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Development of Solar-Powered Water Pump with 3D Printed Impeller

  • Nelson S. Andres EMAIL logo
Published/Copyright: January 16, 2021
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Open Engineering
From the journal Open Engineering Volume 11 Issue 1

Abstract

This study discusses a solar-powered water pump system with 3D printed impeller which was developed to serve as water irrigation to small and medium farms in Bataan, Philippines. One kW solar PV system was used to power an electric motor that drives the centrifugal pump with impeller. In order to minimize the power consumption of the pump, the material of its impeller was changed from brass to plastic using 3D printing technology. The water system was also made automatic so that the water pump will run and stop at the desired schedule of the farmer. Furthermore, in order to provide power at night, storage batteries which are enough to supply the load, were incorporated in the system. Through a series of testing, it is concluded that it is more economical to use a 3D printed plastic impeller than metal impeller in watering small and medium farms considering that there were appreciative changes observed in relation to their water output and power consumption.

Keywords: Solar energy; water pump; impeller; PV system; 3D printing

1 Introduction

For crops to stay healthy and alive, water irrigation is highly needed. Through water pumps, the water is being transported from one place to another. Water pumps are widely used in the Philippines for irrigation purposes and centrifugal pumps are the most used because of its capability of transporting water at various capacity and elevation.

Investment costs for solar powered irrigation systems is dropping down and becoming viable option for farmers. In rural areas, solar powered irrigation are evidently being used where electric grid is not provided and diesel fuel is quite expensive. The first PV pumping systems used centrifugal pumps that are usually driven by a DC or AC motor.

3D printing, more formally known as Additive Manufacturing (AM), is already being adopted for rapid prototyping and rapid manufacturing [1]. AM or 3D Printing processes build parts by adding material one layer at a time. AM processes require no special tooling or fixtures, so initial setup costs are kept to a minimum. 3D Printing is predominately used with plastics and nowadays for metals [2]. Some technologies can produce parts from ceramics, wax, sand, and composites. In 3D printing, the machine operator first prepares the digital file and then sends it to the machine, where it is printed with little human intervention. When printing is complete, the part needs to be cleaned and post-processed, which is the most labor-intensive aspect of the 3D printing manufacturing workflow [3].

The 3D printing of water pump components can be an option for manufacturers and users who desire to improve the parts or components and to create the pump itself more efficiently and at a lower cost. Incremental costs are not increased to produce 3D printed pump components, hence it allows the manufacturers and users to experiment with complex designs or customizations because some of parts or components when broken or lost are currently unavailable on the market [4].

In the observation on the performance of parts or components of conventional centrifugal water pumps particularly the impeller, this part needs not to be made of metal even though it plays a vital part in the pump system. An impeller is a rotating component or part of a centrifugal pump which transfers energy from the motor that drives the pump to the fluid being pumped by accelerating the fluid outwards from the center of rotation The velocity achieved by the impeller transfers into pressure when the outward movement of the fluid is confined by the pump casing. An impeller is usually a short cylinder with an open inlet (called an eye) to accept incoming fluid, vanes to push the fluid radially, and a splined, keyed, or threaded bore to accept a drive shaft [5].

Generally, plastics have lower strength than metals but they have lower density and higher strains at failure. In some cases, plastics will have higher strength per unit weight than metals. Therefore, considering its lower cost and manufacturability with complex designs, plastics could have more advantages in many applications [6]. The impeller, in reference to its function and purpose, may be fabricated as plastic of lower density and high strains at failures. As a substitute to metal impeller, aside from lower cost and manufacturability, the plastic impeller lightened the load carried by the shaft which is driven by the motor. Thus, motor operating at lighter load consumes less electricity. However, sometimes motors are designed to be oversized depending on the application because sometimes they must accommodate peak conditions, such as when a pumping system must satisfy occasionally high demands [7].

The general objective of this study is to develop a solar-powered water pump for small and medium farms and ease small farm owners from spending at high electricity or gasoline bill consumed by their irrigation pumps. The research also aims to automate the water pump system and modify the impeller to minimize the power consumption of the motor. The vital results of this study could be highly significant and thoroughly beneficial to the farmers or farm owners. The automated water irrigation of the farm can be a big help to the production of crops. And due to the automation of the water irrigation, manpower is less needed in the process of watering the crops.

