3. Given 1978 O’Day 25’ Sailboat 1978 O’Day 25’ Sailboat

4. Design Criteria Originally equipped with 15 hp gas engine Originally equipped with 15 hp gas engine Required to convert to electrical motor Required to convert to electrical motor Design constraint: Design constraint: Engine is over powered Engine is over powered Charging system must be enough to recharge batteries for operation Charging system must be enough to recharge batteries for operation Motor must be able to push the craft from dock to position to sail Motor must be able to push the craft from dock to position to sail Must operate at 3 knots for approximately 30 minutes Must operate at 3 knots for approximately 30 minutes

5. Design Criteria Use Wind Generators, Solar Panels, Tow Generator or freewheeling to generate power for the battery Use Wind Generators, Solar Panels, Tow Generator or freewheeling to generate power for the battery Electricity must support all electrical systems required at night and during normal sailing operation (refrigerator, radio, lights, etc) Electricity must support all electrical systems required at night and during normal sailing operation (refrigerator, radio, lights, etc) Equipment may be replaced to optimize efficiency Equipment may be replaced to optimize efficiency 1978 sail boat optimized for today's products 1978 sail boat optimized for today's products

6. Areas of our company General Mechanical General Mechanical General layout of the system General layout of the system Hull and Propulsion Hull and Propulsion Resistance of hull and requirements to take boat through Resistance of hull and requirements to take boat through Electrical Electrical Charging components, batteries, proper charging procedures Charging components, batteries, proper charging procedures

7. Determining Forces on Hull Deciding what is required Deciding what is required Drag on the hull Drag on the hull Force due to acceleration Force due to acceleration Force due to waves in the water Force due to waves in the water FYI-3 knots is 5.06 ft/sec, we rounded to 5 ft/sec FYI-3 knots is 5.06 ft/sec, we rounded to 5 ft/sec

8. Determining Forces on Hull Required parameters Required parameters V is velocity in ft/sec V is velocity in ft/sec ρ is the density of water slug/ft^3 ρ is the density of water slug/ft^3 L is the length of the hull ft L is the length of the hull ft µ is the dynamic viscosity of water lb*sec/ft^2 µ is the dynamic viscosity of water lb*sec/ft^2 Draft=4.5 ft Draft=4.5 ft Beam=8 ft Beam=8 ft Mass=Displacement/32.2 Slugs Mass=Displacement/32.2 Slugs Acceleration Acceleration Decided to keep a constant acceleration at low acceleration (50 sec to move at max velocity a=.1 ft/sec^2 Decided to keep a constant acceleration at low acceleration (50 sec to move at max velocity a=.1 ft/sec^2

9. Determining Forces on Hull Force of the Waves Force of the Waves Strip theory (new computer data base to deal with this) Strip theory (new computer data base to deal with this) Cost $$$ and time were factors Cost $$$ and time were factors Decided that the waves would be Moderate (4.1-8 ft) Decided that the waves would be Moderate (4.1-8 ft) Velocity of the wave would be then 2.06 ft/sec Velocity of the wave would be then 2.06 ft/sec V=πH/T V=πH/T T is the period T is the period H is the height H is the height

10. Determining Forces on Hull ΣF=Fa+Fw+Fd ΣF=Fa+Fw+Fd We have functions for known variables We have functions for known variables These forces will effect the required torque of the propeller These forces will effect the required torque of the propeller

11. Development of spread sheet As can be seen we can replace these variables conveniently for others if we want to resize the ship, sea current, or acceleration As can be seen we can replace these variables conveniently for others if we want to resize the ship, sea current, or acceleration

12. Propeller The propeller has 2 functions velocity and thrust The propeller has 2 functions velocity and thrust We have a 12X9 folding propeller We have a 12X9 folding propeller Folds while sailing to reduce drag and enhance sailing pleasure Folds while sailing to reduce drag and enhance sailing pleasure Diameter=12 in Diameter=12 in Pitch=9 in Pitch=9 in Pitch is the distance that will produce a helix in 1 revolution Pitch is the distance that will produce a helix in 1 revolution =.75 ft/revolution =.75 ft/revolution

13. Velocity & The Propeller Slip is the amount of force that cannot be used due the propeller spin Slip is the amount of force that cannot be used due the propeller spin Sail boat propeller will have a 45% slip theoretical Sail boat propeller will have a 45% slip theoretical V required=V boat + slip V required=V boat + slip (i.e. at 5.0 ft/ sec, the propeller is required to act as if moving 9.09 ft/sec) (i.e. at 5.0 ft/ sec, the propeller is required to act as if moving 9.09 ft/sec) But we must increase our velocity as well, due to the fact of the incoming waves But we must increase our velocity as well, due to the fact of the incoming waves

