Revista de Ciencias Tecnológicas (RECIT). Volumen 3 (1): 10-22
Revista de Ciencias Tecnológicas (RECIT). Universidad Autónoma de Baja California ISSN 2594-1925
Volumen 6 (4): e325. Octubre-Diciembre. 2023. https://doi.org/10.37636/recit.v6n4e325
1 ISSN: 2594-1925
Case studies
Design and implementation process of a pico-hydro power
generation system for teaching and training
Proceso de diseño e implementación de un sistema de generación de energía pico-
hidráulica para enseñanza y entrenamiento
Josefa Morales Morales1, Horacio Bautista Santos2,3 , Rafael Figueroa Díaz4, César Manuel Valencia
Castillo5, Mauricio Leonel Paz Gonzalez6, Isaac Compeán Martinez1, Pedro Cruz Alcantar1*
1Unidad Académica Multidisciplinaria Región Altiplano, Universidad Autónoma de San Luis Potosí UASLPUAMRA, Carretera Cedral
Km, 5+600 Ejido San José de las Trojes, Matehuala, San Luis Potosí 78700, México
2Tecnológico Nacional de México/ Instituto Tecnológico Superior de Chicontepec, Calle Barrio Dos Caminos No. 22. Colonia Barrio Dos
Caminos, Chicontepec, Veracruz 92709, México
3Tecnológico Nacional de México/ Instituto Tecnológico Superior de Tantoyuca, Desviación Lindero Tametate S/N, Colonia La Morita,
Tantoyuca, Veracruz 92100, México; horacio.bautista@itsta.edu.mx
4Departamento de Ingeniería Eléctrica y Electrónica, Instituto Tecnológico de Sonora, ITSON, 85130. Cd Obregón, México
5Coordinación Académica Región Huasteca Sur, Universidad Autónoma de San Luis Potosí UASLPCARHS, 79960 Tamazunchale, San
Luis Potosí
6Facultad de Ciencias de la Ingeniería y Tecnología (FCITEC), Universidad Autónoma de Baja California, Unidad Valle de las Palmas
Tijuana, Baja California, México
Corresponding author: Pedro Cruz Alcantar, Unidad Académica Multidisciplinaria Región Altiplano, Universidad Autónoma de San Luis Potosí UASLP
UAMRA, Carretera Cedral Km, 5+600 Ejido San José de las Trojes, Matehuala, San Luis Potosí 78700, México. E-mail: pedro.cruz@uaslp.mx. ORCID:
0000-0001-9363-494X.
Received: September 3, 2023 Accepted: November 22, 2023 Published: November 29, 2023
Abstract. - In Mexico the development of remote laboratories is incipient, in 2020 the National Council of Humanities, Sciences,
and Technologies (CONAHCYT) created a network of virtual laboratories with nine of its public research centers in order to
create a virtual space that enables the development of experimental and research activities in a distance modality. However,
access to virtual laboratories is limited only to its members, and the platforms are still under development. With this motivation,
this article presents a multi-institutional project for the design, development, and implementation of a pico-hydraulic system
for small-scale power generation for teaching and training purposes with the aim of responding to the current need for distance
or virtual teaching of practical knowledge due to the coronavirus disease (COVID‑19) caused by the SARS-CoV-2 virus. For
the development of the system, technological innovation tools (QFD, TRIZ) were used, with which the design requirements
were obtained considering the users (students and teachers) and the renewable energy-related competence of the curricula.
Finally, the satisfaction of the users (students and teachers) with the use of the designed system shows the advantage of
including it as part of the practical activities of the subjects to improve the development of power generation, transformation,
and transmission system projects.
Keywords: Applications of industry 4.0; Learning and training; Mechanical design; Pico-hydro systems.
Resumen. - En México el desarrollo de laboratorios remotos es incipiente, en 2020 el Consejo Nacional de Humanidades,
Ciencias y Tecnologías (CONAHCYT) creó una red de laboratorios virtuales con nueve de sus centros públicos de
investigación con el fin de crear un espacio virtual que permita el desarrollo de actividades experimentales y de investigación
en la modalidad a distancia. Sin embargo, el acceso a los laboratorios virtuales está limitado sólo a sus miembros y las
plataformas aún están en desarrollo. Con esta motivación este artículo presenta un proyecto multi-institucional para el diseño,
desarrollo e implementación de un sistema pico-hidráulico para la generación de energía a pequeña escala con fines de
enseñanza y capacitación con el objetivo de responder a la necesidad actual de enseñanza a distancia o virtual de
conocimientos prácticos debido a la enfermedad coronavirus (COVID-19) causada por el virus SARS-CoV-2. Para el
desarrollo del sistema se utilizaron herramientas de innovación tecnológica (QFD, TRIZ), con las que se obtuvieron los
requisitos de diseño teniendo en cuenta los usuarios (alumnos y profesores) y las competencias relacionadas con las energías
renovables de los planes de estudio. Finalmente, la satisfacción de los usuarios (alumnos y profesores) sobre el uso del sistema
diseñado muestra la ventaja de incluirlo como parte de las actividades prácticas de las asignaturas para mejorar el desarrollo
de proyectos de sistemas de generación, transformación y transmisión de energía.