2 Solar-Powered Water Pump

Figure 1 depicts the battery-operated water pump system consisting of photovoltaic (PV) panels, charge control regulator with inverter, batteries, timer and water pump. The electric current produced by the PV panels during daylight hours charges the batteries, and the batteries in turn supply power to the pump anytime water is needed. Furthermore, during at night and gloomy periods the system, can still deliver a constant source of power to water the farms.

Figure 1 System Overview
Figure 1

System Overview

The solar-powered water pump can be operated manually or automatically through the use of time relay device. The hybrid inverter, on the other hand, has more technological functions than a regular inverter. This inverter has its own protection from short circuit, overloading and over-heating. It is also a smart technology because it can supply power which is directly coming from the solar panels and at the same time, charging the storage battery through the solar charge controller inside it. At the unavailability of the power from solar panels, it will automatically switch the source to the storage cells. To further protect the system from overcurrent, DC and AC circuit breakers were connected. The design of the prototype done in Autocad is depicted in Figure 2.

Figure 2 Design of Solar-Powered Water Pump System
Figure 2

Design of Solar-Powered Water Pump System

It is known that the production of energy of the solar PV depends mainly on the weather condition. To be able to compensate the poor production of energy at night, Gel type battery storage was incorporated in the system for reliability. The developed solar powered water pump system was able to irrigate the adopted farm anytime of the day and night. Excess generated energy was also used in household needs like in lighting, radio and charging of gadget.

In the developed solar powered water pump system as shown in Figure 3, the system pumps water automatically at pre-set time from the reservoir and transports the water to a farm of about 10-meter distance at normal pressure. In the Philippines, because of the usual hot weather, the adopted farm is being watered three to four times a day for optimum harvest.

3 3D Printed Water Pump Impeller

3D printing or additive manufacturing is a process of making a three-dimensional solid object of practically any shape from a digital model. 3D printers print objects from a digital template to a physical 3-dimensional object. The printing is done layer by layer using plastic, metal, nylon, and over a hundred other materials. Its applications are continually increasing and it's proving to be a very promising technology.

Formlabs Form 2 SLA 3D printer was used to 3d print the impeller. It has a class 1, 405 nm violet laser and a build volume of 145 × 145 × 175 mm. It has a laser spot size of 140 μm and a power of 250 mW. The printer can achieve printing resolutions (layer thickness) of 25, 50, 100 μm.

While for the material, Formlabs White Standard Greyscale Resins were used. The Grey Pro Resin, as commonly called, offers high precision, moderate elongation, and low creep. This material is great for concept modeling and functional prototyping, especially for parts that will be handled repeatedly [8].

The printed prototype from these materials has a matte surface finish, opaque appearance, and precise details. Moreover, Grey Resins are ready to use right off the printer and their neutral undertone also makes a great base for parts that will eventually be painted or undergo other finishing processes [9].

Figure 3 Developed Solar-Powered Water Pump as installed in a small farm in Bataan
Figure 3

Developed Solar-Powered Water Pump as installed in a small farm in Bataan

Commercially available 3D printers like Form 2 and Form 3 are consistently producing high-quality results with less time and effort. 3D printing the impeller was not difficult at all, in fact, it was easy and fast in three major steps. The printed plastic impeller is shown in Figure 4.

Figure 4 Metal and Plastic Impeller
Figure 4

Metal and Plastic Impeller

The first step in the 3D printing process conducted was the designing of the impeller 3D file using an ordinary CAD software. Then the CAD file was imported into the PreForm print preparation software which has the options for automatically orienting, supporting, and laying out the 3D models. The second step was the printing using the Form 2 printer. Its peel mechanism, wiper, and heated resin tank created a consistent, reliable print process of the impeller. Lastly, to come with best results and mechanical properties, all SLA parts were required with IPA rinsing, post-curing and post-processing.

4 Results

From several tests conducted using the prototype, parameters such as current in ampere, operating Voltage and flow rate were measured to support the claim of this study.

