me 340 pump final report

7/30/2019 ME 340 Pump Final Report

1/39

Solar Micro Pump Report

ME 340Instructor: Dr. Lamancusa

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

Executive SummaryWater is a precious resource. This fact is especially known to farmers living in third worldcountries 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 ofthe 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 andas means of income. A solution to this inefficiency is to implement a new watering method: dripirrigation. For a drip irrigation to operate requires a pump to push water from the source to theplant. 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 thewater and turning it on. The centrifugal design of the pump facilitates the suction of waterthrough the inlet whereby it is then spun clockwise by an impeller blade and then dischargedthrough the outlet at 0.8 gallons per minute. Estimated NPV for the solar pump is $3,470,000 atan expected retail price of $20.00.

Table of Contents

Executive Summary Page 11. Introduction Page 3

1. Problem Statement Page 32. Background Information Page 33. Project Planning Page 3

2. Customer Needs and Specifications Page 4

1 ME 340.2 Solar Powered Micro-Pump Detailed Design Report


2/39

1. Identification of Customer Needs Page 42. Design Specifications Page 4

3. Concept Development Page 51. External Search Page 52. Problem Decomposition Page 63. Design Concepts Page 74. Concept Selection Page 7

4. System Level Design Page 75. Detailed Design

1. Modifications to Proposal Sections2. Theoretical Analysis3. Component and Material Selection Process4. Fabrication Processes5. Industrial Design

6. Detailed Drawings7. Economic Analysis

7.1. Unit Production Cost7.2. Business Case Justification

8. Safety9. Actual Construction Process

6. Testing1. Test Plan2. Test Results and Discussion

7. Conclusion Page 98. References Page 10

Appendices Page 12A. Gantt Chart Page 12B. Quality Function Deployment Page

13C. Concept Screening Matrix Page 14D. AHP Weighting Matrix Page 15E. Concept Scoring Page 16F. Patent Search Page 17



3/39

1. Introduction1. Problem Statement

Roughly 600 million farmers in least developed countries lack water needed to grow cropsusing traditional irrigation methods [1]. Yet the majority of these farmers have an abundantsource of sunlight energy. The mission of the solar powered micro-pump is to develop asolution to inefficient use of water by designing a pump that will operate solely off theenergy from the sun in order to operate a drip irrigation system. Due to the variations infarmer needs in regards to drip irrigation configuration, the project will limit itself in scope tothe design of only the micro-pump.

2. Background Information

The pump will be powered by a 30W high-efficiency photovoltaic module. It will bedesigned to be reliant on one user input of turning the pump on or off. A subset condition ofthis constraint is that the pump will need to be self-priming so as to eliminate pump damagedue to the possibility of a low or temporarily nonexistent water level. The pump must be ableto 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, thegeneral pump concepts found during research will be evaluated. After screening the conceptsthey will then be scored using weighted ratings.

Task breakdown will be distributed on an as need basis. When tasks are distributed it is up tothe 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) thatnot only illustrates the milestones for project deliverables, but also the flow of tasks and theirdependency on one another.



4/39

For resources, the team will use the Reber Instrument Room for the assembly and testing ofpump 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 forfurther refinement and to provide appropriate time to rectify any unexpected occurrences.

Once the customer needs were identified they were translated into design specifications thatcould 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 whichconfiguration would best meet the project demands. Once a basic understanding of thedifferent types of pump operations was established, the design problem was decomposed intofunctional sub-problems. Design concepts were then generated based on the informationobtained thus far, after which concept selection followed. Analysis was then conduced on theprototype of the selected concept to determine product specifications and economic viability.

