Engineering Commons^™

Open Source Low-Cost Power Monitoring System, Shane W. Oberloier, Joshua M. Pearce

Department of Materials Science and Engineering Publications

This study presents an entirely open-source, low-cost power monitoring system capable of many types of measurements including both loads and supplies such as solar photovoltaic systems. In addition, the system can be fabricated using only open source software and hardware. The design revolves around the Digital Universal Energy Logger (DUEL) Node, which is responsible for reading and properly scaling the voltage and current of a particular load, and then serializing it via an on-board ATTiny85 chip. The configuration of the DUEL node allows for custom sensitivity ranges, and can handle up to 50 A and 300 V. Up to 127 …

Belt-Driven Open Source Circuit Mill Using Low-Cost 3-D Printer Components, Shane W. Oberloier, Joshua M. Pearce

Department of Materials Science and Engineering Publications

Barriers to inventing electronic devices involve challenges of iterating electronic designs due to long lead times for professional circuit board milling or high costs of commercial milling machines. To overcome these barriers, this study provides open source (OS) designs for a low-cost circuit milling machine. First, design modifications for mechanical and electrical subsystems of the OS Distributed 3-D (D3D) Robotics prototyping system are provided. Next, Copper Carve, an OS custom graphical user interface, is developed to enable circuit board milling by implementing backlash and substrate distortion compensation. The performance of the OS D3D circuit mill is then quantified and validated …

Fused Particle Fabrication 3-D Printing: Recycled Materials’ Optimization And Mechanical Properties, Aubrey Woern, Dennis Byard, Robert B. Oakley, Matthew J. Fiedler, Samantha Snabes, Joshua M. Pearce

Department of Materials Science and Engineering Publications

Fused particle fabrication (FPF) (or fused granular fabrication (FGF)) has potential for increasing recycled polymers in 3-D printing. Here, the open source Gigabot X is used to develop a new method to optimize FPF/FGF for recycled materials. Virgin polylactic acid (PLA) pellets and prints were analyzed and were then compared to four recycled polymers including the two most popular printing materials (PLA and acrylonitrile butadiene styrene (ABS)) as well as the two most common waste plastics (polyethylene terephthalate (PET) and polypropylene (PP)). The size characteristics of the various materials were quantified using digital image processing. Then, power and nozzle velocity …

Self-Sufficiency Of 3-D Printers: Utilizing Stand-Alone Solar Photovoltaic Power Systems, Khalid Yousuf Khan, Lucia Gauchia, Joshua M. Pearce

Department of Materials Science and Engineering Publications

A self-replicating rapid prototyper (RepRap) is a type of 3-D printer capable of printing many of its own components in addition to a wide assortment of products from high-value scientific or medical tools to household products and toys. There is some evidence that these printers could provide low-cost distributed manufacturing in underprivileged rural areas. For the most isolated communities without access to the electric grid, a low-cost alternative energy is needed. Solar energy can be harvested through a stand-alone photovoltaic (PV) power system specifically designed to match the needs of the RepRap. The voltage and current requirement for the printer …

Design Optimization Of Polymer Heat Exchanger For Automated Household-Scale Solar Water Pasteurizer, David C. Denkenberger, Joshua M. Pearce

Department of Materials Science and Engineering Publications

A promising approach to reducing the >870,000 deaths/year globally from unsafe water is flow-through solar water pasteurization systems (SWPs). Unfortunately, demonstrated systems have high capital costs, which limits access for the poor. The most expensive component of such systems is the heat exchanger (HX). Thus, this study focuses on cost optimization of HX designs for flow-through SWPs using high-effectiveness polymer microchannel HXs. The theoretical foundation for the cost optimization of a polymer microchannel HX is provided, and outputs are plotted in order to provide guidelines for designers to perform HX optimizations. These plots are used in two case studies: (1) …

General Design Procedure For Free And Open-Source Hardware For Scientific Equipment, Shane W. Oberloier, Joshua M. Pearce