Palabras clave: Aplicaciones de la industria 4.0; Aprendizaje y formación; Diseño mecánico; Sistemas
pico-hidráulicos.
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1. Introduction
The sustainability education relationship has
generated innovative approaches in education
with respect to social responsibility, the
reduction of environmental impact, the
application of modern technology, and the use of
renewable energies where the experiential study
of real or modeled situations must be privileged
in engineering education [1-5].
Energy production currently represents a social,
economic, and environmental challenge.
Although energy can be obtained from
conventional or renewable energy sources,
energy inequality in society will require in the
short term that each household produce its own
energy for consumption. To meet this challenge,
it is necessary to have well trained professionals
with good management of theoretical and
practical concepts of renewable energy,
especially those related to fluids [6,7].
Currently, the most common self-sufficiency
measures are through biomass, solar energy,
photovoltaic energy, wind energy, small scale
hydropower, and all their possible hybridizations
[8]. Hydraulic energy has been the most widely
used and exploited renewable energy in the world
for the production of electrical power, making up
more than 16% of the world energy matrix [9].
This power source can be converted into
electricity through a hydro turbine and electric
generator using large scale hydro resources to
maximize the efficiency of high head hydro
turbines [10].
The world trend of sustainable hydraulic energy
for electrical power generation is focused on the
use of very low head water resources due to (i)
the low negative impact they have on the
environment, (ii) the low cost to generate
renewable energy and (iii) the fact that it
contributes to the supply of electrical energy to
local or national consumers [11].
Small hydro plants typically have a generating
capacity of 10MW or less; mini hydro plant
capacity is less than 1MW; micro hydro is less
than 100KW; and that of pico-hydro is less than
5kW. A pico, micro, or mini hydroelectric plant
has a minimum water deposit, and its
implantation can be carried out in rivers,
irrigation canals, wastewater, or household water
discharges [12]. Currently, new types of turbines
are being developed that can be used in waters
with the presence of solids [13], such as drainage
or sewage water [14].
Micro hydro currently plays a very important
role in the use of renewable energy, and while a
large infrastructure and technology for power
generation has been developed, the current
challenge is storing the energy produced.
Pumped hydropower is an efficient way of
temporarily storing energy and requires
temporarily storing a large volume of water in an
upper reservoir and releasing it through turbines
to the lower reservoir to produce electricity
during periods of high-power demand [15].
Pumped hydro storage (PHS) accounts for more
than 94% of the world's installed energy storage
capacity. Despite the projection shown, small
scale water resources have been unattractive to
exploit, since low height turbines are unable to
maximize the energy absorbed to convert it into
electricity, along with the scarcity of
professionals trained in these technologies [8].
Neither education nor renewable energies have
been exempted from the technological
development caused by the fourth industrial
revolution or Industry 4.0 [17,21]. Monitoring
energy production has been very important for
renewable sources, in addition to measurement,
transmission and data processing technologies
that can feed information to virtual power plants
[11,23]. This has been achieved thanks to
Internet of Things or IOT systems. In this
context, the integration of digital technologies or
IoT in higher education has become an
opportunity for future engineers to be trained
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with appropriate technological tools. Through
IoT systems, an engineer may be able to gather
vast amounts of data from sensors and processes,
which can be used for optimization of
manufacturing processes and real time
monitoring and control applications [24,25]. The
inclusion of IoT projects focused on renewable
energy helps students to be prepared for
intelligent applications and to introduce a
multidisciplinary work environment for the
development of projects of all kinds.
IoT tools and the COVID 19 pandemic have
greatly triggered what is currently known as
Education 4.0 in order to cover the need for
distance learning [19,20]. Within these efforts for
distance learning is the development of
augmented reality laboratories, virtual
laboratories, or remote laboratories in order to
provide future engineers with practical, technical
knowledge or training as an opportunity for
experience [16,18]. In Mexico, the development
of virtual laboratories is incipient, which
represents a challenge for the attention of
distance students. In this context, this paper
presents the design and development of a pico-
hydraulic system for small scale power
generation for teaching and training purposes.