2. Customer Needs and Specifications2.1 Identification of Customer NeedsCustomer needs were determined from the project outline and from thinking of needs as athird world farmer. From the project outline it was determined that the pump needs to be self-priming, capable of a water elevation change of 0.5 meters, have a minimum flow rate of 0.5gallons/min, and powered only by solar energy. Because of the pumps targeted application tothird world farmers it should be easily maintained, durable, safe, and easy to use. Theseneeds were determined with the intent that third world farmers will use the pump with a dripirrigation crop watering system. With the aforementioned needs satisfied the farmer wouldnot have to worry about maintaining, fixing, or adjusting the pump. Additionally, the pricewill 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 thecustomer need ease of use the corresponding design specification was user input is oneon/off switch. As another example, safety had multiple corresponding designspecifications to include electrical components will be exposed to no water, will have noexposed electrical connections, and will have no exposed mechanical parts. For the entireQuality 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 thatwere screen based on needs and metrics. Once the concepts were screened (Appendix C), thebest among them were then scored using weighted ratings determined from the needs andmetrics (Appendix D). The resulting concept scoring matrix using weighted ratingsdetermined the best concept (Appendix E).

http://www.mcmaster.com/http://www.mcmaster.com/


5/39

Table : Weighted Needs

Weights(%) 20 15 10 5

CustomerNeeds

SafeSelf-Priming

can create a change inelevation can be used in water

high flow rate cost effective

ease of useprovides a constant

water supply

durability

easily maintained

3. Concept Development

3.1 External Search

To design the pump the team performed research on how a pump works, and basic fluiddynamics. A patent search (Appendix F) was also completed to reference inventions that havealready been designed; see Table 3 for a summary of the patents.

Websites dedicated to pumps were the teams best source of information when learning aboutthe functional description of a pump. The two main websites used for external research werewww.pumpscout.com for basic information on the types of pumps and their functions, andwww.pumpfundamentals.com for computational analysis. These two sites provided theinformation needed to create different pump concepts. From these two websites the teamdiscovered that most of the pumps were broken down into two types: positive displacementand centrifugal. The purpose of this research was to determine the advantages anddisadvantage of each type of pump, and how their traits fit into the constraints of the projectapplication. For the positive displacement pumps the biggest challenge would be how precisethe rotating element was housed, and how fast the element was rotating. For the centrifugalpump 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 anunderstanding of how other small homemade pumps have been built. The team also dissecteda fish tank filter pump to observe the motor housing and the impeller in regard to preventingwater leakage. This dissection also provided a better understanding of how the pump workedand the scale of the pump.



6/39

Table 2: Advantages and Disadvantages between pump typesPositive Displacement Centrifugal

Advantages -self priming -simple-consistent output

-output varies depending onthe pressure at the outlet; thisprevents damage to the pump-smaller

Disadvantages -higher maintenance costs-

-use rotation instead of suctionto move water-can develop cavitation-not self-priming-cannot develop high pressure

Table 3: Patent Descriptions

Axial Flow Pump andwater circulating

apparatus: This is anaxial flow pump that ismade up of a motor, anda rotor that acts as anaxial flow blade. Bothare in a casing madefrom a resin. The rotoris held by a bearing thatis integrated into the

casing. The input andoutput ports are builtinto the casing.

Gear Pump: Thispump is a gear pumpthat is made up oftwo gears, made of aceramic material,enclosed in ahousing. The gearsare driven by a motorthat is only drivingone of the gears.When rotated the

gear force the waterto by pumped fromthe inlet to the outlet.

Magnetically

driven axial-flow

pump: This pump ismade up of anelectromagnet thatis surrounding arotor that is fittedwith permanentmagnets. The insideof the rotor is fittedwith a spiral vane

that when rotatedmoves waterthrough it

Submersible pump

with plastic housing:This product is a pumpthat can go underwater. The case ismade to house singleor multiple impellers.The casing is made oftwo halves connectedtogether which reducesleakage and

manufacturing cost.

