10 1 1 172 691

The Power Workout:
Converting Exercise into

Electrical Energy
USD ELEC 492
Final Design Report
Elizabeth Huber, Richie Sanchez, Shin Sato
May 5, 2009
1 The Power Workout
TABLE OF CONTENTS
I. ABSTRACT ................................................................................................................................................. 6
II. INTRODUCTION ...................................................................................................................................... 6
A. Problem Statement ............................................................................................................. 6
B. Purpose of Project............................................................................................................... 6
C. Project Background ............................................................................................................ 6
D. Global, Economic and Environmental Impact .......................................................... 7
E. Design Team.......................................................................................................................... 8
F. Project Design Deliverables ............................................................................................ 8
III. SYSTEM DESIGN OVERVIEW.............................................................................................................. 9
A. Power Workout Subsystems .......................................................................................... 9
1. Mechanical Connection ..................................................................................... 9
2. Electrical Generator ........................................................................................ 13
3. Input Power Conditioning ............................................................................ 15
4. Microcontroller ................................................................................................. 17
5. Output Power Conditioning ......................................................................... 20
6. Battery Charge Display .................................................................................. 20
7. Battery System .................................................................................................. 22
B. Design Specifications ...................................................................................................... 23

C. Alternative Concepts....................................................................................................... 24
1. Flywheel Setup .................................................................................................. 24
2. Additional Generator ...................................................................................... 24
3. AC Induction Motor ......................................................................................... 24
D. Evaluation Techniques................................................................................................... 24
IV. TEST PLAN ............................................................................................................................................. 26
A. KEY REQUIREMENTS ..................................................................................................... 26
1. Safety .................................................................................................................... 26
2 The Power Workout
2. Efficiency ............................................................................................................. 26
3. Implementation Capabilities ....................................................................... 27
B. SPECIFIC STAGE REQUIREMENTS ............................................................................ 27

1. Generator ............................................................................................................ 27
2. Buck Boost Converter..................................................................................... 28
3. Microcontroller ................................................................................................. 34
4. SEPIC Converter ............................................................................................... 34
5. LED Display ........................................................................................................ 35
6. Battery .................................................................................................................. 35
7. Completed System ........................................................................................... 36
V. FINAL DESIGN SYSTEM RESULTS ................................................................................................. 37

A. SPECIFIC SUBSYSTEM RESULTS ................................................................................ 37
1. Mechanical Connection .................................................................................. 37
2. Generator ............................................................................................................ 37
3. Buck Boost Converter..................................................................................... 38
4. LED Display ........................................................................................................ 39
5. Battery .................................................................................................................. 41
VI. WORK BREAKDOWN STRUCTURE ............................................................................................... 42

A. Research .............................................................................................................................. 42
B. Design ................................................................................................................................... 42
C. Material Acquisition ........................................................................................................ 42
D. Assembly ............................................................................................................................. 42
E. Finalization ......................................................................................................................... 43
VII. RESPONSIBILITIES.............................................................................................................................. 44
VIII. BUDGET ................................................................................................................................................... 45
A. Explanation of Expected Cost ...................................................................................... 45
B. Figures .................................................................................................................................. 45
3 The Power Workout
1. Pie Chart .............................................................................................................. 45
2. Budget Breakdown Table ............................................................................. 46
C. Budget Changes ................................................................................................................ 47

IX. SCHEDULE .............................................................................................................................................. 48
A. Description of Process.................................................................................................... 48
B. Major Milestones .............................................................................................................. 48
C. Gantt Chart.......................................................................................................................... 48
X. PERSONNEL ........................................................................................................................................... 50
A. ASSEMBLY STAGE MANAGER: Elizabeth Huber ................................................ 50
B. DESIGN STAGE MANAGER: Richie Sanchez................................................... 50
C. SOFTWARE DEVELOPER: Shin Sato ................................................................. 50
XI. CONCLUSION ......................................................................................................................................... 50
XII. REFERENCES ......................................................................................................................................... 51
XIII. ACKNOWLEDGMENTS ....................................................................................................................... 52
XIV. APPENDICES .......................................................................................................................................... 52
A. RESUMES ............................................................................................................................. 53
Elizabeth A. Huber .................................................................................................. 53
Richie Sánchez .......................................................................................................... 54
Shinichiro Sato ......................................................................................................... 56
B. MECHANICAL CONNECTION SCHEMATIC ............................................................. 57

C. DATASHEETS ..................................................................................................................... 58
4 The Power Workout
LIST OF FIGURES
Figure 1: 2328T72 Rubber Wheels with Metal Bearings ................................................................... 10
Figure 2: A 6Z 4-24DF05016 Polycarbonate Timing Pulley.............................................................. 10
Figure 3: 6484K166 Timing Belt .................................................................................................................. 11
Figure 4: Pulley System Steel Shaft ............................................................................................................. 12
Figure 5: Generator Design ........................................................................................................................... 14
Figure 6: CM31D17NZ26D SUB-FHP Low Rpm PMDC ....................................................................... 14
Figure 7: LTC3780 Buck-Boost Controller ............................................................................................... 16
Figure 8: PIC microcontrollers...................................................................................................................... 18
Figure 9: PIC16HV785 Microprocessor Functional Diagram ........................................................... 19
Figure 10: LM3914 Dot/Bar Display Driver ............................................................................................ 20
Figure 11: LM3914 Block Diagram ............................................................................................................. 21
Figure 12: HR 40-12 Battery......................................................................................................................... 22
Figure 13: Generator Test Setup ................................................................................................................. 23
Figure 14: Multisim Circuit of Buck Boost Converter .......................................................................... 30
Figure 15: LTSpice Buck Boost Converter Voltage Simulation Plot @ Vin = 4V ......................... 31
Figure 16: LTSpice Buck Boost Converter Current Simulation Plot @ Vin = 4V ........................ 31
Figure 17: LTSpice Buck Boost Converter Voltage Simulation Plot @ Vin = 2V ......................... 32
Figure 18: LTSpice Buck Boost Converter Current Simulation Plot @ Vin = 2V ........................ 32
Figure 19: LTSpice Buck Boost Converter Voltage Simulation Plot @ Vin = 31V ...................... 33
Figure 20: LTSpice Buck Boost Converter Current Simulation Plot @ Vin = 31V ...................... 33
Figure 21: LTC 3780 ........................................................................................................................................ 39
Figure 22: Display Circuit ............................................................................................................................... 40
Figure 23: Display Board................................................................................................................................. 40
Figure 24: LED Display .................................................................................................................................... 41

5 The Power Workout
Figure 25: Final Budget Distribution Pie Chart ..................................................................................... 45
Figure 26: Project Gantt Chart ..................................................................................................................... 49

6 The Power Workout
I. ABSTRACT
The objective of the Power Workout project is to design a renewable energy source
based around a piece of exercise equipment. The energy expended in a typical workout at
the gym is usually wasted in the mechanics of the equipment. This project harnessed the
mechanical energy of the machine and converted it to electrical energy using a generator-
based system. The exercise equipment, in this case an elliptical, will be attached to a
generator. This creates a dc voltage which will be fed into a circuit and then sent to a
battery where it can be stored for future use. This report will introduce the project and
present all applicable information regarding the design, development, and the final
product.
II. INTRODUCTION
A. Problem Statement
The field of energy conservation is becoming an increasingly notable subject of research
among the scientific community today. Over the past decade, scientists and engineers around the
world have been designing unprecedented energy-harvesting systems, drawing power from a
variety of sources. One of the most creative and unlimited sources available is the kinetic energy
produced from human exercise. Although recent designs of energy-harvesting exercise
equipment have been introduced into the market, these systems are costly and do not produce a
noticeable output of power. These systems need to be improved and designed for maximum
power output, cost-efficiency, and marketability. Engineered to be used for retrofitting an
existing exercise machine, this project includes an efficient yet controllable power storage and
distribution system.
B. Purpose of Project
The ‘Power Workout’ Senior Design Project has developed an enhanced exercise
system focused on improving the efficiency of current energy-harvesting equipment. This
report has been created for the purpose of presenting all information regarding the
research, design, processes, materials, work schedule, and completed model of the project.
The central concept involves harnessing energy from an exercise machine through the use
of a generator, a converter, and a controller.
C. Project Background
A few fitness-based centers around the world have begun implementing initial
versions of power-generating systems focused on collecting human kinetic energy. These
designs vary in their use of energy-harnessing concepts.
In the Netherlands for example, clubs have used the concepts of piezoelectricity (the
idea that applying mechanical force to certain crystals will produce an electric potential) to
design dance floors which absorb vibrations from dancers and generate electricity
7 The Power Workout
(Rosenthal). In London, researchers have been looking into the idea of harvesting energy
from the vibrations of trains. One of the most exciting and innovative concepts is the
generation of electrical energy from the use of exercise equipment.
A gym implementing power generating cardio equipment could store the energy
and use it to decrease the amount of energy used in everyday operation for building
lighting, charge electrical devices, or powering TV and audio equipment. With the growing
concern over the impending energy crisis in the world, it makes sense to use the work
being constantly exerted at the gym to help the environment. Not only would machines
retrofitted to generate electricity be helping save money by powering the gym, but
environmentally conscious people would have extra motivation by knowing they are
helping save the environment.
Several gyms around the world have begun testing systems based around the idea of
harvesting energy from exercise equipment. California Fitness, a gym located in Hong Kong,
has been testing stationary bikes and elliptical machines retrofitted to work as electrical
generators. A report by Motorwave Limited, a Hong Kong company that develops cost
effective renewable energy sources calculates that “if all the California Fitness gym
exercisers in the world are being used...[their “Power by You” concept] will generate
21,900 MWh/year. To produce the same energy, a power plant will release 11,000 tons of
CO2” (Motorwave).
In Portland, Oregon the Green MicroGym is strongly promoting environmental
saving initiatives (Barclay). In addition to installing solar panels to help decrease the
power consumption of the building, MicroGym also uses energy-efficient treadmills, and
“Human Dynamo” elliptical machines which are capable of charging battery’s to power an
inverter and produce up to 120 volts AC.
D. Global, Economic and Environmental Impact