Department of Materials Science and Engineering Publications

Distributed digital manufacturing of free and open-source scientific hardware (FOSH) used for scientific experiments has been shown to in general reduce the costs of scientific hardware by 90–99%. In part due to these cost savings, the manufacturing of scientific equipment is beginning to move away from a central paradigm of purchasing proprietary equipment to one in which scientists themselves download open-source designs, fabricate components with digital manufacturing technology, and then assemble the equipment themselves. This trend introduces a need for new formal design procedures that designers can follow when targeting this scientific audience. This study provides five steps in the …

Design Of Post-Consumer Modification Of Standard Solar Modules To Form Large-Area Building-Integrated Photovoltaic Roof Slates, Joshua M. Pearce, Jay Meldrum, Nolan Osborne

Department of Materials Science and Engineering Publications

Building-integrated photovoltaic (BIPV) systems have improved aesthetics but generally cost far more than conventional PV systems because of small manufacturing scale. Thus, in the short and medium term, there is a need for a BIPV mounting system that utilizes conventional modules. Such a design is provided here with a novel modification of conventional photovoltaic (PV) modules to allow them to act as BIPV roofing slates. The open-source designs for the mechanical components necessary to provide the post-consumer conversion for a conventional PV module are provided, and prototypes are fabricated and installed on a mock roof system along with control modules …

Ambiance-Dependent Agglomeration And Surface-Enhanced Raman Spectroscopy Response Of Self-Assembled Silver Nanoparticles For Plasmonic Photovoltaic Devices, Jephias Gwamuri, Ragavendran Venkatesan, Mehdi Sadatgol, Jeyanthinath Mayandi, Durdo O. Guney, Joshua M. Pearce

Department of Materials Science and Engineering Publications

The agglomeration/dewetting process of thin silver films provides a scalable method of obtaining self-assembled nanoparticles (SANPs) for plasmonics-based thin-film solar photovoltaic (PV) devices. We show the effect of annealing ambiance on silver SANP average size, particle/cluster finite shape, substrate area coverage/particle distribution, and how these physical parameters influence optical properties and surface-enhanced Raman scattering (SERS) responses of SANPs. Statistical analysis performed indicates that generally Ag SANPs processed in the presence of a gas (argon and nitrogen) ambiance tend to have smaller average size particles compared to those processed under vacuum. Optical properties are observed to be highly dependent on particle …

General Design Procedures For Airport-Based Solar Photovoltaic Systems, Anurag Anurag, Jiemin Zhang, Jephias Gwamuri, Joshua M. Pearce

Department of Materials Science and Engineering Publications

A source of large surface areas for solar photovoltaic (PV) farms that has been largely overlooked in the 13,000 United States of America (U.S.) airports. This paper hopes to enable PV deployments in most airports by providing an approach to overcome the three primary challenges identified by the Federal Aviation Administration (FAA): (1) reflectivity and glare; (2) radar interference; and (3) physical penetration of airspace. First, these challenges and precautions that must be adhered to for safe PV projects deployment at airports are reviewed and summarized. Since one of the core concerns for PV and airport symbiosis is solar panel …

Fabricating Ordered 2-D Nano-Structured Arrays Using Nanosphere Lithography, Chenlong Zhang, Sandra Cvetanovic, Joshua M. Pearce

Department of Materials Science and Engineering Publications

Recent advances in the use of plasmonic metamaterials to improve absorption of light in thin-film solar photovoltaic devices has created a demand for a scalable method of patterning large areas with metal nanostructures deposited in an ordered array. This article describes two methods of fabricating ordered 2D nanosphere colloidal films: spin coating and interface coating. The two methods are compared and parameter optimization discussed. The study reveals that:

• For smaller nanosphere sizes, spin coating is more favorable, while for larger nanospheres, the angled interface coating provides more coverage and uniformity.

• A surfactant-free approach for interface coating is developed …