Innovative technology such as quality tools
(QFD), TRIZ tools and functionality analysis
were used to develop the system. For the
monitoring of the system, IoT tools were used.
Finally, the results show the degree of student
involvement and learning and identified areas of
opportunity to improve the curricula.
2. Materials and methods
2.1 Quality function deployment
(QFD)
QFD is a systematic deduction and analysis
methodology that prioritizes interpreting and
satisfying customer or market requirements
during the design and manufacturing process.
QFD promotes the interaction of design
stakeholders such as: engineers, technicians,
users, vendors, etc. The QFD approach is based
on the deployment of user expectations (the
''What'') in terms of design and production related
parameters (the ''How'') for the new product. This
process is represented by a succession of double
entry ''What/How'' tables that enable identifying
and prioritizing the correlations between the
inputs [26]. A crucial step during QFD is the
translation of customer needs into engineering
characteristics such as design, production, or
technological requirements [26,27].
The first matrix is called the "House of Quality"
(HoQ) and consists of the rows that contain the
relevant information for the client, and the
columns, which contain the corresponding
technical translation of their needs. In addition to
the "What/What" correlations, this matrix
facilitates integrating elements related to the
analysis of competencies and the identification of
contradictions among different product features
[28]. The main activities within the construction
of the HoQ are the documentation of the
environment in which the product is used, the
classification of the needs in a logical order and
the evaluation of the relative importance of those
needs. The understanding of client needs is
summarized in the product planning and the
identification of the technical requirements that
directly influence the satisfaction of said needs.
Typically, design teams have to base their
estimates on their own experience, intuition, and
determination [29].
2.2 Theory of inventive problem
solving (TRIZ)
The Theory of Inventive Problem Solving
(TRIZ) is the result of extensive research carried
out by Russian scientists headed by G. Altshuller
[30,31]. Thousands of patents from the former
Soviet Union from different areas of technology
were analyzed, which allowed to understand the
creation of a systematic process for the invention
of new systems and the improvement of existing
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ones [31]. TRIZ integrates a set of simple tools
to understand the problems and detailed
techniques for systems analysis [32].
The theoretical basis of the classic TRIZ is the
Patterns of Technological Evolution. Altshuller,
based on this discovery, developed a set of
Patterns that describe the evolution of
technology, as presented within the collection of
world patent literature [8]. TRIZ aims to
highlight both positive (helpful functions) and
negative (harmful functions) relationships
between components of a system and, more
importantly, uses function analysis as a means to
identify contradictions and ineffective, excessive
and harmful relationships in and around a
system. Among the main tools of TRIZ are the
following: i) 40 inventive principles, ii) nine
windows, iii) eight evolution trends of technical
systems, iv) Function analysis and substance
field analysis, v) 39 parameters of engineering,
vi) matrix of contradictions, and vii) ARIZ, the
Algorithm for Solving Inventive Problems,
among others [30-32].
2.3 Nine windows creativity technique
The nine windows or system thinking operator is
a technique for exploring systems and their
possible impacts by examining the past, present,
and future. Altshuller's idea was to combine the
technical evolution of a system from the past
through the present to the future or thinking about
time and scale to contextualize a problem and
find solutions [32]. This technique consists of
setting up a table with nine entries forming a 3x3
matrix, separated into three categories:
supersystem, system and subsystem in the three
time periods. The first step is to fill in the cells
with the descriptions corresponding to the
present for the three categories of systems, in
order to contextualize the problem addressed in
external and internal environments [33]. Second
is to fill in the rest of the cells analyzing its
historical trajectory and the desired future
progression. With the above, the temporal
evolution of the system environment is
considered, and the work group is required to
define and reconcile the system’s future
perspectives.
2.4 Functional analysis
The functional analysis aims to analyze the
interactions between all the components of a
system or the functions it must perform to meet
the established requirements or needs, keeping
the system from having components or
mechanisms with no function or that do not
respond to a system or user need [33]. Function
analysis helps bring to light hard to recognize
issues in problems. To formulate the problem
with the TRIZ approach, it is convenient to make
a functional description of the system under
development to define innovation directions
based on areas of opportunity identified for
improvement. The functional analysis technique
involves defining the primary useful function of
the product, that is, what the product is going to
do. The main function is then broken down into
subfunctions of the product and they are
represented in a diagram known as the functional
tree. The functional tree is a top-down
decomposition analysis of the primary useful
function.