From the Tables 1 and 2 above, the average current consumption of the water pump motor with plastic impeller is 3.08 A with an average flow rate of 1.07 L/s. On the other hand, the average current consumption of the water pump motor with its original (metal) impeller is 3.64 A with an average flow rate of 1.10L/s. The current has decreased by 15.38%. At 220-V operating voltage, it follows that power consumption has also decrease by 15.38%.

Table 1

Testing the Pump using Plastic Impeller

Plastic Impeller
TEST Ampere Voltage Power Flow Rate
1 3.10 A 220 V 668.36 W 1.13 L/s
2 3.05 A 220 V 650.87 W 1.06 L/s
3 3.10 A 220 V 661.54 W 1.06 L/s
4 3.08 A 220 V 657.27 W 1.10 L/s
5 3.10 A 220 V 661.54 W 1.11 L/s
6 3.00 A 220 V 640.20 W 1.03 L/s
7 3.10 A 220 V 661.54 W 1.04 L/s
8 3.10 A 220 V 661.54 W 1.11 L/s
9 3.10 A 220 V 668.36 W 1.04 L/s
10 3.08 A 220 V 664.04 W 1.07 L/s
Table 2

Testing the Pump using Metal Impeller

Metal Impeller
TEST Ampere Voltage Power Flow Rate
1 3.62 A 220 V 780.47 W 1.11 L/s
2 3.65 A 220 V 786.94 W 1.09 L/s
3 3.60 A 220 V 776.16 W 1.10 L/s
4 3.62 A 220 V 780.47 W 1.13 L/s
5 3.70 A 220 V 789.58 W 1.10 L/s
6 3.63 A 220 V 774.64 W 1.10 L/s
7 3.68 A 220 V 785.31 W 1.09 L/s
8 3.66 A 220 V 789.1 W 1.11 L/s
9 3.63 A 220 V 782.63 W 1.11 L/s
10 3.61 A 220 V 778.32 W 1.11 L/s

In Table 3, at same volume of water being pumped and delivered to the farm, though the number of hours of operation was a little longer, the energy consumed using the plastic impeller was found to be lesser. Thus, it also follows that there will be cost reduction when the energy consumed is monetized at Php 10.00 per kW-hr.

Table 3

Summary of Output and Consumption

Material No. of hours operating Volume filled Energy Consumed Cost of Consumption
Metal 300.00 1188000L 251.16 kW-hr P 2511.60
Plastic 308.41 1188000L 218.48 kW-hr P2148.80

5 Conclusion

The general objective of this research is to ease the small and medium farm owners from spending in high electricity or gasoline bill consumed by their water pumps; through the development of solar PV powered water pump system with 3D printed impeller. This is attained through the following conclusions:

  1. The developed solar water pump system was able to irrigate the adopted farm anytime of the day and night. Excess generated energy was also used by the farm owner in his household needs like in lighting, radio and charging of gadgets.

  2. The current has decreased by 15.38% when the 3D printed plastic impeller was substituted to the original metal impeller of the water pump. By 3D printing the water pump component (impeller), the water pump itself was innovated into more electrically efficient machine and can be reproduced at lower cost.

  3. There was a slight change in the output volume of water pumped with the impeller changed into plastic. The pump with metal impeller can supply 1188000 liters in 300 hours while the modified pump with plastic impeller can supply 1188000 liters in 308.41 hours. However, the power consumption of the pump with plastic impeller, based on the measurement and computation, was found to be lower as compared to the power consumption of the pump with metal impeller.

  4. The 3D printed plastic impeller was found to be reliable and rigid to perform the function of a conventional metal impeller through the series of testing conducted. Though, small chipping and cracks were observed in the 3D printed plastic impeller after more than 300-hour run. It is suggested the use of Rigid Resin materials which have the highest modulus of all Formlabs materials and has great heat resistance and stability [10].

Acknowledgement

The 3d printers and 3d printing materials used in this study were provided by BPSU's Additive Manufacturing Research Laboratory (AMReL). AMReL is a joint project of the Department of Science and Technology - Philippine Council for Industry, Energy, and Emerging Technology Research and Development (DOST-PCIEERD) and the Bataan Peninsula State University (BPSU). The authors would like to thank Prof. John Ryan C. Dizon and Mr. Ray Noel M. Delda for assistance in 3d printing of the impeller.