Analysis: This design issimple and can beconstructed with littleparts. The only variablethat would change the

Analysis: Thisdesign is simple butmanufacturing thegears very preciselycould end up being a

Analysis: Thisdesign is similar tothe axial flow pumpexcept building theelectromagnet will

Analysis: This ideacould be implementedin our pump and beeasily manufactured onthe rapid prototype



7/39

flow process is theshape of the impeller.

challenge. take time away fromother design aspects

machine.

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 themselvesabout 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 discussconcepts. Instead of focusing on the whole of the pump as one problem the pump wasdecomposed into functional subsystems. Concepts were created based on impeller position,pump orientation, and pump type. These concepts focused on making the particularsubsystem in question the most important part of that design and all other systems were builtaround it. In total 10 concepts were generated in the concept generation phase and can beseen in Appendix G.

3.4 Concept Selection

To make the concept screening process manageable the 10 concepts were categorized into 5major design types. The concept types screened included: gear, centrifugal, piston, vane, andmagnet driven pumps. A detailed concept screening matrix to find the most desirableconcepts to score is found in Appendix B. From the screening matrix it was clear that ourconcepts within the centrifugal and magnetic driven design types were going to be scored tofind the best individual design.

From the centrifugal pumps there were three designs to score, and from the magnetic drivenpump 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 mostimportant consideration is housing the motor and the impeller design. Although the resultsproved that the axial driven pump was the best, the team felt the snail shell design was thebest solution.

4. System Level Design



8/39

The design that was chosen was made to be simple, durable, and require little to nomaintenance. Since the team picked a centrifugal design for the pump it will need to beprimed prior to operation. Therefore, the pump must be waterproof. This meant that the pumpneeded parts that would not wear when exposed to water and still be strong enough to operatefor a long period of time.

Water will be drawn axially in through the front plate by a centrifugal impeller. The water isthen accelerated out of a tube on the top of the impeller housing. The motor will be housed inbehind the pump housing in a piece of PVC piping. The whole pump is connected togetherusing four bolts.

5. Detailed Design

5.1Modifications to Proposal SectionsThe new design uses the same type of pump but is more detailed than in the proposal. Threemajor 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 similarbacking. This change was made after alpha prototype testing revealed that the flat fins did notpush water as well as expected. The pump housing will still use PVC for the motor housingand a custom injection molded housing for the impeller. Now, however, three plates, one oneach end and one included in the injection mold, and in conjunction with 4 bolts, act to clampthe unit together. Selection of the motor was changed to take advantage of a faster no loadspeed in order to ensure the motor operated with as little resistance as possible when loadedby the impeller and the force of the fluid. A more detailed pump performance analysis wascomputed and can be seen in section 5.2.

5.2 Theoretical AnalysisFor the pump analysis three graphs were constructed to find the operating points. The first ofthese 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 Model1-42 pump, along with similarity laws to scale the pump. The original pump operated at 3250RPM, and had a 1.5 inch diameter impeller with 0.25 inch tall blades. The pump to be buildwill only have a 1 inch diameter impeller so scaling laws were used at 2400 RPM, 3000RPM, 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) wasfound using a Moody diagram.

The points where the three pump curve crossed the system curves were used to find the inputtorque. These points for flow rate and corresponding head at each speed can be seen below inTable 4.

Table 4: Flow rate and head values

2400 3000 3500

Q 9.65602 GPH Q 34.7444 GPH Q 48.7375



9/39

GPH

H 1.646427 m H 1.750292 m H 2.69815 m

The equationT = 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 modelnumber 2125528.These lines represent motor torque at varying voltages. Using no-load andstall data from the manufacture the values for Kt/Ke, Tloss, and Ra were found. These valueswere plugged into TLoad-Tloss=Kt/Ra[V-KE ] . The straight lines were made bychanging 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 findthe current using equation IV=T. These points for torque and corresponding angularvelocity 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