2.5 Matrix of contradictions
Contradictions are a key point in TRIZ theory
when trying to increase the main function of a
system. They are considered the main agents of a
system’s technological evolution. These
contradictions can be arranged in a table called a
contradiction matrix used to resolve technical
contradictions through the 40 principles of
invention. This matrix is formed by relating the
39 engineering parameters located horizontally
and vertically [34]. The cells of the matrix
provide the principles that relate two parameters
so that when one of them improves, it does not
affect the other. With the above, the numbers
referring to the principles of invention that can be
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used to eliminate a given contradiction can be
found within the matrix. The use of the
contradiction matrix is intuitive and efficient for
solving a contradiction [35]. Tables 1 and 2
below show the 39 engineering parameters and
40 Altshuller inventive principles used in the
contradiction matrix.
Table 1. 39 engineering parameters
1.Weight of moving
object
2.Weight of nonmoving
object
3.Length of moving
object
4.Length of nonmoving
object
6.Area of nonmoving
object
7.Volume of moving
object
8.Volume of
nonmoving object
9.Speed
11.Tension, pressure
12.Shape
13.Stability of object
14.Strength
16.Durability of
nonmoving object
17.Temperature
18.Brightness
19.Energy spent by
moving object
21.Power
22.Waste of energy
23.Waste of substance
24.Loss of information
26.Amount of
substance
27.Reliability
28.Accuracy of
measurement
29.Accuracy of
manufacturing
31.Harmful side effects
32.Manufacturability
33.Convenience of use
34.Repairability
36.Complexity of
device
37.Complexity of control
38.Level of
automation
39.Productivity
Table 2. 40 inventive principles
1. Segmentation
2. Extraction
3. Local Quality
4. Asymmetry
5. Consolidation
6. Universality
7. Nesting (Matrioshka)
8. Counterweight
9.Prior Counteraction
10. Prior Action
11. Cushion in
Advance
12. Equipotentiality
13. Do It in Reverse
14. Spheroidality
15.Dynamicity
16.Partial or
Excessive Action
17. Transition into a New
Dimension
18.Mechanical Vibration
19. Periodic Action
20.Continuity of Useful
Action
21.Rushing Through
22. Convert Harm into
Benefit
23. Feedback
24. Mediator
25. Self-service
26.Copying
27.Dispose
28.Replacement of
Mechanical System
29. Pneumatic or
Hydraulic Constructions
30.Flexible Membranes or
Thin Films
31.Porous Material
32.Changing the Color
33.Homogeneity
34.Rejecting and
Regenerating Parts
35.Transformation of
Properties
36. Phase Transition
37. Thermal Expansion
38. Accelerated Oxidation
39. Inert Environment
40. Composite Materials
2.6 QFD and TRIZ integration
research
QDF and TRIZ integration for problem solving
has been widely reported in new product design
areas, among others [36-38]. The main advantage
of integrating both techniques is to meet client
needs efficiently and with the perspectives of
technological evolution of a system, allowing the
proposal of totally new solutions based on
knowledge of the system. QFD and TRIZ
interaction is very interesting because while QFD
identifies present needs, TRIZ identifies future
needs through patterns of technological evolution
[33]. Mainly, this integration occurs at the design
specification and decision-making stages. One of
the main contributions of the interaction between
QFD and TRIZ occurs at the top of the quality
house where negative correlations between
quality parameters desired for the design can be
identified [37]. With the above, the contradiction
matrix can be used to resolve these design
conflicts through the 40 principles of invention.
Additionally, in this work, to increase
interaction, the technical requirements or quality
characteristics were selected using 39
engineering parameters proposed by Altshuller
as a reference. The following figure shows the
QDF and TRIZ integration proposal used in this
work.
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Figure 1. QDF and TRIZ integration proposal used.
In the QFD and TRIZ integration proposal, user
or client demands and technical or engineering
requirements are placed in the QFD quality
house. The roof of the quality house will present
positive and negative interactions with respect to
the requested requirements that can be solved by
combining the QFD and the TRIZ. Other
important fac-tors to find a suitable solution are
the knowledge and experience of the work team.
Once the interaction of QFD and TRIZ was
defined, the methodological process to be
followed for the design and development of the
pico-hydraulic power generation system was
elaborated. The following figure shows the
proposal of the activities to be developed using
the QFD and TRIZ tools that go from the
definition of the problem to obtaining the final
prototype.
Figure 2. QFD -TRIZ methodological proposal
Work team
For the development of this work and in order to
collect the necessary information from university
institutions, the criteria of 28 participants were
counted among teachers and students, laboratory
technicians and vendors who are related to the
subject. In addition to the above, an exhaustive
search for patents and scientific articles was
carried out, which was complemented with a
benchmarking.