References

[1] J. R. C. Dizon, A. H. Espera, Q. Chen, and R. C. Advincula, “Mechanical characterization of 3D-printed polymers,” Addit. Manuf., vol. 20, 2018.10.1016/j.addma.2017.12.002Search in Google Scholar

[2] J. R. C. Dizon, Q. Chen, A. D. Valino, and R. C. Advincula, “Thermo-mechanical and swelling properties of three-dimensional-printed poly (ethylene glycol) diacrylate/silica nanocomposites,” MRS Commun., vol. 9, no. 01, pp. 209–217, 2019.10.1557/mrc.2018.188Search in Google Scholar

[3] J. R. C. Dizon, A. H. Espera, Q. Chen, and R. C. Advincula,“3D-printing and Advanced Manufacturing for Electronics“, 2018.Search in Google Scholar

[4] https://www.yeggi.com/q/centrifugal+water+pump/Search in Google Scholar

[5] https://en.wikipedia.org/wiki/ImpellerSearch in Google Scholar

[6] https://www.3dhubs.com/knowledge-base/injection-molding-manufacturing-technology-explainedSearch in Google Scholar

[7] “Determining Electric Motor Load and Eflciency, Fact Sheet, A Program of the U.S. Department of Energy“, https://www.energy.gov/sites/prod/files/2014/04/f15/10097517.pdf, 2014.Search in Google Scholar

[8] https://formlabs.com/materials/engineering/Search in Google Scholar

[9] https://formlabs-media.formlabs.com/datasheets/Grey_Pro_Technical.pdfSearch in Google Scholar

[10] D. Kazmer, in:M. Kutz (Ed.), “Three-Dimensional Printing of Plastics, Applied Plastics Engineering Handbook – Processing, Materials and Applications“, A volume in Plastic Design Library, 2nd Edition 2017.10.1016/B978-0-323-39040-8.00029-8Search in Google Scholar
Received: 2020-04-30
Accepted: 2020-10-18
Published Online: 2021-01-16

© 2021 Nelson S. Andres, published by De Gruyter

This work is licensed under the Creative Commons Attribution 4.0 International License.

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https://doi.org/10.1515/eng-2021-0015
Keywords for this article
Solar energy; water pump; impeller; PV system; 3D printing
Creative Commons
BY 4.0