The potential scope of this senior design engineering project is much larger than our
local community. As evident in the background section of this report, companies around
the world are interested in producing energy-harnessing systems. However, the systems
they currently use have proven costly and lack a high level of efficiency. Designing an
inexpensive system with a high output would benefit businesses around the world, as the
feasibility of implementing these systems would increase greatly. In addition to providing
a more accessible source of energy-harvesting technology to other countries, the system
has the potential to improve other situations closer to home.
For example, the economy is currently in shambles. Financial firms such as Merrill
Lynch, insurance underwriters like AIG and the nation’s largest savings and loan
Washington Mutual are experiencing severe financial crisis. The situation has created an
increased need for cutting costs. One avenue that is currently being focused on is the
search for alternative cost effective energy sources. This need for alternative fuel sources
along with a heightened awareness of the importance of living a healthy lifestyle and the
8 The Power Workout
growing concern over environmental awareness create an environment where the

conversion of existing products is the most feasible avenue to explore. The number of
fitness centers has increased. This growth creates competition between different
companies, and finding ways to cut expenses becomes more important. The combination
of these issues results in a grave necessity to discover an alternate source of power (Energy
Information Administration).
On a final note, the Power Workout system provides obvious environmental
benefits. One of the greatest sources of energy today comes from the burning of fossil fuels.
The problem with this current method is that the world only has a limited supply of such
fuels. The burning of fuels also creates pollution and damages the environment. However,
in a renewable-energy system such as in exercise equipment, the source is unlimited and
essentially pollution-free. For these reasons, it is evident that a human-powered energy-
producing system would provide countless benefits to the global market, the economy, and
the environment.
E. Design Team
The team assembled to complete this project is comprised of three Electrical
Engineering students at the University of San Diego: Elizabeth Huber, Richie Sanchez, and
Shin Sato. Each student’s resume and previous engineering experience is attached at the
end of this report. A faculty advisor, Dr. Thomas Schubert, supervised the team’s progress.
All applicable research, design, development, and testing was done in the Engineering Labs
of Loma Hall.
F. Project Design Deliverables

Upon completion of the project, our group will present a fully designed system to harness
kinetic energy. Our system is designed for retrofitting a current elliptical, and generating at least
50 to 150 Watts per exercise machine. In addition, it will efficiently monitor, regulate, and
distribute the power produced. For marketability, our design will also be aesthetically pleasing
and have a low consumer price. Further technical and functional specifications are included in
the Design section of this report.
9 The Power Workout
III. SYSTEM DESIGN OVERVIEW

The Power Workout system is comprised of seven subsystems that will work
collectively to efficiently produce the desired 50 to 150 watts of power. The first
subsystem is the mechanical connection which is will transfer the kinetic energy from
inside the elliptical to the generator. The second subsystem is the electrical generator. This
subsystem transfers the rotational movement created when an elliptical is in use to the
rotor of a permanent magnet dc motor (PMDC) which will in turn output a DC voltage. The
third subsystem is the Input Power Conditioning module which adjusts the input from the
generator by stepping up or stepping down the voltage to a useable 12 volts. The fourth
subsystem, the Charge Controller, monitors the charge produced by the generator and the
charge stored in the battery. The Charge Controller adjusts the output to a single lead acid
battery to optimize the use of the generated energy. This component will play a major
factor in the efficiency of the system. The fifth subsystem is the Output Power Conditioning
module which will be regulated by the microcontroller to adjust the output voltage to the
battery. A sixth subsystem displays the level of charge stored in the battery. The seventh
and final subsystem is the Energy Storage which is a battery where the generated energy is
stored for future use.
A. Power Workout Subsystems
1. Mechanical Connection
The energy harvesting process begins with the conversion of the rotational
motion inside the elliptical into a more practical form of energy. The flywheel
located within the machine resists changes in its rotational speed. This means that
when a person is exercising on the elliptical, the flywheel ensures that the user is
exerting less energy than what was required to start the rotational motion. The
team decided to use this flywheel as the basis of converting motion into electrical
energy. A pulley system was designed to be attached to the flywheel inside the
elliptical which will then be connected to a generator to process the conversion.
a. Technical Description
The components used for the entire pulley system consisted of a rubber wheel,
Polycarbonate timing pulleys, timing belt and a steel shaft specifically designed for
this purpose.
The rubber wheel utilized in the design was the Conductive Rubber Wheels with
Plain Metal Bearings model number 2328T72 from McMaster-Carr. Seen below in
Figure 1 and Table 1 is a picture of the rubber wheel and the important dimensional
information respectively.
10 The Power Workout
Table 1: Dimensional Information of 2328T72
Diameter Width Axle Diameter Hub Length

3 inches 15/16 inches 1/4 inches 15/16 inches
Figure 1: 2328T72 Rubber Wheels with Metal

Bearings
The Polycarbonate timing pulleys used on both ends of the pulley system
were the timing pulley, model number A 6Z 4-24DF05016, from www.sdp-si.com.
The bore configuration was an aluminum insert with a hub. It is manufactured with
two flanges on both sides of the pulley to prevent the timing belt from slipping off.
Seen below in Figure 2 and Table 2 are a picture of the timing pulley and its crucial
dimensional information respectively.
Figure 2: A 6Z 4-24DF05016 Polycarbonate

Timing Pulley
Table 2: Dimensional Information of A 6Z 4-24DF05016
Pitch Diameter Outside Diameter Bore Size Belt Width Pitch Size No. of Grooves
2.865 inches 2.835 inches 0.500 inches 0.5 inches 0.375(L) 24
For the timing pulley that was chosen, the corresponding timing belt that
matched the specifications was the single-sided timing belt product number
6484K166 from McMaster-Carr. It has trapezoidal teeth, the material is Neoprene
and fiberglass. Figure 3 and Table 3 show the picture of the timing pulley belt and
the characteristics of the belt.
Figure 3: 6484K166 Timing Belt
Table 3: Dimensional Information of 6484K166
Circumference Belt Width Pitch Size Number of Teeth