The universities and academic programs related
to this multi-institutional work are: mechanical
engineering (UASLP UAMRA - CARHS),
chemical engineering (UASLP UAMRA),
electronic engineering (ITSCHI), electronic
industrial engineering (ITSCHI), renewable
energy engineering (UASLP UAMRA) and
mechatronic engineering (ITSON, UASLP
UAMRA). Each academic program mentioned
above has its own objectives, courses and
policies, but all programs have a common
professional competency in energy or renewable
energy in their curricula. This professional
competence was generalized by the work team
as: ability to manage, analyze and develop
projects in energy generation, transformation,
and transmission systems.
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Table 3 shows the institutions that participated in
the development of this project.
Table 3. Institutions participating in the work team
City
Institution
Number of lectures
and students
Chicontepec, Ver. Mexico
Instituto Tecnológico Superior De Chicontepec (ITSCHI)
5
Obregón, Son. Mexico
Instituto Tecnológico de Sonora (ITSON)
5
Matehuala, SLP. Mexico.
Universidad Autónoma de San Luis Potosí Coordinación
Académica Región Altiplano (UASLP -UAMRA)
13
Tamazunchale, SLP. Mexico.
Universidad Autónoma de San Luis Potosí Coordinación
Académica Región Huasteca Sur (UASLP -CARHS)
5
3. Results
All information required to implement the nine
windows technique was gathered with input from
each institution and work team to contextualize
the study addressed in external and internal
environments in teaching hydraulic systems for
power generation at the engineering level. For the
development of this technique, the main system
was defined as a hydraulic system for power
generation, while the subsystem was all the
components or elements that allow the main
system function to be carried out, and the
supersystem was the environment or context
where the functions of the system are developed,
in this case teaching and training activities. The
nine TRIZ windows are shown in Table 4.
Table 4. Nine windows - hydraulic system for power generation
Manual labor
Small work groups
Incidence of local
knowledge
Limited training topics
Small work groups
Human-machine interface
Incidence of local knowledge
High demand for use
Difficult access for student use
Specialized training to operate
Incidence of global knowledge
Flexible usage platforms at the human-
machine interface
Large number of work groups or
unlimited students
Focus on sustainability
Virtual education environment
Better learning experience
E-Learning approach
Augmented reality environment
Virtual labs
Simple systems
Analog measurement
Large size and robust
Reconfigurable
Large-scale energy
production
In-person instruction Complex and
robust systems
Access to data locally through a
display
Not reconfigurable
Digital parameter measurement
Expensive equipment
Specialized maintenance
Large-scale energy production
Flexible, reconfigurable systems
Control of operating parameters via
internet
Remote data access via the cloud
Real-time access with audio and video
Small-scale energy production
Low cost
Use of smart devices
High-pressure hydraulic
pumps
Series piping circuit
Manual valves
Manual control
Industrial electrical
connection
Turbine
Electric generator
Analog sensors
Turbine generator brake system
Robust digital sensors
Hydro pumps
Series piping circuit
Central control
Central display
Adjustable frequency drive (AFD)
Industrial electrical connection
Desktop
Software
Smart sensors
Microcomputers
Micro or Pico hydraulic generator
Free software
Domestic electrical connection
Reconfigurable piping circuit
Video-Audio
Internet access
Cloud database
Past
Present
Hypothetical Future
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The main results obtained from the nine windows
will help the work team to identify the
requirements that can be included when
proposing a solution or offer several ideas or
reflections on the possible solution. These results
are found in the last column where the
hypothetical future for the hydraulic system for
power generation is located. Analysis of this
column shows (i) under subsystem, elements
such as microcomputers, free software, smart
sensors, internet access, among others., (ii) under
system, elements such as the use of Smart
devices, flexible reconfigurable systems, remote
access through the cloud, among others., and (iii)
under supersystem there are features such as a
focus on sustainability, incidence of global
knowledge, unlimited number of work groups,
among others. Without a doubt, technology and
development have caught up with us, and many
of the elements considered in the hypothetical
future of the system are currently being
developed and implemented, but not yet in a
generalized way, which offers an opportunity to
consider them for this work.
Now, we analyze the main functions required
when using hydraulic system for power
generation to draw up a hierarchical diagram of
functional requirements. With the above, the
work team will be able to propose a complete
design solution that includes the functional
requirements of the system. These functions are
everything that a user needs to be included in the
design to build functionality. For the purpose of
functional analysis, the users were defined as
teachers and students, and the essential activity
was energy production and teaching. The
functional analysis is shown in the figure below.
Figure 3. Functional analysis of the system
Like the nine windows of TRIZ, by identifying
the main functions of the system, it will be
possible to include everything that a user or
system needs to be included in the requirements
to increase the ideality and functionality of the
design proposal by the work team.