14. Slip

15. Efficiency of the Prop Efficiency is a function of the slip and the pitch ratio (diameter/pitch) Must be added to the ΣF

16. Motor Selection PMG 132 Permanent Magnet Motor PMG 132 Permanent Magnet Motor Capability Capability –24V~72V –110 Amp Continuous Current –200 Amp 10 Minute Current Light Weight (24.8lb) Light Weight (24.8lb)

17. Advantages of PMG 132 Motor In comparison to the Briggs and Stratton ETEK: In comparison to the Briggs and Stratton ETEK: –PMG 132 has 50% higher power peak at the same Voltage. –PMG 132 is a “Pancake Style” Motor with dimensions of 222mm O.D. and 162.55mm Width compared to the ETEK dimensions of 254mm O.D. and 187.7mm width. –Cost Etek: $1199.00 Etek: $1199.00 PMG 132: $989.00 PMG 132: $989.00

18. 85% efficiency at Running Speed of required 5.067 ft/s 5.303hp to produce a Running Speed of required 5.067 ft/s Motor Curve from PMG

19. Peak Energy Consumed at 51s Energy Consumed Per Second Decreases at 52s. (5.067ft/s)

20. 85% of Battery Life Will be Remaining after 30min Drive Time Battery Life Will Be Depleted After 86min Drive Time

21. Controller AXE Performance Products used for SERIES Wound or Permanent Magnet Electric Motors AXE Performance Products used for SERIES Wound or Permanent Magnet Electric Motors

22. Controller AXE 4834 AXE 4834 24 – 48V 24 – 48V Current Limit: 300A Current Limit: 300A 5 min rating: 200A 5 min rating: 200A 1 hour rating: 135A 1 hour rating: 135A –Voltage drop @100A: 0.30V

23. Throttle Interface between driver and motor controller Interface between driver and motor controller Specifies amount of electricity to be sent to motor Specifies amount of electricity to be sent to motor

24. Throttle Curtis type Potbox potentiometer Curtis type Potbox potentiometer Designed to be easily connected to a foot pedal by cable Designed to be easily connected to a foot pedal by cable $85 $85

25. Electrical diagram for motor

26. Other components include: Other components include: – Toggle switch for forward/reverse – Contactor (battery disconnect, operated by controller) – Fuse – Ignition switch

27. POWER GENERATION AND ELECTRICAL SYSTEM

28. 1978 O’Day25

29. Distribution of Power MOTOR HOUSE WINDSOLAR FUEL GENERATOR AC GENERATOR BATTERIES WATER

30. House Amp Draw Appliance (DC Power) Volt power AmpsX Usage Hours/Day= Power Consumed Amp-Hours/Day Auto Pilot.5- 1.5Amps depending on trim 12 18 AM/FM/CD Radio1 2 2 Bilge Blower2.5 (15 min).25.625 Depth Sounder0.1 12 1.2 GPS0.1 12 1.2 Inverter (Cell Phone)0.3 2 0.6 Knotmeter0.1 12 1.2 Light, handheld spotlight4.8 (10 min) 0.16.768 Light, anchor (LED)0.1 8 0.8 Light, Port (LED)0.168 2 0.336 Light, starboard (LED)0.168 2 0.336 light, stern (LED).04-.25 2 0.5 Light, Masthead (LED).04-.25 0.5 0.125 Light, Foredeck lighting2 (15 min) 0.25.5 light, cabin courtesy lighting LED (5 fixtures).026(5) 4 amps with 2 fixtures 0.104 Compass0.1 2 0.2 Portable DVD player2.2 2 4.4

31. House Amp Draw Appliance (DC Power) Volt power AmpsX Usage Hours/Da y= Power Consumed Amp- Hours/Day If using Built in VHF radio Wind Speed Indicator0.1 2 0.2 Radio, VHF, receive1.5 7 10.5 Radio, VHF, transmit5 (15 min) 0.25 1.25 Radio, VHF, standby0.5 7 3.5 Total Amps/Day 48.38 If using Handheld VHF radio Radio, VHF, receive1.5 2 3 Radio, VHF, transmit5 0.25 1.25 Handheld VHF radio (M72) charger0.04125 8 0.33 Good for up to 20 hours use(90% standby) Total Amps/Day 37.71

32. Battery Power Our motor batteries will be powering a DC motor with a 48 volt, 110-amp draw once the motor is up to speed. Our system will be a 48V 280Ah bank, however most experts agree that marine batteries should not be run below 50% charge, thus leaving us with about 140Ah to work with. In our situation, we consider the batteries dead at 50%. Our propulsion team estimates that the batteries will be at 85% after powering the boat into a sailing position. Doing this allows us to have more power for returning and also providing less dependency on recharging tools while sailing.