81.7 inches 0.5 inches 0.375 inches 218
The steel shaft was designed to hold the pulley system in place.
Measurements were made inside the elliptical to determine the dimensions of the
steel shaft. The design was constructed in the USD Engineering building with
assistance from John Crow. A picture of this component can be seen in Figure 4.
Figure 4: Pulley System Steel Shaft
b. Design Approach
The most important requirement for portion of the system is to be able to convert as
much of the rotational energy from the flywheel within the elliptical to the generator so that
the generator is operating at the desired speed. The minimum speed in which the generator
had to be operating in was 450 rpm. The preliminary testing of the elliptical revealed that
the flywheel would be spinning at 360 revolutions per minute for an average workout. This
meant that the pulley system needed to have a 2: 1 ratio with the elliptical flywheel to
increase the rotational speed to meet the operating standard of the generator. The diameter
of the flywheel was 12 inches which means that the pulley at most, could be 6 inches to
achieve the desired ratio.
The bore size of the pulley was determined by making measurements on the
generator. The diameter of the rotor on which the pulley would be attached was 0.5 inches.
Since the rubber wheel created enough rotation from the flywheel, the two pulleys on each
side of the system could be identical.
Due to the limited amount of space inside the elliptical, the timing belt on which the
pulley system would be operating on had to be thin. By taking measurements, the team was
able to determine that a belt size smaller than 1 inch would be sufficient to be placed in the
elliptical without causing mechanical issues. Since the timing belts are manufactured in
specific lengths, we determined that the 817L size which corresponds to 81.7 inches
(approximately 7 ft.) would be ideal for our design. Since the belt has to spam from inside
the elliptical to the generator and then back to inside the elliptical, the actual distance
between the pulleys would be 3.5 ft. which was close to what the initial design was. Another
minor specification that the timing belt had to meet was that the pitch, the distance between
the grooves, on the timing belt had to match the pitch on the pulley which in this case was
0.375 inches.
As noted earlier, the rubber wheel would spin by rubbing against the flywheel inside
the elliptical. The pulley then would have to be attached to the rubber wheel so that the
pulley would be spinning at the same rotational speed. This was accomplished by using
dowel pins. Three holes were drilled into both rubber wheel and pulley in the same
location. Then, the dowel pins were placed into each of those hold to secure the pulley to
the rubber wheel.
The steel shaft portion of the design was very crucial in ensuring the pulley system
worked. Once the rubber wheel – pulley combination was placed on the steel shaft, it had to
remain in that position or the wheel would not be able to catch on to the spinning flywheel
and the pulley system would not work. The rubber wheel – pulley combination location had
to be fixed and this was accomplished using two steps. The first step was to create a
cylindrical spacer. The bore size of the pulley and the rubber wheel were 0.5 inches and
0.25 inches respectively. This meant that if the diameter of the spacer was smaller than that
of the pulley but larger than that of the rubber wheel, it would prevent the rubber wheel –
pulley combination from moving towards the steel shaft. By securing the other side of the
bolt with a nut, the combination was now fixed to the location that was designed. The
schematic design can be seen in Appendix B.
The same idea was applied to the connection between the steel shaft and the plate
inside the elliptical in which the entire pulley system would be attached to. A cylindrical
spacer was placed to fix location of the steel shaft.
2. Electrical Generator
The electrical energy for the system is generated by a Permanent Magnet DC
(PMDC) motor. The rotational motion of the flywheel within the elliptical housing is
transferred to the rotor of a permanent magnet through a system of gears and pulleys. As
the rotor turns the rotation of the permanent magnets creates a voltage potential through
back emf. The higher potential at the generator induces a current flow toward a lower
potential (battery). This basic concept is visible below in Figure 1.
High Potential Current Flow
Low Potential
Figure 5: Generator Design
The motor used to generate electricity is a CM31D17NZ26D SUB-FHP Low Rpm
permanent magnet dc motor manufactured by Leeson Electric Corporation (Figure 2).
The motor achieves 12 volts output with a max current rating of 25 Amps.
Figure 6: CM31D17NZ26D SUB-FHP Low Rpm PMDC
Table 4: PMDC Per Phase Specs
Load Curve Data
Output Pwr (HP) RPM AMP Torque (LB-IN)

.16 1721 13.2 94
.27 1472 25 188
b. Design Approach
There are a number of reasons why a PMDC Motor would be best suited for the
design of this project. A few of the Power Workout group’s design goals were to
create a system that is cost-effective, reliable, and safe. Brushless Permanent
Magnet DC Motors typically have a longer life than Brushed motors due to the fact
that brushes erode over time and must be replaced. In addition, brushless motors
are relatively inexpensive, produce a strong output and provide high reliability,
therefore making them a logical choice for the design.
c. Evaluation Approach
Analysis of the CM31D17NZ26D motor specs shows that it can produce a
sufficient voltage to charge a battery within a relatively low rpm range. In order for
a dc motor to work as a generator for our application, two very important factors
needed to be taken into account. First, the desired operating voltage of the
generator and second, the maximum sustainable power output level. For our
system, we chose 12 volts as the desired output since most household electronics
operate on 12 volts DC power. Research has shown that the maximum sustainable
power that a healthy person can produce is approximately 400 Watts for a short
period of time and 150 Watts during a one hour workout on a bicycle. Since our
device is an elliptical we do not expect that a person will be able to achieve the same
amount of output power. Given the desired voltage and the range of output power
that we expect to be produced the motor ratings were determined using the
following calculations.
3. Input Power Conditioning

The generator for the Power Workout system produces an output voltage the range of 4
to 20 Volts. In order to optimize the efficiency of the overall system, the voltage produced
by the generator is regulated to maintain an output of 12 volts independent of the input.
This ensures that if the battery is close to fully charged, the low voltage input from the
generator will be stepped up to a higher voltage to complete the charge cycle. This is
achieved by the implementation of a Buck-Boost DC Controller.
The LTC3780, 4-Switch Buck-Boost Controller (Figure 3) is a high performance
buck-boost switching regulator that can operate with an input voltage above, below
or at the desired output voltage. A 3V to 30V (36V maximum) input and output
range make this converter ideal for our system. The essential function of this
subsystem is to maintain an output voltage of 12 Volts independent of the input
voltage. For our application the Buck-Boost converter will be operating within the
range of 3.5 to 25 Volts.
Figure 7: LTC3780 Buck-Boost Controller
b. Design Approach
Since the power generated by a person on the elliptical will not be at a constant
rate the design required a subsystem that would effectively step up or step down
the voltage to a useable output. During our testing of the generator we were able to
achieve up to 6 volts at a relatively low 580 rpm. Testing done with the elliptical
showed that a user could fairly easily achieve this speed by implementing a gearing
ratio of 6:1.
The minimum speed required to maintain an input of 3.5 volts was 19

revolutions per minute on the elliptical pedals. The elliptical contains an internal
flywheel that turns at a rate six times faster increasing the speed at this point to 114
RPM. The pulley system then transfers this rotational motion to the generator
further increases the speed by a factor of 4.28 resulting in a final output speed of
487.92 RPM. This speed produces an output voltage of 3.58 volts which is slightly
above but within an acceptable range of the minimum required input voltage to the
Buck Converter. (Table 5)
Table 5: Minimum required speed
Elliptical User Elliptical Flywheel Pulley Output

(rpm) (rpm) (rpm) (Volts)
19 114 487.92 3.58
The primary requirement of this subsystem was that it be able to convert a
varied input voltage into a useable output for our charging system. The design team
evaluated several DC to DC converters before the choice was made to implement a

Buck-Boost into the design. The Buck-Boost converter was an obvious choice for
this application due to the wide range of inputs under which a constant output could
be maintained.
Table 6: BUCK-BOOST CONVERTERS
BUCK-BOOST Vin Min Vin Max Output Current Vout Min Vout Max
CONVERTER
LTM4609 4.5 36 4 0.8 34
LTC3780 4 36 20 0.8 30
LTM4607 4.5 36 5 0.8 24
LT3433 4 60 0.4 3.3 20
LTM4605 4.5 20 5 0.8 16
4. Microcontroller
The microcontroller is an integral component of the system and is used to continuously
monitor and compare the output of the generator to the charge levels of the battery. In
order for the system to achieve high efficiency, the controller will be required to closely
monitor the battery charge and adjust the supply voltage and current according to the
charge state of the battery. Lead acid batteries require multi-step charging and the
accuracy of the monitoring system will affect not only the efficiency of the power
transmission to the battery but also the overall life of the battery.
The microprocessor that is used in this design is a PIC16HV785: Programmable
Lead Acid Battery Charger manufactured by Microchip. This is a 20-Pin Switch
mode charger with many features that makes it a favorable choice for the project. It
has an internal 10 bit ADC and regulates the output voltage and current internally
which made it easy to implement into our design. The controller is capable of
monitoring the charge on the battery and the output of the generator to determine
the proper stage of the charging cycle. The PIC16HV785 initializes in the presence of
a battery and charging supply. The first stage is charge qualification where the
battery’s voltage is measured to determine the appropriate initial state. The possible
states are Charge Suspend, Precharge and Current Regulation. Charge Suspend halts
charging if preset charging conditions are not met. Precharge allows deeply
discharged battery’s to recover by applying a low charge rate. Current Regulation

provides a constant current and limited voltage. The Voltage Regulation state is
entered after the target voltage is reached where a constant charge voltage is
applied until the current has decreased to a minimum current threshold. Charging
continues at a constant voltage until the current decreases to the minimum current
threshold. Charging is terminated at the minimum current threshold and the
controller enters the End of Charge state.
Figure 8: PIC microcontrollers
b. Design Approach
The PIC16HV785 model microcontroller meets the functional requirements
needed to successfully complete the project. The microprocessor is capable of
converting from analog to digital in order to convey the data from one part of the
circuit to another. It is able to perform the AD conversion to distribute the data
between the input, output, relay system and the voltage regulators accurately in
order for the system to be efficient. The microprocessor is also be capable of power
management, power metering and circuit protection. In order to monitor every part
of the circuitry and transmit the data back, the microprocessor must be capable of
power metering. The ability to measure the circuit through the microprocessor is
very important because it directly affects how the design will operate. If the system
is not being measured constantly, there is a high probability of damaging the battery
or the controller. The functional diagram of what the microprocessor is capable of is
seen in Figure 5. All the above requirements are fulfilled by the PIC16HV785 model
microprocessor which makes it a logical choice to be used in the system design.
Figure 9: PIC16HV785 Microprocessor Functional Diagram
Our design team selected PIC16HV785 due to the many functions that the
controller can perform without the need for additional components. The
PIC16HV785 is designed for battery-charging applications where monitoring and
regulating the system are necessary for efficiency. The PIC16HV785 contains an
internal A/D Converter which can sample output measurements for the voltage and
current through two feedback loops. The microcontroller can be programmed with
the charging algorithms necessary for lead acid batteries. As an added protection
factor it can detect damaged or overheated components and suspend the charge
process when necessary.
5. Output Power Conditioning