T 14.011529 T9.93404

8 T5.35302

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 (FigureH3 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 thesepoints crossed is the operating point, and the voltage and current from this point were 7.85Volts and 0.396 Amps.Now a new motor torque line was created on the Torque vs. Angular Speed graph at 7.85Volts. This graph (Figure H4) can be seen in Appendix H with only the torque line at 7.85Volts (red) and the pump torque (black). These lines crossed at a torque of 5.95 mN-m and aspeed of 4900 RPM. Since the operating speed was 4900 RPM a new pump curve on theHead vs. Flow Rate graph was made at this speed. A graph (Figure H5) with only the systemcurve and pump curve at 4900 RPM can be seen in Appendix H. These lines crossed at anoperating head of 2.34 feet, and flow rate of 81 GPH. The total results of the analysis can beseen below in Table 6.

Table 6: Results

Final Results

Q 1.35 GPM

H 0.713 metersw 4900 RPM

T 5.95 mN-m

i 0.3964 Amps

V 7.85 Volts



10/39

Using the pump curve at 4900 RPM it is seen that the pump will operate at 87 GPH or 1.45GPM at a head of 0.5 meters. These are the operating conditions that the pump will be testedat.

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 andtime. Injection molding requires no machining; therefore reduces cost due to labor. Since thepump will be in contact with water, plastic is the best option to prevent rust or any other typeof water wear.The motor housing will be a simple off the shelf cut of PVC piping. This piping provides thenecessary waterproofing that is needed. The piping is sold in lengths of 10 feet, which allowsfor roughly 30 units to be assembled from one length of piping. The only machining requiredis a cut on the band saw. PVC will also be used because of electrical connections beinghoused inside; there will be reduced risk of a short circuit because PVC does not conductelectricity.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 theimpeller with minimal labor hours. The impeller will also be made from plastic to avoidcorrosion from water contact. Plastic also offers a better resistance to bending on the impellerblades.The front and back plates will both be machined from quarter inch clear chemical resistantplastic. Plastic again will be used due to it being in contact with water as well as it not beingable to conduct electricity. The plastic plates will be milled to size. This is the same processfor an aluminum or steel plate, but the plastic stock is cheaper and more resistant todeformation.All electrical components will be purchased from Jameco Electronics in bulk. A waterproofswitch 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 andsecured 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 UnitInjection molding will be used to manufacture both the impeller housing and the impeller. Allother components are standard parts that will be purchased from suppliers. JamecoElectronics will be the supplier of the motor, wires, toggle switch, waterproof boot, and PVpanel 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 bemade up of two parts, the casing for the motor and the impeller housing. The motor casingwill be waterproof so that the wires and motor cannot be damaged by water. The seal will becreated by mounting the motor in a plastic pipe and pressing a back plate against the back ofthe pipe and pressing the front of the pipe against the plate on the impeller housing. The twoplates will be held together by four bolts. Gaskets or o-rings will be used at the mating



11/39

surfaces to hold the seal. This seal will insure that the electrical connections are safe and theuser 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 caneasily be switched on and off. The switch will also be protected from water by using a rubbercover and a gasket on the mating surfaces of the switch and the back plate.

5.6 Detailed DrawingsFigure 1: Isometric view of pump

5.7 Economic Analysis5.7.1 Unit Production Cost

Table 7: Bill of materials# Part Vendor Info Bulk (100,000) unit cost ($)

1 PVC Motor Housing McMaster Carr 48925K14 0.762 Impeller (IM) Xcentric Molding 0.303 Pump Housing (IM) Xcentric Molding 0.474 Front Plate McMaster Carr 8733K18 0.075 End Plate McMaster Carr 8733K18 0.076 Rubber Gaskets McMaster Carr 9774K43 0.237 Steel Bolts McMaster Carr 91251A089 1.70

8 Pipe Fitting McMaster Carr 5346K18 1.109 Wing Nuts McMaster Carr 98143A015 0.1610

Electrical Switch Jameco 76523 1.25

11

Motor Jameco 2125528 1.95



12/39

5.7.2 Business Case Justification

The product will be sold at $20.00 per unit. This yields an $8.25 profit per unit. Selling100,000 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 canbe 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 areinherently reduced risks to the end user. All electrical components are well sealed andinsulated within a non-conductive enclosure. The impeller is enclosed within a housing thathelps eliminate injury due to misuse. This enclosure also eliminates user harm due toimpeller 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 inadvertentmotor activation during repair; though the power source should be disconnected prior toservice.

