel or the Energy Bike would be too difficult for an ordinary user to manage. 

However, once we attached a smaller wheel, made of PCB pipe, pedaling was far too easy, and the user could easily outdo 12 volts (in one instance, we managed 21) and drive the inverter wild. We needed to find a wheel size in between the two that made pedaling a chore, but not an impossible one.

Original Wheel on Left, Smaller Wheel on Right

     
Final Wheel Upper Right


In addition to being the middle ground between our two original wheels, the new wheel also solved the pedaling problem: it is much easier to maintain a constant current with this sized wheel. Because pedaling is simpler with this size wheel and a constant current is easy to maintain, an extra battery pack may no longer be necessary.

Next, we moved onto the switches. Our store-bought switches were designed to turn a circuit one or off, not switch between two different circuits. In other words, we could not put our bulbs in series with these switches. After much deliberation, we decided to edit the switches ourselves rather than return them and locate the right ones to purchase. We simply turned the ground prong (green) into another option within the switch to allow the current to flow in one of two directions depending on what direction the switch was flipped.

 



New Circuit Diagram for In Series Design
Getting it In Series...

We Had to Break into the Switches to Edit Them

An Edited Switch, Ground is Now an Alternate Route
Now that the switches are all fixed, we can put the circuit in series and test as to whether or not it works in this manner.

Finally, we began to decorate our board and attach safety instructions and fun facts. We still need to figure out how we are going to qualify the concept of kilowatt-hours to the user in layman's terms, but our first priority is to make sure the user understands how the Energy Bike works so they do not get hurt while using it.

Decoration Plans

Testing

Despite all our progress, there is still a lot that needs to be done.

1.) The board needs to be decorated for real
2.) The switches need to be covered slightly so that only the switch part is visible to the user
3.) The NEW circuit needs to be tested with the bike
4.) We need to get a more permanent bike for the display - Christina needs hers back for the summer

However, for the moment, we are ready for the final week of preparations and we can not wait to see how our project is going to turn out.


One bulb down...seven to go.