The output power from the generator is regulated to 12 volts. This voltage will need to
be stepped down at times, depending on the charge state of the battery. When the battery
charge is low the charging voltage is lowered to reduce the risk of damaging the battery. A
DC to DC converter is implemented for this purpose.
The voltage and current output to the battery is adjusted through a SEPIC (Single Ended
Primary Inductor Converter) which is controlled by the PICPIC16HV785 microcontroller.
This form of a DC to DC converter is used at the output due to the fact it allows the output
voltage to be above, below, or equal to the input voltage. This type of converter can be
controlled by changing the duty cycle of the control transistor to increase the output
voltage. Another advantage of a SEPIC converter is the added safety that is provided by
isolation between the input and output ensuring that the voltage will drop to zero at shut
down. (Figure 6)
6. Battery Charge Display

One of the main objectives of this project is that the end user of this system realizes
the benefit of renewable energy. For our system we chose to implement a 10 bar led
display to show the charge of the battery. The higher the charge the more led’s that would
be lit on the display.
The display is driven by a LM3914 Dot/Bar Display Driver. The LM3914is an
integrated circuit that senses analog voltage levels and drives 10 LEDs, providing a linear
analog display. The driver is capable of displaying the charge as a moving dot or bar graph.
The current drive to the LEDs is user regulated and programmable which eliminates the
need for additional resistors and allows the system to be operated with a low input of 3V.
(Figure 7 and 8)
Figure 10: LM3914 Dot/Bar Display Driver

Figure 11: LM3914 Block Diagram
b. Design Approach
The design team evaluated several possibilities for displaying the charge stored
in the battery. Initially we intended to have the efficiency and charge data available
for a user to download possibly through a serial port to monitor the performance of
the system. This concept was abandoned due to the fact that it would require
additional active components and further decrease the output power of the system.
We decided on implementing a simple display that would be read easily, could be
powered by the battery itself and operate at a nominal voltage.
The design team evaluated several LED drivers for use in the Power Workout
system design including the MAX6965 manufactured by Maxim Integrated products
and the LT3599 - 4-Channel 120mA LED Driver manufactured by Linear
Technologies. The alternative drivers were abandoned due to an implementation
requirement of additional control signals and a higher operating voltage
respectively.
Table 7: LED Drivers
OPERATING
LED DRIVER CONTROL INPUTS
VOLTAGE
MAX6965 2-3.6 4 control signals
PWM input
LT3599 2.7-30
required
LM3914 2.4-4.2 Battery
7. Battery System
The relay and battery system will store the energy created by the electrical generator.
In order for this system to add to the efficiency of the system as a whole it will need to
dissipate as little power as possible during transmission.
The battery used in our system is a U1 high rate discharge lead acid battery. The
battery has a rated internal resistance of less than 6mΩ a maximum charge current of
11.4A. (Figure 7)
Figure 12: HR 40-12 Battery
b. Design Approach
There are a number of reasons why we chose a lead acid battery for the storage
system. They are the most common type of secondary or storage battery in use.
Lead-acid and sealed lead-acid (SLA) batteries are relatively inexpensive and
commonly used in applications like ours where weight is not a significant design
consideration. Lead acid batteries are commonly found in standby power

applications, such as uninterruptible power supplies and emergency lighting.
SLA Characteristics:
• Good long-term charge retention
• Must be charged slowly…typically 8 to 16 hours
• Do NOT exhibit a memory effect. Capacity loss, when experienced, is usually
permanent. However, “sulfating” can be corrected with some newer
accessory charging systems
B. Design Specifications
a. Mechanical Connection
• Fix the location of the rubber wheel and pulley combination.
• The pulley placed on the rotor of the generator must reach the desired
operating rotational speed of 500 rpm.
• Be able to maintain the general operation and aesthetic of the elliptical
b. Generator
• Produce between 50 and 150 watts of power
• Produce sufficient voltage through most of the rpm range achievable by
the average user
• Our generator has been tested, and has produced an average if 1800 RPM
and 9.6 volts. The testing setup is visible in Figure 8.
Figure 13: Generator Test Setup

c. Charge Controller
• Sample output voltage of generator at 100,000 samples per second
conversion rates.
• Sample battery charge at 100,000 samples per second conversion rates.
• Control relay system to route generated electricity.
• Display charge and generator information for user.
• Store data so that it can be retrieved later to monitor system efficiency
d. Battery System
• Store generated electricity to power electrical devices.
C. Alternative Concepts
1. Flywheel Setup
An alternative to the pulley system that the team was considering was
placing a flywheel in front of the elliptical. An extension of the handle bars
connect to the foot pedal on the elliptical. Similar to a rowing exercise machine,
this extension would be attached to a flywheel where by pulling the handle bars,
it rotates the flywheel. This idea was not utilized in this project due to the
complexity of the design compared to the pulley system.
2. Additional Generator
An additional generator may be attached to the elliptical if it can be
implemented without being to obtrusive. The additional generator would
increase the amount of energy that could be generated from one machine.
3. AC Induction Motor
Another commonly used motor for generating electricity is an AC induction
motor. Although the system was designed to use a DC motor to eliminate the
need for a rectifier circuit and further decrease the cost of production additional
testing may be performed to determine the output of AC induction motors
versus DC permanent magnet motors
D. Evaluation Techniques
In order to ensure successful completion of the project, there are a number of
checkpoints which must be reached by various points throughout the semester. Major
deadlines for evaluation are specified in the Schedule section of this report. Continuous
evaluation of design progress was completed by Dr. Schubert, the Senior Design advisor. A
Final evaluation at the end of the School Year will be completed by the Engineering Faculty.
The progress of the group throughout the spring semester will mainly be judged
based on the Test Plan and writing assignments. The Test Plan included in this report
explains the details of system development and analysis.
IV. TEST PLAN

The testing will be conducted on each of the subsystems and on the final product
1. Generator
2. Buck Boost Converter
3. Microcontroller
4. SEPIC Converter
5. LED Display
6. Battery Storage Unit
7. The Completed System
The testing engineers were responsible for verifying that the project components
meet the design requirements. The testing engineers will verify whether or not the
subsystem satisfies the set criteria. If a component does not pass for any reason, the
team will evaluate the failure and make the necessary revisions.
A. KEY REQUIREMENTS
1. Safety
The safety test is the most crucial aspect of the test plan and each stage of the design
must pass the safety test before moving on. The safety is important to three elements of
the design. The first element is the user or the consumer. The project is designed for
people who use this on a daily basis and safety evaluations need to ensure nothing will
compromise the user’s safety. After all, something healthy such as exercising should
not turn into something unhealthy. The second element of the safety test is for the
servicing of the design. This means that the project should not discharge or bring harm
to the person working on the design. The last element is the electronic device that will
be connected to the battery. This may be a HD TV, iPod, your Blackberry cell phone or
any other electronic device connected to the design. This project is being developed to
save the user energy and money. Destroying expensive electronics would have the
reverse effect of the original objective.
2. Efficiency
The efficiency of each component needs to be as high as possible. The method of
determining efficiency was different for each subsystem. For the generator, it requires
high conversion efficiency from mechanical energy into electrical energy. The
microprocessor needs to have the least amount of processing time as possible and this
means streamlining the code as much as possible but maintaining the basic functional
requirements. A high efficiency is required for each component to get the maximum
result from the entire design which will translate into more energy and more money
saved.
3. Implementation Capabilities
The implementation capabilities apply mainly to the aesthetics and marketability of
the design. The design needs to be compact enough to be used at home next to the
elliptical but also durable enough to be used regularly at popular fitness centers.
B. SPECIFIC STAGE REQUIREMENTS
1. Generator
The major operation characteristics of the Leeson CM31D17NZ26D generator that
require testing are the revolutions per minute(rpm), voltage output and current output.
The specifications of the model indicate that the generator operates between 1400 and
2000 rpm. The test engineer will measure the speed that the rotor of the generator is
spinning using a portable handheld tachometer. A reflective sticker will be placed on
the rotor of the generator and the tachometer will be able to accurately measure the
rpm using a laser. The laser coming out from the tachometer will be pointed at the
sticker. As the rotor spins, the laser will be reflected back into the sensor of the
tachometer when it hits the reflective sticker. The tachometer will then calculate the
rpm of the generator from the frequency in which the laser was reflected. If the
generator does not run at the specified speed, it will produce undesired values of
voltage and current. This then means that the test engineer must ensure the generator
is running and continues to run at optimal speed.
After the requirements for the rpm are satisfied, the test engineers will measure the
voltage and current values being produced by the generator. In an optimal condition,
the generator will be producing 12 Volts and a maximum of 25 Amps. These values will
be measured using a multimeter and the results will be recorded on an Excel
spreadsheet with the corresponding rpm. The importance of testing the current value
cannot be stressed enough because it affects the safety of the generator. If more than
25Amps of current flows through the armature, the generator will produce more power
than what this system was designed to handle. This excess power will be released in
the form of heat. This will lead into the danger of the armature overheating and
possibly permanently damaging the generator. In order to prevent such disaster, the
test engineers must maintain the generator speed at a desirable level to keep the
voltage and current ratings under control. The generator is the first subsystem in the
design and thus it is crucial to ensure it is working as intended. Faulty generator
performance will ripple across to the rest of the system. To prevent such errors,
thorough testing will be conducted and analyzed. Figure ***** summarizes the
functional requirements of the generator when it is in operation.
Table 8: Requirements of Generator Operation
Revolutions per Minute(RPM) 1800-3900