3.1 QFD and HOQ
With the information collected from the 9
windows technique and the functional analysis, it
was possible to determine the needs and
requirements of the clients (students and
teachers). The procedure to establish the
requirements is a dynamic analysis and a team
activity, for which the entire work team (5
universities, 28 people between students and
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teachers) participated. By consensus of the work
team, the quantified weight was assigned to each
of the requirements considered in order to rate
them and define which ones will be a priority in
the design stage. To qualify the weight of the
requirements, importance values of 5, 3 and 1
were proposed as established by the QFD
methodology, 5 being the most important and 1
the least important [39].
A satisfaction survey will be used to verify or
validate the requirements established by the work
team, since the information gathered is firsthand
or professional experience in the area. The
requirements are shown in table 5.
Table 5. Client requirements
Client requirements
Importance
Small-scale energy production
5
Reproduce processes
1
Adjustable-reconfigurable
5
Modular design
3
Students able to carry out training
5
Machine-user interface
1
Wide range of pressures and flows
5
Easy understanding of principles of flow, pressure, and power
3
Combination of different instruments to measure pressure, flow, and electrical power generated
5
Access to data in real time
3
Environment for smart devices
5
Visualize data locally (display)
1
Visualization and processing
5
Analog and digital data acquisition
3
Open software
3
Domestic type electrical connection
5
Accessible maintenance and operation
3
Low cost
5
3.2 Technical requirements
For technical or engineering requirements, the
work team translates the client's needs into an
engineering language. This is done so that, at the
design stage, designers have clearly defined
parameters and properties that must be included
in the innovative design proposal. To increase the
interaction between the QDF and TRIZ, an
attempt was made to relate the 39 engineering
parameters to the customer's requirements to
include them as technical requirements. These
parameters are undoubtedly very general, but
some can be considered for this study. For
example, the small-scale power production
requirement can be related to the Power
engineering parameter. Table 6 shows the
requirements related to the 39 engineering
parameters that were selected.
Table 6. Relationship of customer requirements with TRIZ engineering parameters
Small-Scale Energy Production - Power
Reproduce processes- Adaptability
Flexible-reconfigurable - Shape
Modular Design - Manufacturability
That allows the student to carry out training - Convenience of use
Machine-user interface, Convenience of use- Complexity
Wide range of pressures and flow rates - Pressure, amount of substance, measurement accuracy
Easy understanding of flow, pressure and power principles- Complexity, Level of automation
Combination of different instruments to measure pressure and flow- Level of automation
Analog and digital data acquisition - Level of automation
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With the above information, the work team was
able to declare the technical requirements
translated into engineering language. These
technical requirements are shown in Table 7.
Table 7. Technical or engineering requirements
Power
Adaptability
Shape
Automation level
Manufacturability
Convenience of use
Complexity
Access to data in real time
Pressure
Measurement accuracy
Amount of substance
Environment for smart devices (cell
phone, tablet, laptop)
Domestic type electrical
connection 110 V
Open software
LCD display
Visualization and processing of data in
the cloud
After the customer requirements and technical
requirements have been identified, the design
team proposed the following correlations for the
"What" / "How", between each customer need
and each engineering feature, being a 5 strong
correlation, 3 moderate correlation, 1 weak
correlation. Once the values of importance and
the values of the correlations have been defined,
the value of absolute importance (B) is calculated
as the sum of the product of the evaluation of the
clients multiplied by the weight corresponding to
the degree of dependency. The result is given at
the end of the quality house column and shows
the importance of the requirement, that is, the
priority quality characteristics for a customer.
3.3 Technical and competitive comparison evaluation
The House of Quality QFD tool allows direct
comparison of how a design or product stacks up
against competition in meeting customer
requirements. The design team, with input from
all members, identified several existing products
to be compared, typically the proposed product
and two or three other relevant competitors
[26,40]. One of the purposes of this phase is to
find out how the products of the competitors
compare with the requirements of the client, in
comparison with the product proposed by the
design team.
To carry out the competitive evaluation, three
commercial hydraulic systems for the generation
of commercial energy were taken as close to the
proposal of this work or to the equipment that the
participating universities have. The following
systems were considered competitors: Gunt HM
430C, Erides METP 10 and Edibon TPC. Once
the competitors have been identified, a table is
generated with the satisfaction of the customer's
requirements by each of the competitors and the
design team's proposal using a five-level scale
where 1=very low satisfaction and 5=very high
satisfaction.
The design quality house for the pico-hydro
power generation system proposed by the design
team is shown in the following figure.
