UNIVERSITY OF SOUTH AFRICA

DEPARTMENT OF MECHANICAL ENGINEERING

MDP3701

Design Project Report

Assessment 4

Project title: Electricity Generation Using Weights

Surname and full names : Malvern Kgaugelo Malabane

Student Number
Date : 2023-10-08
Table of contents
1. Social impact and environmental solutions.......................................................................3
1.1. Social impact.....................................................................................................................3
1.2. Environmental solutions.................................................................................................3
2. Budget and Risk Analysis......................................................................................................3
2.1. Budget.................................................................................................................................4
2.1.1. Engineering BOM......................................................................................................4
2.1.2. Sales BOM..................................................................................................................4
2.1.3. Manufacturing BOM..................................................................................................5
2.1.4. Labour BOM...............................................................................................................5
2.2. Risk Analysis.....................................................................................................................6
2.2.1. Material use................................................................................................................6
2.2.2. Material reduction.....................................................................................................6
2.2.3. Product life extension..............................................................................................6
2.2.4. Recyclability...............................................................................................................7
2.2.5. Modularity...................................................................................................................7
2.2.6. Repairability...............................................................................................................7
2.3. Time and change management.....................................................................................7
2.4. Quality Assurance............................................................................................................8
2.5. Economic principles........................................................................................................8
3. References.................................................................................................................................8

Tables
Table 1: EBOM Table.............................................................................................................................4
Table 2: Purchasing/ Sales BOM............................................................................................................4
Table 3: Manufacturing BOM................................................................................................................5
Table 4: Labour BOM.............................................................................................................................5

Figures
Figure 1: Gantt Chart of time and change management........................................................................7
 1. Social impact and environmental solutions
1.1. Social impact
Electricity generation using weight technology can have both positive and negative
social impacts. It can promote health and fitness, encourage community
engagement, raise awareness about renewable energy, enhance energy access and
equity, and drive technological innovation in renewable energy. However, it also
presents challenges such as maintenance and safety precautions, potential
inequality in access, and displacement of traditional energy sector jobs. Additionally,
the impact on existing electricity infrastructure and the grid needs to be evaluated for
compatibility and reliability. Despite these potential benefits, it is crucial to consider
the challenges and implement strategies carefully to maximize the positive social
impacts. Therefore, careful consideration and addressing potential challenges are
necessary to maximize the positive social impacts of electricity generation using
weights.
1.2. Environmental solutions
The design can be used as renewable energy sources, providing access to electricity
during loadshedding. They also promote energy efficiency by minimizing energy
usage, reducing environmental impact. Distributed energy generation allows energy
production closer to consumption, reducing transmission losses and increasing
reliability. Education and awareness about the benefits of these machines can
encourage sustainable practices. Governments can implement incentives and
policies to encourage the adoption of these machines as a contingency plan during
loadshedding, such as tax benefits, energy-efficient equipment regulations, and
partnerships between energy providers and fitness centres. These solutions can
address societal and environmental challenges by promoting renewable energy,
enhancing energy efficiency, and 01 08
empowering local communities. 02

06
2. Budget and Risk Analysis
07
Item Description:
1. Frame 04
2. Pulldown bar
3. Motor and battery frame 03
4. 12V Motor 05
5. Seat
6. V-belt pulley system
7. Wire rope pulley system
8. Pulley bracket
9. Knee holder bracket
10. Weight stack
11. 12V battery

09 10
11
2.1. Budget
2.1.1. Engineering BOM
Table 1: EBOM Table

2.1.2. Sales BOM

Table 2: Purchasing/ Sales BOM
2.1.3. Manufacturing BOM
Table 3: Manufacturing BOM