Output Voltage 12V
Maximum Output Current 25A

As stated in the system design overview, the voltage produced in the generator will
vary with time because the user on the elliptical will not be running at a constant rate
and thus a regulator is required to maintain a constant flow of power into the battery.
The requirement of the Buck Boost Converter is to have an output of 12V when an input
ranging from 4V to 30V is supplied from the generator. Also, the conversion time
should be under 10milliseconds (ms). The engineers will utilize three sources for
conducting tests on the Buck Boost Converters. The three methods will be electronic
simulation, breadboard testing and printed circuit board (PCB) testing. The different
methods of testing will ensure the integrity and validity of the design. The testing
procedures will be similar for all three methods of analysis. Test engineers will supply
different values of voltages into the converter and will observe the results. By analyzing
the results, the test engineers will be able to determine the range of input voltages the
converter operates in. The results will be compared with the theoretical values and
necessary changes will be made to the design.
LTSpice will be used for the electronic simulation of the converter circuit. Figure 1
shows the circuit that was created using Multisim. The plot in Figure 11 is the transient
analysis of the circuit where the blue line represents the input voltage and the green
line represents the output voltage. With a constant input of 4V, the Buck Boost
Converter was able to amplify the voltage to produce 11V in approximately 5ms.
Similarly, Figure 12 shows the analysis of the same circuit where the blue line again
represents the input voltage but this time, the red line represents the output current.
The converter was able to amplify the current to 4A in approximately 5ms. Figure 13
and Figure 14 shows the output voltage and output current respectively for an input
voltage of 2V. The output never approaches the values seen when the input voltage was
4V. This is because 2V is outside the range of inputs this Buck Boost Converter is
designed to operate in. In this case, the 2V is below the minimum value of input voltage
for the converter to operate. Figure 15 and Figure 16 shows the opposite case when the
input voltage is above the maximum value. The input voltage is not within the range of
operation and thus, the voltage is not regulated. Table 3 summarizes the results
obtained through electronic simulation analysis and verifies the assumption that the
Buck Boost Converter operates at input voltages between 4V and 36V.
Table 9: Electronic Simulation Results of Buck Boost Converter
Input Voltage
Theoretical 2V 4V 12V 25V 31V
Output Voltage at Steady State 12V 0V 11A 11A 11A 0V
Output Current at Steady State 5A 0A 4A 4A 4A 270uA
Time Required to Achieve Steady State 1ms N/A 5ms 5ms 5ms 1ms
The breadboard testing will be done after the electronic simulation meets the
requirements. After constructing the circuit on the breadboard, a visual inspection will
be conducted to identify basic circuitry errors which include but not limited to open
circuits, short circuits, incorrect components and overlapping wires. The circuit will
then be tested using lab equipment. The results will be compared with the theoretical
range and the range obtained from the electronic simulation. This will help validate the
accuracy of both the breadboard circuit results and the electronic simulation results.
Both methods should yield similar ranges of input voltage for the desired operation of
the Buck Boost Converter. Test engineers will compile the results obtained into a
Microsoft Excel document for future reference.
The PCB testing will be the final step in measuring the validity of the Buck Boost
Converter design. Test engineers will utilize the same method used for the previous
two tests for the PCB. Team members will verify that the PCB was assembled correctly
accordingly to the design and that the results produced on the PCB is identical to those
obtained in the previous two methods. A visual inspection will also be conducted on
the PCB in a similar fashion to the breadboard circuit.
12 V C2 C10
27µF 3.3µF
GND
GND GND
R6
51kΩ
Q1
SUD40N04-10A
Rload
GND D1 2.5Ω
1N5819
D3 R9 C3
U1 100kΩ 4.7µF D4 C9 C1
1N750A Q3 22F 1µF
MBRS340
D5 SUD40N04-10A
GND
Vin
C6
INTVcc
1N5819 GND GND
EXTVcc
GND 220nF GND
Run Pgood L1 R7
Boost2 Boost1 4.7µH 113kΩ
Q4
C7 TG2(A) TG1(D)
220nF SW2 SW1
SUD40N04-10A
BG2(B) BG1(C)
Q2
GND C8 STBYMD Vosense
Ith FCB
SUD40N04-10A
D2
R3 1nF SS PLLFLT MBRS340 R8
GND SGND PLLIN
GND 8.06kΩ
C5 100kΩ C12
10nF 100pF LTC3780 GND
Sense+
Sense-
R1 R2
PGND
GND GND GND 18mΩ 18mΩ

C11 R5
GND C4
100Ω GND
100pF
1nF R4
100Ω
Figure 14: Multisim Circuit of Buck Boost Converter

Figure 15: LTSpice Buck Boost Converter Voltage Simulation Plot @ Vin = 4V
Figure 16: LTSpice Buck Boost Converter Current Simulation Plot @ Vin = 4V
3. Microcontroller
The PIC16HV785 Microchip is programmed using the PIC-C software. Thus, the
majority of the testing will be conducted by debugging the code on PIC-C. The first
step will be to compile the code successfully by removing any syntax errors or basic
coding errors. As the main application of the microcontroller is to monitor the battery
and change the duty cycle of the SEPIC converter, this will be the main focus of testing.
Theoretical values of the generator voltage and battery charge will be inserted into
the code. The code will be run using those theoretical values and the test engineers
will make revisions to the program as necessary.
4. SEPIC Converter
The charge in the battery storage unit increases when the elliptical is operated and
decreases when it applies charge to the user’s electronic device. The SEPIC converter
regulates the flow of voltage into the battery to allow the battery to be charged at
maximum efficiency and safety. The converter uses duty cycle to regulate the voltage
and the test engineers must confirm the accuracy of this operation. Similarly to the
Buck Boost Converter, the SEPIC converter will be tested using three different sources
of analysis. The three methods of analysis will be electronic simulation, breadboard
circuit testing, and PCB testing.
The electronic simulation analysis will be conducted on Multisim or LTSpice in a
similar fashion to the Buck Boost Converter. In order for the SEPIC converter to
properly regulate the voltage flow, it first must be operating in the continuous mode.
A SEPIC converter operates in the continuous mode if the current through the
inductor on the source side never reaches zero. Electronic simulation analysis will
help the test engineers determine if the converter design will consistently operate in
continuous mode by observing the current plot through the inductor. Once the test
engineers confirm the continuous mode operation of the converter, the next step will
be to test the effects it has on the output voltage when the duty cycle is modulated.
The simulation analysis will conducted with different values of the duty cycle and the
output voltage will be observed to determine if the converter is working as intended.
The range of outputs desired from the SEPIC converter will range from 0V to 13V
because the voltage required to charge the battery will differ depending on the
remaining charge left in the battery. The test engineers will confirm through
electronic simulation that the converter is able to regulate the duty cycle to output a
voltage range of 1V – 13V.
The breadboard circuit will be constructed to verify the results obtained in the
LTSpice simulation. A visual inspection will be conducted on the completed circuit to
identify basic circuitry errors which include but not limited to short circuits, open
circuits, and incorrect components. An oscilloscope will be used to analyze the effect
of the duty cycle on the output voltage and confirm that the converter is operating in
the continuous mode. The waveform generator has a feature implemented that
allows the altering of the duty cycle and this will be used to observe the output
voltage. Test engineers will transfer the results obtained and store them in Microsoft
Excel for future reference.
The team will have the PCB constructed and will test the integrity of the final circuit.
Similarly to the first two methods, the effects of the duty cycle on the output voltage
and the consistent operation in the continuous mode will be confirmed by the testers.
5. LED Display
The main test required for the LED display will be to confirm that the LED display
accurately conveys to the user, the remaining charge in the battery. Each of the ten
LED bulbs will represent 10% increments of the battery charge, which totals to 100%
(Table 4). This means that the LED display requires at least 10% accuracy compared
to the actual value. The testing method will be very straight forward. The actual
energy of the battery will be measured and compared with the display. Any necessary
adjustments required to calibrate the display will be conducted.
Table 10: LED Display Chart for Battery Charge
LED Display Battery Charge

Light 10 (Green) 100%
Light 9 (Green) 90%
Light 8 (Green) 80%
Light 7 (Yellow) 70%
Light 3 (Red) 30%
Light 2 (Red) 20%
Light 1 (Red) 10%
6. Battery
The battery testing phase will include two parts. The first part will be analyzing the
capacity of the battery. The measured value of the battery capacity will be compared
to the theoretical value. The second part will be to determine if the battery is
properly charging and discharging energy. The second evaluation will be conducted
at the circuit level by taking measurements while it charges and discharges into the
simulation circuit.
7. Completed System
Once the entire design is completely constructed, a sweeping inspection will be
conducted on all the components that were previously tested to ensure the integrity of
each subsystem. The entire design will be tested as one unit with one input and one
output. If the output values are irregular, the test engineers will debug each subsystem
until the problem is isolated and repaired. The full system analysis will be continuously
conducted until the output consistently meets the expected results.
After the complete system operates in the desired state, the efficiency will be tested and
improved by the engineers. The efficiency of the design can be calculated simply by
comparing the input power to the output power. The team will continuously work on
improving the efficiency by methods such as reducing power losses in the circuit, reducing
code processing time to a minimum, and keeping an overall stable system.
V. FINAL DESIGN SYSTEM RESULTS