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Figure 4. Design quality house for pico-hydro power generation system.
In the last section of QFD analysis, the
importance of all client requirements and the
contribution that each technical requirement
must meeting the client’s requirement is
analyzed. This final analysis is crucial for the
design since here the information obtained in the
evaluations of the other matrices is compiled and
the result of each technical requirement will be
assessed and finally, they are reordered to give
way to the design.
From the quality house results, especially the
results of absolute technical importance (B) and
priority, some requirements are more important
than others. This is quite similar to the
methodology, but despite its score, all
requirements are met and included in the design
generated by the work group. From the results of
technical importance, the following can be
recovered:
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1) The automation level technical
requirement ranked the highest with an
importance index 254 and a priority order
of 1. This requirement refers to the
combination of different analog and
digital instruments to measure pressure,
flow, and power. This means that in the
proposed design these elements must be
considered for the operation of the
system, and, in addition, this requirement
also impacts other requirements such as
the environment for intelligent devices or
data access in real time.
2) The technical power requirement
obtained a high importance index of 233
and a priority order of 2. This
requirement refers to small scale energy
production. Most of the decision making
regarding the design parameters of the
system depends on this requirement.
3) The technical requirement of data access
in real time obtained a high importance
index of 194 and a priority order of 3.
This technical requirement mainly
impacts how the user will interact with
the variables that have to be measured
during teaching or training of the system.
Finally, the remaining features were lower
priority, but will also be considered for the
system design proposal. As can be seen within
the house of quality in the competitive and
technical evaluation section, the design team's
proposal always remained superior to the
competitions in most aspects.
The interactions between the technical
requirements or quality features were set out on
the 'roof' of the house of quality where both
positive and negative correlations between
quality characteristics are established. These
interactions allow us to identify the
contradictions they may present. From the
analysis of the quality house, 15 strong positive
interactions, 21 moderate positive interactions
and 5 negative correlations were found. Without
a doubt, for the design process, all of them must
be taken into account; however, the main ones
that must be addressed are the negative
correlations. Negative correlations are not
necessarily all contradictory. For example, four
of these refer to Manufacturability with respect
to power, adaptability, pressure, and amount of
substance, and one with respect to the level of
adaptability and automation (software, intelligent
environments). In this sense, establishing
unjustified requirements of pressure, power,
amount of substance or adaptability will make
the manufacturability properties more complex,
it will be more expensive or the maintenance and
repair more complicated. Negative interactions
raise the need to act on conflicting technical
requirements. The following table shows the
negative correlations, the technical requirements
in conflict, and the inventive principles provided
by the matrix of contradictions.
Table 8. Negative correlations and inventive principles
Parameter
Correlation
Parameter
Inventive Principles
Power
Negative
Manufacturability
26 Copying,10 Prior Action,34 Rejecting and Regenerating Parts
Adaptability
1 Segmentation,13 Do It in Reverse, 31 Porous Material
Pressure
35 Transformation of Properties, 19 Periodic Action,1 Segmentation, 37
Thermal Expansion
Amount of
substance
29 Pneumatic or Hydraulic Constructions, 1 Segmentation, 35
Transformation of Properties, 27 Dispose
Free software
Negative
Smart Device
Environments
27 Dispose, 34 Rejecting and Regenerating Parts, 35 Transformation of
Properties
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Of the inventive principles shown in the previous
table, those that did not contribute to the work
team's proposal were discarded and some
creative ideas were generated for the conceptual
design of the system considering the fulfillment
of the functions and requirements of the system.
The principles used and the ideas generated are
shown in Table 9.
Table 9. Principles used in brainstorming
Inventive principles
Ideas generated
Frequency
1 Segmentation,
It can be considered a hydraulic circuit that can be disassembled with quick couplings,
divided into two sections that can be integrated as a series or parallel circuit.
Instead of having a single high-power and expensive hydraulic pump, two lower-cost
pumps can be placed, and a greater range of pressure and flow would be obtained.
3
10 Prior Action,
Use adjustable resistors for various load cases, adjust series or parallel circuits to produce flow
and pressure, select whether measured data will be displayed locally or via the internet
1
13 Do It in Reverse,
Use adjustable resistors for various load cases, adjust the system to work as a hydraulic circuit
only or as a power generation system
1
26 Copying,
Use inexpensive sensors or measuring instruments that are easily removable and
interchangeable, circuitry and inexpensive hydraulic connection accessories.
1
27 Dispose
Use inexpensive, short-lived materials, accessories, and sensors
2
34 Rejecting and
Regenerating Parts,
The system can be modified during its operation, either to work as a hydraulic system or
a power generation system through valves
The system can be modified during its operation, whether it works in series or in parallel
to obtain a wide range of pressures and flows.