33. Battery Schematic

34. Battery Selection Motor Batteries: (8x) Group 31, 140 amp hour, 12 volt, wet-cell, deep cycle marine battery (8x) Group 31, 140 amp hour, 12 volt, wet-cell, deep cycle marine battery Defender store (online): $111.27 each online 13.00" L x 6.75" W x 9.50" H, 63.40 Lbs. House Battery: (1x) Group 27, 110 amp hour, 12 volt, wet cell, deep cycle marine Battery Defender store (online): $82.75 each online 12.00" L x 6.75" W x 9.88" H, 51.00 Lbs. While wet cell batteries require more maintenance, however the cost played a larger role in selection. Compared to wet cell batteries, Gel-Cell batteries are roughly twice as expensive, and AGM are three times as costly. The house power, with our LED kit, will be drawing approximately 37 Ah. The available options gave us one 110Ah battery needed to power the house bank. We were originally planning a 36V system, however, we switched to a 48V system to allow for a 12V or 24V charging method.

35. Wind & Water Generator Constraints High output High output Low drag Low drag Limited space Limited space Low weight Low weight Marine use Marine use

36. Wind Generator Output Rutland 913 Weight13kg28lbs Turbine Dia.910mm35-7/8in Start up5knots Drag1lb per 1knot Wind @ 10knots1amp24hours Total24amp-hours Ampair 100 Weight12.5kg27lbs Turbine Dia.928mm36-1/2in Start up6knots Drag1lb per 1knot Wind @ 10knots0.5amp24hours Total12amp-hours

37. Wind Generator Rutland 913 Had highest output Had highest output Quiet in operation Quiet in operation Low wind start up Low wind start up Robust Robust

38. Wind Controller 24 volt 24 volt 2 battery bank options 2 battery bank options Shutdown switch Shutdown switch LCD display LCD display LED Light LED Light

39. Water Generator Output Aquair 100 Weight10kg22lbs Turbine Dia.280mm11in Start up3knots Drag20lbs @ 4knots Water @ 4knots0.5amp12hours Total6amp-hours Under Water 100 Weight10kg22lbs Turbine Dia.312mm12-1/4in Start up2knots Drag25lbs @ 4knots Water @ 4knots2amp12hours Total24amp-hours

40. Water Generator Under Water 100 Low start up speed Low start up speed High output High output Fresh water Fresh water

41. Water controller 24 volts 24 volts 3 battery banks 3 battery banks Will need a Ammeter Will need a Ammeter

42. Solar Power Generation Design Constraints Design Constraints  available sunlight  maximum amperage generation  limited mounting options  12 volt system  no energy loss from shading

43. Solar Panels Required Unisolar US-11 Unisolar US-11  located on sliding top of cabin  power = 11 watts  nominal voltage = 12 volts  operating voltage =16.5 volts  operating current = 0.62 amps  weight = 3.53 lbs  length = 19.34 in  width = 15.08 in  depth = 0.87 in  quantity = 2  warranty is ten years Unisolar US-64 Unisolar US-64  located on radar arch  power = 64 watts  nominal voltage = 12 volts  operating voltage = 16.5 volts  operating current = 3.88 amps  weight = 20.2 lbs  length = 53.78 in  width = 29.2 in  depth = 1.85 in  quantity = 1  warranty is twenty years

44. Solar Power Generated  Based on an average of 4.5 hours of sunlight per day, 5.58 amp-hours per day are generated from the two Unisolar US-11 panels 5.58 amp-hours per day are generated from the two Unisolar US-11 panels 17.46 amp-hours per day are generated from the one Unisolar US-64 panel 17.46 amp-hours per day are generated from the one Unisolar US-64 panel  23.04 amp-hours per day are generated for the total solar system

45. Preliminary Radar Arch Design

46. Power Inverter Selections Motor battery config. Motor battery config. –Output amperage –Output voltage –Input voltage –Max Power Output House Battery config. House Battery config. –Output amperage –Output voltage –Input voltage –Max Power Output

47. Type of Inverters Selected Motor battery config. Motor battery config. –Output Amps = 20 Amps –Output Volts = 48 Volts DC –Input Volts = 120 Volts AC –Power Output = 950 Watts –MSRP Value = $445.97