The design team was happy with the overall system performance. There were several
setbacks that were encountered during development of the control and output subsystem
but in the end the design met most of the initial goals that were set by the design team. The
individual performance of the subsystems follows.
2. Generator
4. LED Display
5. Battery Storage Unit
A. SPECIFIC SUBSYSTEM RESULTS
2. Generator
The Leeson CM31D17NZ26D generator was tested at two different speeds in order
to determine the target speed that would be necessary to maintain an output of 3.5
volts, the minimum required by the Buck Boost Converter.
Speed Voltage
490 3.59
1794 11.13
Linear Model of Voltage vs. Speed
The minimum speed required to maintain an input of 3.5 volts was 19 revolutions per
minute on the elliptical pedals. The elliptical contains an internal flywheel that turns at
a rate six times faster increasing the speed at this point to 114 RPM. The pulley system
then transfers this rotational motion to the generator further increases the speed by a
factor of 4.28 resulting in a final output speed of 487.92 RPM. This speed produces an
output voltage of 3.58 volts which is slightly above but within an acceptable range of
the minimum required input voltage to the Buck Converter. (Table 1)
Table 11: Minimum required speed

19 114 487.92 3.58
The minimum required speed was significantly lower than the average speed
achieved by a user on the elliptical during testing. Several users were asked to use the
elliptical for a one minute interval. The pedal rotations were counted and the average
calculated. The average speed achieved was approximately 60 revolutions per minute.
A speed well above the minimum required to power the system. (Table 2)
Table 12: Average speed attained

60 360 1540.8 9.69334
Our system required a converter to increase the input voltage from the generator to a
useable 12 volt output. After simulation of the circuit proved that the converter would
perform within the desired specifications we began to assemble the circuit. The design
team made several attempts at debugging the converter when it did not operate
correctly. Ultimately we contacted the manufacturer of the converter, Linear
Technology for technical support. After speaking to several technicians about the
particular converter that we were using it became clear that building the circuit
ourselves would be a project within itself. Linear Technology donated a demo board for
the LTC3780, the converter that we used in our design.
The Buck Converter requires a minimum input voltage of 3.5 volts in order to step up
the output to the desired 12 volt output necessary to charge the battery. The range of
voltages under which the converter would operate correctly was 3.49 to 25 volts. The
converter was rated for an input of up to 32 volts but was only tested to 25 volts to
lower the risk of damage to the converter. (Table 3)
Table 13: Buck-Boost performance
Input Voltage Output Voltage

3.48 V (Minimum) 12.02 V
25 V (Maximum) 12.02 V
Figure 21: LTC 3780
4. LED Display
The display circuit was adjusted to measure a range of 2.8 volts since the charge
range for lead acid batteries is within 3 volts of fully charged. The design was
modified to include two potentiometers that would adjust the brightness of the
display and the range of the operating voltage.
Figure 22: Display Circuit
Figure 23: Display Board

Voltage Range
Display Brightness
Figure 24: LED Display
5. Battery
The battery performed according to specifications charging and discharging
regularly. The battery is fully charged at 12.4 volts and considered discharged at 11.2
volts. No testing was done on the lifecycle of the battery so there is no data for the
expected lifetime.
VI. WORK BREAKDOWN STRUCTURE

To complete this project, there were five main stages of development. They were:
Research, Design, Purchase of Materials, Assembly, and Finalization. The research stage
included looking into existing products, contacting companies for consultation, and
exploring general design ideas. The design stage was the most creative step and consisted
of the team developing a concrete plan for the circuitry and setup of the project. The
material-purchasing stage consisted of ordering necessary pieces of equipment, and filing
reimbursement forms for our Associated Students Grant. In the spring, the team managed
the last two stages of the project (assembly of the design and finalization of reports and
presentation) The following list is a breakdown of tasks that was necessary for each stage.
A. Research
1. General Background Research
a. Existing Products
b. Marketability
2. Contact Companies
a. Set up Conference Call with Adam Boesel from MicroGym
b. Contact Hudson from ReRev.com
3. Research Design Ideas
a. Piezoelectricity
b. Generators (AC vs. DC)
B. Design
1. General Schematics of the Machine
2. Circuitry
a. PCB Board
b. FPGA
c. Multisim
3. Code-Writing
C. Material Acquisition
1. Cost-comparison shopping
2. Actual Purchase and Delivery of equipment
3. Record all expenses in an accounting file
4. File Reimbursement forms with Associated Students
D. Assembly
1. Build the Exercise Machine
2. Design and Test circuits
a. Simulations
b. Construction
3. Test of system
4. Debugging
5. Total system integration
E. Finalization
1. Finalize the Report and Project Presentation
2. Final design evaluation
3. Completion of Project
VII. RESPONSIBILITIES
To give each member of the Senior Design group the opportunity to contribute
equally, we divided the tasks listed above among each member of the team. For the first
stage, we decided that all of us will research different concepts together. The Final Stage
will also be a team effort and we plan to share the responsibility of tasks as they surface.
For the three middle stages of developments, we have broken down responsibilities into
two levels.
Each stage was managed by a different team member, who was responsible for
ensuring tasks are completed successfully. The different tasks in the stage were further
broken down among the team members.
VIII. BUDGET
A. Explanation of Expected Cost
Our final project cost is $549.95. This reflects the amount of money we have
actually spent on parts for the project. Revisions have been made to the more costly
components of the system. Originally we had intended to use a high end elliptical for the
design due to the fact that our target market is fitness centers or gyms that already have
multiple elliptical machines in use. Designing around the same type of machine you would
find in a gym would have been ideal but is not within the scope of what we could do with
the funds we have available. We acquired an elliptical for $150.00 that is a similar design
to the types of machines that we have found in local gyms. In addition, a few parts such as
the battery and the Microchip samples were donated to our project. Another decrease in
project cost is due to the fact that instead of sending the PCB off to be built, we decided to
construct it in the labs. With our AS Research grant of $1500.00, we would still have
$950.05 left for contingencies or additional parts. The following figures further illustrate
the breakdown of the final budget (Figure 17 & Table 7).
B. Figures
1. Pie Chart
Figure 25: Final Budget Distribution Pie Chart

46
Description Source Quantity Unit Cost Shipping Total Cost Order Date
The Power Workout Final Budget
The Power Workout
1 Elliptical Machine Private Seller, Craig's List 1 $150.00 $0.00 $150.00 11/21/2008
Permanent Magnet 12VDC Motor TENV 1/6hp
1800/3900 RPM 31GS Frame Leeson Electric Electric Motor WareHouse 1 $178.88 $13.85 $192.73 3/16/2009
2 Motor #M1120046
Linear Technology LTC3780EG#PBF: Buck
Newark.com 2 $17.30 $0.00 $17.30 3/16/2009
2. Budget Breakdown Table
3 Boost Controller
National Semiconductor LM3914N-1/NOPB:
Newark.com 2 $4.94 $0.00 $4.94 3/16/2009
4 LED Driver IC
5 AVAGO Technologies HDSP-4832: Bar Graph LEDNewark.com 2 $12.90 $0.00 $12.90 3/16/2009
6 Fairchild Semiconductor NDS9947: MOSFET Newark.com 5 $6.60 $0.00 $6.60 3/16/2009
Vishay Formerly International Rectifier
Newark.com 5 $2.10 $0.00 $2.10 3/16/2009
7 MBRS340TRPBF
8 STMicroelectronics 2N7002: MOSFET Newark.com 5 $0.21 $0.00 $0.21 3/16/2009
Rubber Wheel Cushion Tread, 3" x 15/16", Plain
McMaster-Carr 2 $3.78 $2.02 $5.80 4/16/2009
9 Bearing, 100# Cap
Conductive Rubber Wheel Cushion Tread, 3" x
Table 14: Budget Breakdown
McMaster-Carr 2 $6.92 $2.02 $8.94 4/16/2009