5.9 Actual Construction Process of Beta Prototype

Construction of the beta prototype began with the creation of the impeller and impellerhousing from the rapid prototyping machine. A center hole was then drilled into the back ofthe impeller housing for the motor shaft. Two end plates were milled from Plexiglas. Fourholes 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 centerhole was also drilled and tapped into the front end plate to serve as the inlet when a fittingwas fastened into the hole; Teflon tape was wrapped around the fitting thread to preventleakage. 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 backend plate, for the wires, which was waterproofed with silicon sealant. Later it was decidedthat 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 theshaft hole because the lengths of motor mounting screws available were too short. Inaddition, two holes for the mounting screws were drilled into the impeller housing. Once theimpeller housing was milled and mated with the motor the set screws were used to fasten themotor to the impeller housing. A piece of PVC was also cut to serve as the motor andelectrical housing. With all pieces made the entire assembly was then secured with the fouraforementioned cap screws and wing nuts.

Figure 2: Assembled Pump



13/39

Figure 3: Front end plate with inlet fitting

removed



14/39

6. Testing

6.1 Test ProcedureThe test that will be conducted on the motor will be a dynamometer test. The materialsrequired for this test will be an electric motor, a variable voltage input, a string, weights withknown masses, a stopwatch, and a tape measure. To do this test a string will be put on themotor 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 bedone for multiple weights at a constant voltage. With the data know torque, velocity, andforce can be solved for. This will lead to angular velocity values. This test will be used tocompare 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 doneusing 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 thepump. The flow rate will be tested by taking the time it takes to fill the container to a certainvolume. Then the flow rate will be tested at different pressure head heights by raising theoutlet. 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.

6.2Test Results

After testing was completed the results revealed that the motors worked as expected by themanufactures specifications (efficiency 60%-70%). The data was plotted on a Torque vs.Angular Velocity graph and this can be seen in AppendixJ. The blue line was the one foundfrom the torque equation with a voltage of 6 Volts, and the red is from the testing. At stall thecalculation 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 motormade 66% (12.909/19.44) of the power that was expected by at the same input power. Thismeans that the manufactures specifications of efficiency between 60%-70% are correct andthe motors are performing as expected.After testing flow rates at different outlet heights, the performance curve for our pump wasfound and can be seen Appendix J. This graph can now show the flow rate at any heightbetween 0 to 1.14 meters. At 0.5 meters of head the pump will have a flow rate of 0.825GPM. When compared to the analysis there is a 43% error.



15/39

This is from the fact that the analysis it is assumed that when changing the impellers size thatit is scaled perfectly. So when the diameter drops from 1.5 inches to 1 inch the height of theimpeller blades at 0.25 inches should drop to 0.167 inches. The impeller that we used is only0.1 inches. For this analysis it is assumed that the size dropped by only 33% when in realitythe 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 directlyproportional to the impeller size the true expected flow rate can be found from setting up aproportion:

1.45GPM0.167inches=expected flow0.1inchesSolving this shows that the expected flow rate from the analysis should be 0.868 GPM basedon the impeller that was used. This is only a 5.5% error from the actual flow rate of 0.82GPM

7. ConclusionThis pump is the most viable option for a third world drip irrigation system as it is affordable andprovides the necessities to operate said system. Key features include easy disassembly formaintenance 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 producingit. 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 lengthof the impeller blades could have been doubled as this would have allowed more water to bepushed and therefor increasing the overall flow rate of the pump. The set screws for the motorwere not recessed enough into the motor housing to provide necessary motor support. This lackof support caused shifting of the motor leading to a rubbing of the shaft during operation. A nutor 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 engineersjob consists of. The team learned how to conduct research and gain knowledge that was thenused to come up with viable initial designs. We also learned how to take a SolidWorks drawingand 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 fewerprojects assigned during the semester as to not distract teams from the final project. A moredetailed and involved class in the machine shop to develop machining skills would greatlyreduce 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.