48. Type of Inverters Selected House Battery config. House Battery config. –Output Amps = 15 Amps –Output Volts = 13.6 Volts DC –Input Volts = 120 Volts AC –Power Output = 200 Watts –MSRP value = $99.97

49. Generator Selection Requirements Lightweight Lightweight Size Size The power required for the inverters must be at least 1150 Watts. The power required for the inverters must be at least 1150 Watts. Noise produced Noise produced Preferred diesel powered Preferred diesel powered

50. Type of Generator Selected Honda-EU2000i Honda-EU2000i –Weight = approximately 47lbs. –Size = 20.1”x11.4”x16.7” –Power = 1600 Watts, 120 Volts AC, at 13.3 Amps continuous. –Noise level = 59 dB at continuous load. –Fuel tank capacity = 1.1 Gallons –MSRP Value = $1,079.95

51. Reasoning Behind Selection Diesel generators are too heavy for an application on a 25’ boat. Diesel generators are too heavy for an application on a 25’ boat. The generator selected meets all of the design requirements and is the most efficient choice to use. The generator selected meets all of the design requirements and is the most efficient choice to use.

52. Project Progression Selection of solar charge controller Selection of solar charge controller Wiring diagrams Wiring diagrams Hardware attachment designs Hardware attachment designs Central control panel Central control panel Cost analysis Cost analysis

53. General Mechanical Progress Report

54. Battery Mounting

55. Extra 5 Batteries will be mounted in same area as existing batteries. Extra 5 Batteries will be mounted in same area as existing batteries. New Batteries Removed Existing Batteries

56. Mounting Considerations Weight of the Battery Weight of the Battery Dimensions of Battery Dimensions of Battery Dimensions of Engine Room Dimensions of Engine Room Material is Water Proof Material is Water Proof Federal Regulations Federal Regulations Symmetry of placement so boat does not lean front to back or left to right. Symmetry of placement so boat does not lean front to back or left to right.

57. Battery Mounting 18 Gal Gas Tank Full x 5.67lbs/gal gas = 102lbs 18 Gal Gas Tank Full x 5.67lbs/gal gas = 102lbs 4 more Batteries for engine at 63.4 = 253.6lbs 4 more Batteries for engine at 63.4 = 253.6lbs 1 additional battery for house at 51.0 lbs 1 additional battery for house at 51.0 lbs Gaining 202.6lbs in the engine room. Gaining 202.6lbs in the engine room.

58. Battery Mounting U.S. Coast Guard Federal Regulations. Battery must undergo a force of 90lbs for a duration of one minute and may not move more than one inch. On both vertical and horizontal axis.

59. Motor Mounting

60. Upper Intermediate Housing Input Shaft Seal has been removed

61. Lower Intermediate Housing Water Pump

62. Shift Rod and Water Passages Shift Rod Water Passages

63. Lower Unit Assembly Lower Unit Housing Gears Bearing Housing Propeller Housing has been repaired in this area

64. Progress to Date Difference of.019 Inch in these measurements

65. Progress to Date Chart locations and dimensions of holes in existing intermediate housing Chart locations and dimensions of holes in existing intermediate housing Determine parts needed to reassemble existing lower unit Determine parts needed to reassemble existing lower unit Order parts for lower unit Order parts for lower unit Devise a way to measure resistance in lower unit due to friction in bearings and seals Devise a way to measure resistance in lower unit due to friction in bearings and seals

66. Progress to Date Locate and obtain another lower unit Locate and obtain another lower unit Begin stress calculations Begin stress calculations Preliminary design of replacement components Preliminary design of replacement components Gather information for design requirements of components that need to be mounted Gather information for design requirements of components that need to be mounted

67. Crankshaft Modification Cut Here And here

68. Crankshaft Modification Secured by set screws Connecting Sleeve is fabricated Crankshaft is turned down and keyway cut into shaft

69. Motor Spacer Top View of Motor Spacer Locating Rings

70. Intermediate Housing Adapter Bottom of Motor Spacer Locating Rings Adapter Plate

71. Housing adapter Bolts to existing lower intermediate housing Motor spacer will allow mounting of different motors if desired

72. Lower Unit Modifications

73. Gas Engine Operation Water Enters Travels Across Bearing Housing Travels up through lower unit housing Fills Intermediate Housing Pumped throughout the engine for cooling

74. Modification of Housing Block off water intake port Drill Hole to allow oil to enter and fill cavity

75. Modification of Housing Block off water passage Drill Hole to allow water to escape cavity