10 15/16", Plain Bearing, 100# Cap
Rubber Wheel Hard Tread, 3" x 15/16", Plain
McMaster-Carr 2 $4.58 $2.02 $6.60 4/16/2009
11 Bearing, 125# Cap
Trapezoidal Tooth Neoprene Timing Belt 3/8"
McMaster-Carr 1 $22.87 $2.02 $24.89 4/16/2009
12 pitch, Trade Sz 8171, 81.7" outer circle, 1/2"w
.375(L) Pitch, 24 Teeth, Polycarbonate Timing
SDP-SI.com 4 $60.92 $12.52 $73.44 4/16/2009
13 Pulley With Aluminum Insert
14 12V-55AH Battery Pack - Donated PowerStride Batteries 1 $0.00 $0.00 $0.00 5/2/2009
DVDP32 Power Inverter Target Entertainment-
1 $43.49 $0.00 $43.49 5/2/2009
15 Electronics
16
Total $549.95
C. Budget Changes
Over the past 8 months, the budget for this project has undergone numerous
changes. In October, the initial expected project cost was $4,481.16. Since the preliminary
design was made with the intention to design a system that would enhance existing
exercise equipment currently in use in fitness centers, the original estimate was very high.
The design team expected to buy new parts, and from initial research of typical costs, the
generator, PCB, and exercise machine would be very expensive. The average price for an
elliptical similar to the kind currently in use by gyms in the area is over $1000. Also, in
order to produce a product that would be even more appealing to fitness center owners,
our initial design incorporated a converter, a power generator, and an LCD Display into the
unit to eliminate the need for additional equipment. Designing a converter would require
the design of a second PCB board, and additional funds would have to be allocated for
possible future revisions of that board. Included in the original estimate was $1,081.86 for
an elliptical and $2,220.00 for the PCB boards alone.
The group was aware that $4,481.16 was an excessively high estimate, and soon
realized that enormous budget cuts were required in order to realistically be able to fund
the project. After receiving word from USD’s Associated Students that we had received a
research grant of $1,500. 00, the design group reviewed and cut down the budget. By the
Preliminary Design Presentation in December, the budget had been slimmed down to
$1400.00. One major difference was the purchase of an elliptical for $150.00, which we
found on Craig’s List and is very similar to the type of machine we were planning to modify.
Another factor that affected the change was the reevaluation of PCB costs. Although
$1400.00 is still a great amount of money, it would be sufficient to thoroughly complete the
design. However, there were still more changes to come.
In May, the team evaluated the final budget and found that the cost of materials
turned out to be $549.95. This is about $850.00 less than the Preliminary Design Estimate,
and $3,900.00 less than the Initial Estimate. The team was lucky enough to have a few
parts donated to the project, and designing and building the PCB in lab cut down on
manufacturing costs. In addition, cost comparison was used in order to decrease prices.
The final budget is not only well within the amount of our research grant, but it is also a
reasonable total that proves the design team’s planning paid off.
IX. SCHEDULE
A. Description of Process
Over the course of the past year, we have been planning, building, and testing our system
design. The Fall Semester was mainly a planning and organizational phase. We drew up the
plans for our design, determined exactly what materials were needed, and submitted proposals to
the Engineering faculty. We also did a formal proposal presentation to the faculty, and later
participated in the Engineering Open House in December. A few of the many department
requirements that we completed for the project included weekly progress reports submitted to
our faculty advisor, numerous drafts of our Project proposal, and extensions to our paper as we
progressed throughout the semester. All of this work prepared us well for the following stages
on the project which would take place in the spring.
Beginning in January, the group started ordering parts for the system and starting to piece
it all together. We developed a circuit design and began putting it together. We continued
submitting weekly progress report, and did another formal presentation. The advice we received
from the faculty during this presentation was invaluable, and we incorporated some suggestions
into our project. One of the major changes we made was slimming down our budget. Our initial
budget was so high that it would make such a project not only unrealistic, but unmarketable to
the gyms who might eventually be interested in such a design. Our expected budget at the
beginning of the spring semester was about $1400.00. However, we were able to find some of
the parts we needed for much less money than initially expected, and our final budget is about
$549.95. Our design is almost complete, and the only remaining portion we are working on is
the construction of the circuit. This Friday, May 8, 2009, we will be doing our final project
presentation at the Spring Engineering Open House, an event open to the entire campus.
B. Major Milestones
Major Milestones that we met:
October 21, 2008: Project Proposal Presentation
December 5, 2008: Preliminary Design Review
December 9, 2008: Submission of Preliminary Design Review Report
March 3, 2009: Submission of Final CDR
March 5, 2009: Critical Design Review by Engineering Faculty
April 21, 2009: Creative Collaborations at IPJ
May 8, 2009: Completion of Senior Design
C. Gantt Chart
On the following is a Gantt chart of the entire process of our senior design. The
milestones stated above are included in this Gantt chart and are represented by circled
diamonds.
Figure 26: Project Gantt Chart

X. PERSONNEL
A. ASSEMBLY STAGE MANAGER: Elizabeth Huber

Elizabeth has dealt with design development and management numerous times
during her time as an Engineering student. Through completion of various circuitry and
programming projects over the past years, she has learned the importance of organization
and attention to detail.
B. DESIGN STAGE MANAGER: Richie Sanchez

Richie has a very strong background in hardware development. His skills include
theoretical circuit design, computer simulation, and discreet circuit fabrication and testing.
He can also draw on experience from internships he has held with Stratagene technologies,
a division of Agilent Inc. and Remote Ocean Systems where he was able to work directly
with engineers on prototype design and testing.
C. SOFTWARE DEVELOPER: Shin Sato

As a diligent and confident worker, Shin has been able to complete the tasks assigned to
him over the years and be able to come up with solutions to many obstacles. He has
experience working with different types of programming software such as Matlab and
VHDL, allowing him to contribute to the project group. This makes Shin a great candidate
for supervising the software designing and troubleshooting aspect of the project.
XI. CONCLUSION
This report has laid out the major elements of the Power Workout’s design and
construction process. From planning proposals and organizing schedules to building
components, this was an incredible learning experience for the Senior Design Team. All of
the work that has been put into the project will contribute to success in future engineering
projects. This project has involved many different aspects of Electrical Engineering. It
incorporated parts of Circuit Design and Simulation, Electronics, Power, Programming, and
a little bit of Mechanical Engineering as well. Software was used that includes MultiSim
and Ultiboard. The team was able to practice researching materials and get a good feel of
what design projects will be like in the real Engineering world. We have learned an
incredible amount over the course of this project.
XII. REFERENCES
"California Fitness "Power by You" Concept." Motorwave. Feb. 2007. Motorwave. 22 Sept.
2008 <http://www.motorwavegroup.com/new/californiafitness/html>.
Barclay, Eliza. "Portland's Green Microgym Channels Human Exercise Power Into Electricity."
25 Aug. 2008. Treehugger. 1 Oct. 2008
<http://www.treehugger.com/files/2008/08/green-microgym.php>.
Rosenthal, Elizabeth. "Partying Helps Power a Dutch Nightclub." New York Times. 23 Oct.
2008. Rotterdam Journal. 2 Mar. 2009.
"Table 5. U.S. Average Monthly Bill by Sector, Census Division, and State 2006." Nov. 2007.
Energy Information Administration. 1 Oct. 2008
<http://www.eia.doe.gov/cneaf/electricity/esr/table5.html>.
Zarda, Brett. "Sweatin' for the Planet." Popsci.com. 18 July 2008. 1 Oct. 2008
<http://www.popsci.com/entertainment-gaming/article/2008-07/sweatin-planet>.
XIII. ACKNOWLEDGMENTS
Dr. Schubert – Thank you for your encouragement and invaluable advice. Without your
knowledge and support we would not be nearly as far in our project as we are today. Your
contribution to our design team and project development has made this a great
professional experience and will undoubtedly prove useful in our future careers.
John Crow – Thanks for the advice and help in constructing our mechanical design.
Dr. Huang – Your knowledge of mechanical engineering was a tremendous help to us in our
design of the mechanical portion of the lab. Thank you.
Engineering Faculty – Thank you for the invaluable advice and knowledge you have taught
us over the past few years. All the hard work and commitment you have put into our
engineering education has more than prepared us for the project we are completing today.
Associated Students – Thank you for the generous financial support you have given to our
project. The Associated Students Research grant we were awarded played a significant role
in successful completion of our design.
XIV. APPENDICES
Appendix A: Resumes
Appendix B: Mechanical Connection Schematic
Appendix C: Data Sheets
A. RESUMES:
Elizabeth A. Huber
5998 Alcala Park Unit 4020
San Diego, CA 92110
(805) 509-7433
elizabeth-09@sandiego.edu
OBJECTIVE
Assignment to a Senior Design team, for the purpose of using course knowledge to
design and develop a project in the field of electrical engineering
EDUCATION
Dual B.S./B.A. in Electrical Engineering, expected May 2010
Minor in Mathematics completed May 2008
University of San Diego (USD)
GPA: 3.0
Related Courses
Electrical Engineering: Programming, Circuits, Microcomputers, Electronics, Digital Logic
Design, Signals and Systems, Applied Electromagnetics, Communication Principles
and Circuits, Principles of Electrical Power
Mechanical Engineering: Mechanics, Statics, Intro to Thermal Science
Mathematics: Calculus I - III, Applied Math for Engineering I and II, Probability and
Statistics
SKILLS AND EXPERIENCE

Leadership
• Midshipman in the USD/SDSU NROTC program, served in various
leadership positions including squad leader and platoon guide
• Teachers assistant for Sophomore circuits class in Spring of 2008
Organizational
• Served as Assistant Personnel Officer in NROTC, helped organize and update
records for all members of the program
Design Skills
• Alarm Clock Programming Project for Digital Logic Design class in Spring 2008
• Thermostat Design Project for Digital Logic Design Class, Spring 2008
• NIFTY Project, designing a PB&J Sandwich machine in Spring of 2006
OTHER WORK EXPERIENCE