16/39

3. Lowes. N.p., n.d. Web. 07 Oct. 2012. . The Lowes online storewas used to price materials.

4. "Jameco Electronics."Electronic Components Distributor. N.p., n.d. Web. 07 Oct. 2012.. 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.. The online McMaster Carr store was used to pricematerials.

6. Postel, Sandra. "Drip Irrigation Expanding Worldwide."National Geographic. N.p., 25June 2012. Web. 06 Oct. 2012..

7. Manda, Takahike, Yoshifumi Tanabe, and Kazunori Murakami. Axial Flow Pump andFluid 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 FluidMechanics. 7th ed. Hoboken, N.J.: Wiley, 2009.

12. Hyman, Barry.Fundamentals of Engineering Design. 2. Prentice Hall, 2002. 374. Web.

Appendix A Gantt Chart



17/39



18/39



19/39

Appendix B Quality Function Deployment



20/39

Metrics

Changeinelevationofatleast0.5m

Flo

wrateofatleast0.5gpm

Ele

ctricalcomponentswillbeexposedtonowater

No

primingofthepumpisrequired

Userinputisoneon/offswitch

Partswillresistmostdamagefromen

vironment

Tubinginnerdiameterof3/8"

Willcost30dollarsorless

Willhavenoexposedelectricalconne

ctions

Willhavenoexposedmechanicalparts

Willhavenosurgeinwater

Canbeopenedwithouttools

Can create a change in elevation X

High flow rate X X

Can be used in water X X

Self priming X X

Ease of use X X X X

Durability X X X

Cost effective X

Safe X X X

Easily maintained X

Provides a constant water supply XEasily repairable X

Appendix C Concept Screening Matrix



21/39

Selection Criteria Gear

ImpellerCentrifug

alPistonPump

VanePump

Electromagnet Pump

can create a change inelevation 3 3 3 3 3

high flow rate 2 5 1 2 4can be used in water 5 5 5 5 5

Self-priming 5 3 5 5 3

ease of use 3 3 3 3 3

durability 3 3 2 3 5

cost effective 1 4 2 2 3

safe 3 3 3 3 3

easily maintained 3 4 2 3 4

provides a constant watersupply 2 5 2 2 5

Total 30 38 28 31 38

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

Appendix D AHP Weighting Matrix



22/39

cancreateachangeinelevation

highflowrate

canbeusedinwater

Selfpriming

easeofuse

durability

costeffective

safe

easilymaintained

providesaconstantwatersupply

Totals

Weights

RoundedWeights

cancreateachangein

elevation

1/2

1

1/2

1

2

2

1/3

1

2

101/3

8.528198

10

highflowrate

2

1/2

1/3

1

2

2

1/3

1

1

101/6

8.390646

10

canbeusedinwater

1

2

1/2

1

1/3

1

1/3

1/2

2

82/3

7.152682

5

Selfpriming

2

3

2

1

1

3

1/2

2

3

171/2

14.4

4292

15

easeofuse

1

1

1

1

1

2

1/3

1

3

111/3

9.353508

10

durability

1/2

1/2

3

1

1

3

1/3

1

2

121/3

10.1

7882

10

costeffective

1/2

1/2

1

1/3

1/2

1/3

1/4

1/3

1/2

41/4

3.507565

5

safe

3

3

3

2

3

3

4

4

3

28

23.1

0867

20

easilymaintained

1

1

2

1/2

1

1

3

1/4

3

123/4

10.5

227

10

providesaconstantwatersupply

1/2

1

1/2

1/3

1/3

1/2

2

1/3

1/3

55/6

4.814305

5

Total1211/6

Basedonascaleofrelativeimportance:1-equals,2-slighltyimportant,3-moderatelyimportant,4-extrem