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  60. Predictive analysis of the impact of the time of day on road accidents in Poland
  61. User’s determination of a proper method for quantifying fuel consumption of a passenger car with compression ignition engine in specific operation conditions
  62. Analysis and assessment of defectiveness of regulations for the yellow signal at the intersection
  63. Streamlining possibility of transport-supply logistics when using chosen Operations Research techniques
  64. Permissible distance – safety system of vehicles in use
  65. Study of the population in terms of knowledge about the distance between vehicles in motion
  66. UAVs in rail damage image diagnostics supported by deep-learning networks
  67. Exhaust emissions of buses LNG and Diesel in RDE tests
  68. Measurements of urban traffic parameters before and after road reconstruction
  69. The use of deep recurrent neural networks to predict performance of photovoltaic system for charging electric vehicles
  70. Analysis of dangers in the operation of city buses at the intersections
  71. Psychological factors of the transfer of control in an automated vehicle
  72. Testing and evaluation of cold-start emissions from a gasoline engine in RDE test at two different ambient temperatures
  73. Age and experience in driving a vehicle and psychomotor skills in the context of automation
  74. Consumption of gasoline in vehicles equipped with an LPG retrofit system in real driving conditions
  75. Laboratory studies of the influence of the working position of the passenger vehicle air suspension on the vibration comfort of children transported in the child restraint system
  76. Route optimization for city cleaning vehicle
  77. Efficiency of electric vehicle interior heating systems at low ambient temperatures
  78. Model-based imputation of sound level data at thoroughfare using computational intelligence
  79. Research on the combustion process in the Fiat 1.3 Multijet engine fueled with rapeseed methyl esters
  80. Overview of the method and state of hydrogenization of road transport in the world and the resulting development prospects in Poland
  81. Tribological characteristics of polymer materials used for slide bearings
  82. Car reliability analysis based on periodic technical tests
  83. Special Issue: Terotechnology 2019 - Part II
  84. DOE Application for Analysis of Tribological Properties of the Al2O3/IF-WS2 Surface Layers
  85. The effect of the impurities spaces on the quality of structural steel working at variable loads
  86. Prediction of the parameters and the hot open die elongation forging process on an 80 MN hydraulic press
  87. Special Issue: AEVEC 2020
  88. Vocational Student's Attitude and Response Towards Experiential Learning in Mechanical Engineering
  89. Virtual Laboratory to Support a Practical Learning of Micro Power Generation in Indonesian Vocational High Schools
  90. The impacts of mediating the work environment on the mode choice in work trips
  91. Utilization of K-nearest neighbor algorithm for classification of white blood cells in AML M4, M5, and M7
  92. Car braking effectiveness after adaptation for drivers with motor dysfunctions
  93. Case study: Vocational student’s knowledge and awareness level toward renewable energy in Indonesia
  94. Contribution of collaborative skill toward construction drawing skill for developing vocational course
  95. Special Issue: Annual Engineering and Vocational Education Conference - Part II
  96. Vocational teachers’ perspective toward Technological Pedagogical Vocational Knowledge
  97. Special Issue: ICIMECE 2020 - Part I
  98. Profile of system and product certification as quality infrastructure in Indonesia
  99. Prediction Model of Magnetorheological (MR) Fluid Damper Hysteresis Loop using Extreme Learning Machine Algorithm
  100. A review on the fused deposition modeling (FDM) 3D printing: Filament processing, materials, and printing parameters
  101. Facile rheological route method for LiFePO4/C cathode material production
  102. Mosque design strategy for energy and water saving
  103. Epoxy resins thermosetting for mechanical engineering
  104. Estimating the potential of wind energy resources using Weibull parameters: A case study of the coastline region of Dar es Salaam, Tanzania
  105. Special Issue: CIRMARE 2020
  106. New trends in visual inspection of buildings and structures: Study for the use of drones
  107. Special Issue: ISERT 2021
  108. Alleviate the contending issues in network operating system courses: Psychomotor and troubleshooting skill development with Raspberry Pi
  109. Special Issue: Actual Trends in Logistics and Industrial Engineering - Part II
  110. The Physical Internet: A means towards achieving global logistics sustainability
  111. Special Issue: Modern Scientific Problems in Civil Engineering - Part I
  112. Construction work cost and duration analysis with the use of agent-based modelling and simulation
  113. Corrosion rate measurement for steel sheets of a fuel tank shell being in service
  114. The influence of external environment on workers on scaffolding illustrated by UTCI
  115. Allocation of risk factors for geodetic tasks in construction schedules
  116. Pedestrian fatality risk as a function of tram impact speed
  117. Technological and organizational problems in the construction of the radiation shielding concrete and suggestions to solve: A case study
  118. Finite element analysis of train speed effect on dynamic response of steel bridge
  119. New approach to analysis of railway track dynamics – Rail head vibrations
  120. Special Issue: Trends in Logistics and Production for the 21st Century - Part I
  121. Design of production lines and logistic flows in production
  122. The planning process of transport tasks for autonomous vans
  123. Modeling of the two shuttle box system within the internal logistics system using simulation software
  124. Implementation of the logistics train in the intralogistics system: A case study
  125. Assessment of investment in electric buses: A case study of a public transport company
  126. Assessment of a robot base production using CAM programming for the FANUC control system
  127. Proposal for the flow of material and adjustments to the storage system of an external service provider
  128. The use of numerical analysis of the injection process to select the material for the injection molding
  129. Economic aspect of combined transport
  130. Solution of a production process with the application of simulation: A case study
  131. Speedometer reliability in regard to road traffic sustainability
  132. Design and construction of a scanning stand for the PU mini-acoustic sensor
  133. Utilization of intelligent vehicle units for train set dispatching
  134. Special Issue: ICRTEEC - 2021 - Part I
  135. LVRT enhancement of DFIG-driven wind system using feed-forward neuro-sliding mode control
  136. Special Issue: Automation in Finland 2021 - Part I
  137. Prediction of future paths of mobile objects using path library
  138. Model predictive control for a multiple injection combustion model
  139. Model-based on-board post-injection control development for marine diesel engine
  140. Intelligent temporal analysis of coronavirus statistical data
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