Parking Services Employee, University of San Diego, CA, November 2006 – Present
Food and Beverage Hostess, Walt Disney World Resort, Orlando, FL, Summer 2006
Dining Services Employee, University of San Diego, CA, Fall 2005
HONORS AND AWARDS

California Society of the Order of Founders and Patriots of America Award
University of San Diego Presidential Scholarship
REFERENCES Available upon request
Richie Sánchez
3803 Marquette Place #5P
San Diego, CA 92106
(562) 400-8427
richie-08@sandiego.edu
SUMMARY OF QUALIFICATIONS
I am a Senior level Electrical engineering student seeking a position within a progressive, forward thinking
company. I am a person with strong sense of responsibility, neat, efficient, and thorough. I have a cheerful
outlook, and a positive attitude. I am committed to completing tasks, attentive to time schedules, detail-
oriented, self motivated, well organized, and have a great ability to learn quickly.
STRENGTHS
• Electronics schematic drafting • Xilinx ISE 9.2i

• Electronic breadboards • Keil Microvision
• 8051 design architecture • Electronics Work Bench
• OrCad • Adobe Acrobat
• Visio • Microsoft (Word, Excel, Outlook etc.)
• VHDL • MatLab
• Electronic Testing instruments • Auto-CADD
(Oscilloscope, multimeter etc.)
WORK HISTORY
Aug, 2008 Entropic Communications

Present San Diego, CA
Position: Compliance Testing Intern
• Execute MoCA compliance testing on candidate devices based on MoCA test procedures
• Help resolve testing issues in the lab
• Provide reports on the executed test procedures
• Perform manual measurements (i.e., Ixia Traffic Generator, spectrum analyzer, and power meter)
June, 2008- Agilent Technologies

Aug, 2008 Stratagene Product Division
La Jolla, CA
Position: Electrical Engineer Intern
• Provide general engineering support to Product Development in the design and development of Agilent
products
• Model and analyze analog circuitry using OrCad.
• Electro-mechanical product development from conception to finished product, from component level thru
system integration
• Perform and Document Software Testing Protocols for product firmware development
• Design, model and analyze digital combinatorial and sequential circuits, including microprocessor systems.
• Assemble electro-mechanical prototypes
• Perform other duties as assigned
February, 2008- Remote Ocean Systems

June, 2008 San Diego, CA
Position: Electrical Engineer Intern
• Provide general engineering support to Product Development in the design and development and
maintenance of ROS products
• Electro-mechanical product development from conception to finished product, from component level thru
system integration
• Assemble electro-mechanical prototypes
• Provide electrical and mechanical troubleshooting
• Electronics schematic drafting
• Produce, assemble, modify, and maintain product research, processes and procedures
• Provide product training presentation
• Provide input for operation and maintenance manuals
• Perform other duties as assigned
August, 2006- Helix Water District

February, 2008 La Mesa, CA
Position: Engineering Intern
PRINCIPLE RESPONSIBILITIES:
• Inspect Project Plans/Ensure plans meet Water Agency Standards.

• Update asbuilt plans to reflect construction changes
• Research easement locations and boundaries using GIS and Metroscan.
• Create AutoCAD diagram of easements from legal documents.
• Assist Engineers/Right of Way technicians in recording and filing legal documents
• Update GIS data archives
• Distribute project plans to appropriate personnel
EDUCATION
University of San Diego

5998 Alcala Park
San Diego, Ca 92110
Cerritos College
11110 Alondra Blvd
Norwalk, CA 90650
Strathmore High School

22568 Avenue 196
Strathmore, CA 93267
REFERENCES FURNISHED UPON REQUEST

Shinichiro Sato
8930 Taurus Place
San Diego, CA 92126
(808) 255-7662
shinichiro-08@sandiego.edu
Education
Bachelor of Science Expected Graduation: June 2009
University of San Diego, San Diego, CA
Major: Electrical Engineering Major GPA: 3.0
Minor: Mathematics
Related course work:
• Material Science • Signals and Systems
• Electromagnetics • Electronics
• Microcomputers • Optoelectronics
• Electrical Power • Communication Principals
Design Experience
Multi-Stage Amplifier Spring 2007
• Designed a multi-stage amplifier using BJTs/FETs on a breadboard
• Took into consideration the stability, feedback, gain, high/low frequency, input/output
resistance and more during construction
• Tested and proved that the circuit meets the project requirements
Xilinx Stopwatch Spring 2007

• Used Xilinx program and Basys board to make stopwatch
• Will display time elapsed on 4 seven segment display
Mark III Robot Fall 2006

• Created the Mark III robot including soldering components to the motherboard
• Wrote the program to make the robot follow a line on the ground
Balsa Wood Bridge Spring 2006

• Built a balsa wood bridge then competed on efficiency and strength
Computer Skills
MathCAD Electronic Workbench
MATLAB AutoCAD
PIC C Compiler Xilinx
C++ Microsoft Office
Work Experience
University of San Diego Campus Card Office Student Worker 10/2004 – 06/2007
MobilePC Electronics Repair Technician 09/2007 - Current
B. MECHANICAL CONNECTION SCHEMATIC:
Welding
0.4" 0.25"
0.125"
2"
4"
7" 6.5"
2.5"
0.25"
Welding
C. DATASHEETS:

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The Power Workout:

Converting Exercise into

2. Electrical Generator ........................................................................................ 13

3. Input Power Conditioning ............................................................................ 15

5. Output Power Conditioning ......................................................................... 20

6. Battery Charge Display .................................................................................. 20

7. Battery System .................................................................................................. 22

B. Design Specifications ...................................................................................................... 23

2. Additional Generator ...................................................................................... 24

3. AC Induction Motor ......................................................................................... 24

3. Implementation Capabilities ....................................................................... 27

B. SPECIFIC STAGE REQUIREMENTS ............................................................................ 27

2. Buck Boost Converter..................................................................................... 28

4. SEPIC Converter ............................................................................................... 34

5. LED Display ........................................................................................................ 35

7. Completed System ........................................................................................... 36

V. FINAL DESIGN SYSTEM RESULTS ................................................................................................. 37

3. Buck Boost Converter..................................................................................... 38

4. LED Display ........................................................................................................ 39

VI. WORK BREAKDOWN STRUCTURE ............................................................................................... 42

1. Pie Chart .............................................................................................................. 45

2. Budget Breakdown Table ............................................................................. 46

C. Budget Changes ................................................................................................................ 47

Richie Sánchez .......................................................................................................... 54

Shinichiro Sato ......................................................................................................... 56

B. MECHANICAL CONNECTION SCHEMATIC ............................................................. 57

Figure 2: A 6Z 4-24DF05016 Polycarbonate Timing Pulley.............................................................. 10

Figure 3: 6484K166 Timing Belt .................................................................................................................. 11

Figure 4: Pulley System Steel Shaft ............................................................................................................. 12

Figure 5: Generator Design ........................................................................................................................... 14

Figure 6: CM31D17NZ26D SUB-FHP Low Rpm PMDC ....................................................................... 14

Figure 7: LTC3780 Buck-Boost Controller ............................................................................................... 16

Figure 8: PIC microcontrollers...................................................................................................................... 18

Figure 9: PIC16HV785 Microprocessor Functional Diagram ........................................................... 19

Figure 10: LM3914 Dot/Bar Display Driver ............................................................................................ 20

Figure 11: LM3914 Block Diagram ............................................................................................................. 21

Figure 12: HR 40-12 Battery......................................................................................................................... 22

Figure 13: Generator Test Setup ................................................................................................................. 23

Figure 14: Multisim Circuit of Buck Boost Converter .......................................................................... 30

Figure 21: LTC 3780 ........................................................................................................................................ 39

Figure 22: Display Circuit ............................................................................................................................... 40

Figure 23: Display Board................................................................................................................................. 40

Figure 24: LED Display .................................................................................................................................... 41

Figure 25: Final Budget Distribution Pie Chart ..................................................................................... 45

Figure 26: Project Gantt Chart ..................................................................................................................... 49

D. Global, Economic and Environmental Impact

growing concern over environmental awareness create an environment where the

F. Project Design Deliverables

III. SYSTEM DESIGN OVERVIEW

A. Power Workout Subsystems

Table 1: Dimensional Information of 2328T72

Diameter Width Axle Diameter Hub Length

Figure 1: 2328T72 Rubber Wheels with Metal

Figure 2: A 6Z 4-24DF05016 Polycarbonate

Table 2: Dimensional Information of A 6Z 4-24DF05016

Figure 3: 6484K166 Timing Belt

Table 3: Dimensional Information of 6484K166

Circumference Belt Width Pitch Size Number of Teeth

Figure 4: Pulley System Steel Shaft

High Potential Current Flow

Figure 5: Generator Design

Figure 6: CM31D17NZ26D SUB-FHP Low Rpm PMDC

Table 4: PMDC Per Phase Specs