elyimportant



23/39

Selection Criterial Weights Rating Score Rating Score Rating Score Rating Score

Can create a change in elevation 0.10 4 0.4 3 0.3 3 0.3 3 0.3

High flow rate 0.10 3 0.3 3 0.3 2 0.2 3 0.3

Can be used in water 0.05 4 0.2 4 0.2 3 0.15 5 0.25Self priming 0.15 3 0.45 2 0.3 4 0.6 4 0.6

Ease of use 0.10 3 0.3 3 0.3 4 0.4 4 0.4

Durability 0.10 3 0.3 3 0.3 2 0.2 2 0.2

Cost effective 0.05 3 0.15 3 0.15 4 0.2 2 0.1

Safe 0.2 4 0.8 4 0.8 3 0.6 2 0.4

Easily maintained 0.1 3 0.3 3 0.3 3 0.3 3 0.3

Provides a constant water supply 0.05 4 0.2 4 0.2 4 0.2 4 0.2

Weighted Total 3.4 3.15 3.15 3.05

Axial Driven Snail Flat Orientaiton Magnetic Driven

Concepts

Appendix E Concept Scoring

Appendix F Patent Search

Patent 1: Axial Flow Pump



24/39

Patent 2: Gear Pump



25/39



26/39

Patent 3: Magnetically Driven Flow Pump



27/39



28/39

Patent 4: Submersible Pump with Plastic Housing



29/39



30/39

Appendix G Design Concepts

Figure G1- Initial design concepts



31/39

Appendix H Theoretical AnalysisFigure H1

Figure H2

Figure H3

Figure H4

Figure H5

Appendix I NPV



32/39

Year

Year

Year

Year

($valuesinthousa

Q1

Q2Q3

Q4Q1

Q2Q3

Q4Q1

Q2

Q3Q4

Q1Q2

Q3Q4

0

1

2

3

4

5

6

7

8 910

1112

1314

1

DevelopmentCost

-45-45

-45-45

Ramp-Upcost

-5

-5

marketingandsupport

-2.5

-2.5 -2.5-2.5

-2.5-2.5

-2.5-2.5

-2.5-2.5

-2.5

-2.

productcost

-73.4375-73.4375

-73.4375-73.4375

-73.4375-73.4375

-73.4375-73.4375

-73.4375

-73.4375-73.437

Productvolume

2500025000

2500025000

2500025000

2500025000

2500025000

2500

Unitproductioncost

-0.00294-0.00294

-0.00294-0.00294

-0.00294-0.00294

-0.00294

-0.00294-0.00294

-0.00294-0.0029

salesrevenue

500500

500500

500500 500

500500

50050

salesvolume

2500025000

2500025000

2500025000

2500025000

2500025000

2500

unitprice

0.020.02

0.02

0.02 0.020.02

0.020.02

0.020.02

0.02

PeriodCashFlow

-45-45

-45-50

-7.5424.0625

424.0625424.0625

424.0625424.0625

424.0625424.0625

424.0625424.0625

424.0625424.062

PVYear1,r=10%

-45-44

-43-46

-7

375366

357348

340331

323315

308300

29

ProjectNPV

3470

Appendix J Testing Results



33/39

Figure J1: Motor Test Results

Figure J2: Pump Curve from Test

Appendix K Part Drawings



34/39

Figure K1: Impeller

Figure K2: Housing



35/39



36/39

Fig

ure K3: Motor Housing



37/39

Figure K4: Front plate



38/39

Figure K5: Back Plate



39/39

me 340 pump final report

Documents