2.1.4. Labour BOM

Table 4: Labour BOM
 2.2. Risk Analysis
2.2.1. Material use
The life cycle of electricity generation using weights design involves various stages,
including manufacturing, assembly, operation, support structures, maintenance, and
end-of-life. A combination of materials like steel, aluminium, carbon steel, rubber and
polyurethane are used in manufacturing to ensure durability of the design.
Assembling the design requires additional materials like bearings, fasteners, screws,
bolts, and connectors. These materials hold the different parts of the machine
together, ensuring stability and safety. During the operation of the design, the
weights provide the necessary force to generate electricity. The materials used in
this stage are the actual weights or counterweights, which are made of AISI 1020
low carbon steel.
Regular maintenance involves simple visual inspection, lubrication and cleaning
agents. End-of-life: When the machine reaches the end of its life cycle, materials
may be salvaged or disposed of. The materials used in this project can be salvaged
for future use and all materials that cannot be used and scrap are to separated
according to their types and send to recycling centre for disposal to minimize
environmental impact.
2.2.2. Material reduction
The design has been optimized to reduce material usage. This was achieved
through lightweight frame design with less welding requirement that contribute to
weight of structure, efficient manufacturing, integrated design, material recycling,
material substitution, and lifecycle assessment. Lightweight materials like
polyurethane, ABS, and acrylonitrile butadiene styrene composites reduce the
weight of the machine while maintaining structural integrity. Advanced technologies
like CAD and CAE were issued to minimize material waste. The design allows for
easier maintenance and replacement of specific components as required, prolonging
the equipment's life cycle. Alternative materials used with lower environmental
impact were used to reduce carbon footprint.
2.2.3. Product life extension
The life cycle of a gym machine can be extended through several strategies. These
include a robust design, regular maintenance, use of replaceable parts,
upgradability, user education, and refurbishment. Robust design ensures the
machine can withstand intensive use, while regular maintenance prevents wear and
tear. Replaceable parts allow for easy repair and replacement of worn-out
components. Upgradability allows for future enhancements without replacing the
entire unit. User education on proper usage and weight limits can prevent premature
wear and damage. Refurbishment and repurposing can extend the machine's
usefulness and value. These strategies help prolong the machine's lifespan, reduce
waste, and maximize its overall value.
 2.2.4. Recyclability
Recyclability significantly improves the life cycle of the design, this involves the
selected recyclable materials i.e., steel, aluminium, and plastics, designing
disassembly with disassembly in mind, clearly labelling and identifying materials,
partnering with recycling facilities, implementing take-back programs, and actively
promoting material recovery. By implementing these strategies, the design can be
efficiently recovered and reintroduced into the production cycle, reducing waste and
conserving resources. Implementing take-back programs also ensures proper
disposal of the design, ensuring they are sent to appropriate facilities. Recyclability
of the design contributes vastly to the sustainability of energy generation process.

2.2.5. Modularity
Modularity is a key factor in the life cycle of the design. It involves breaking down the
system into smaller, interchangeable modules that can be easily replaced or
upgraded. This design allows for flexibility and adaptability throughout the design's
life cycle. The electrical configuration is designed to suit several lat-pull machines
already existing and gym facilities. It simplifies maintenance and repair processes,
reducing the need for entire machine replacements. It also allows for easy
upgradability and scalability, extending the equipment's lifespan. The design also
offers customization options, enhancing user satisfaction and engagement. The
designs also reduce waste generation by promoting the replacement of individual
modules. End-of-life considerations ensure efficient recycling and disposal of
recyclable materials.
2.2.6. Repairability
Repairability is a crucial aspect of the electricity generation using weights design. It
was designed with repairability in mind, incorporating diagnostic features, ensuring
the availability of spare parts (off the shelf parts), provide repair training and support,
offering user support, and offer extended warranty and service contracts. By
prioritizing repairability throughout the life cycle will minimize downtime, reduce
waste, and extend the useful life of the equipment, promote sustainability and
customer satisfaction.
2.3. Time and change management.
 Figure 1: Gantt Chart of time and change management.

2.4. Quality Assurance

To ensure quality in the design, it involves understanding expectations and
specifications, developing a detailed design and engineering plan, conducting
testing, complying with safety standards, implementing continuous monitoring and
evaluation, and actively seeking input from all stakeholders. Understanding the
desired output, efficiency requirements, safety regulations, and guidelines, from
professors, and industry experts is crucial. Regular inspections, performance testing,
and feedback loops will be implemented to identify deviations from expected
standards. Collaboration and feedback from all stakeholders will help identify
potential improvements and meet industry standards.
2.5. Economic principles
The design considers economic principles, including short-term cost versus long-
term value. This includes evaluating the initial investment, operational costs, and
long-term benefits of the design. A comprehensive cost-benefit analysis was
conducted, considering both tangible and intangible benefits, such as environmental
impact i.e., materials used and their recyclability and disposal methods. By applying
these principles, the project's economic viability and sustainability can be ensured,
aligning with the project's overall objectives.

3. References
[1]. https://www.safasteel.com/tools/Tools_SteelGrades.html (accessed Oct.
05, 2023)
[2]. https://www.youtube.com/watch?v=GX1G6Wo7vVY (accessed Oct. 03,
2023)
[3]. https://www.powertransmission.com/articles/993-guide-to-v-belt-selection-
and-replacement#:~:text=The%20tensile%20cord%20is%20the,can
%20handle%20heavier%20shock%20loads. (accessed Oct. 06, 2023)
[4]. https://www.steelwirerope.com/WireRopes/Galvanised/6x19-fibre-core-
wire-rope.html (accessed Oct. 06, 2023)
[5]. https://www.skfptp.com/CategorySearch/Index/2 (accessed Oct. 06, 2023)
[6]. https://www.siemens.com/global/en/products/drives/electric-
motors.html(accessed Oct. 07, 2023)