2
35 Transformation of
Properties,
Flexibility, operating parameters such as pressure, flow or load can be changed.
The measured parameters can be visualized locally or via the internet
3
The system design proposal will be generated
through the global analysis of the results obtained
from the 9 TRIZ windows, the functional
analysis, the QFD and the ideas generated with
the inventive principles.
3.4 Preliminary design
Figure 5 shows the hydraulic circuit and the basic
components proposed for the pico-hydraulic
power generation system. Considering the ideas
generated above, a hydraulic circuit made up of
two sections that can function as a series or
parallel circuit was contemplated to have a
broader threshold of flows and pressures for the
electric generator. In addition, two lower cost
pumps were placed in the same way to have a
greater pressure and flow range. To modify the
system during its operation, either to work as a
hydraulic system or a power generation system,
valves and a bypass were used. Regarding the
sensors or measuring instruments, pressure and
flow sensors of different technologies were
placed.
Figure 5. Hydraulic circuit and the basic components of
the system.
Once the hydraulic circuit was defined, the
preliminary design of the pico-hydraulic energy
generation system was carried out. Figure 6
shows the design.
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Figure 6. Preliminary design of the pico-hydraulic power generation system.
Easily removable and interchangeable low-cost
sensors or measuring instruments, inexpensive
hydraulic connection hardware and circuitry
were used.
To carry out the construction of the system,
accessories and economic commercial
instruments were considered. The following
table describes the components used.
Table 10. Characteristics of the components used
Component
Description
G1/4 Pressure Transducer Sensor / Pressure Transmitter
Accuracy:1%FS, Pressure Range 0-1.2Mpa, Input 5V
Output 0.5-4.5V
F50-12V 10W DC Micro Hydro Generator.
Max. output voltage: 5V (1.2mpa)
Max. output current: 220mA (12V)
DIGITEN G1-1/2" G1.5" Water Flow Sensor
Flow range: 5-150L/min, Sensor: Hall effect, Max. current:10
mA (DC 5V)
Digital Pressure Gauge. Bourdon tube pressure gauge with digital
indicator
-100~0 kPa, 0.2%FS 0.4%FS
Dual scale pressure gauge. Bourdon tube pressure gauge
0-10BAR/PSI
Peripheral Water Pump (1 hp)
Flow Rate 45 LPM, 6 Bar
PVC piping, PVC ball valve, and accessories
Diameter 1 in
Panel Digital Dual Display Voltmeter Ammeter Current Meter
0-100V & 0-10A
Arduino and accessories
UNO R3
TDS-100H-M1/M2+S1/2 Handheld Ultrasonic Flow Meter Flowmeter
Clamp on Sensor
Flow Range: 0~±32m/s non-contact ultrasonic measurement.
Requirements such as low cost, maintenance,
modular design, type of electrical power, among
others, were considered in the pico-hydraulic
power generation system construction process.
The system consists of an electrical generator
coupled to a hydraulic circuit that can be
reconfigured to work in series or parallel
powered by two 1 hp hydraulic pumps. The
piping system, valves and accessories are made
of PVC, and a bypass was added in the electric
generator section to have the ability to configure
the system as a simple hydraulic circuit or as a
power generation system. Various measuring
instruments were placed throughout the system
to meet the automation requirements, such as
pressure gauges of various technologies, flow
meters, current and voltage meters. In addition,
an ultrasonic flow meter was integrated into the
module as an external accessory. The built
prototype is shown in the figure below:
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Figure 7. Pico-hydraulic power generation system final assembly.
To satisfy the requirement of displaying data
measured locally, Arduino boards and display
screens were used in each of the sensors. In
addition, to measure the power of the electric
generator, a digital current and voltage panel was
used. Regarding the automation level
requirements that contemplate access to
measurement data in real time, visualization, and
processing, free software and environment for
intelligent devices, a platform was developed
using the Internet of Things (IoT).
With the results, it was possible to carry out the
connectivity tests of the system with other users
remotely. The following figures show the
physical space where the system is located within
the thermofluids laboratory of the UASLP -
UAMRA campus in Matehuala SLP.
Figure 8. Physical space - Thermofluids laboratory of
the UASLP -UAMRA campus in Matehuala SLP.
The details of the system were able to be shared
online with students and teachers from the
different participating institutions using the MS
Teams virtual platform. The following figure
shows the link that was made:
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Figure 9. Virtual broadcast in MS Teams.
4. Discussion
It was possible to design, build and implement a
pico-hydraulic power generation system which
has the requirements requested by users (students
and teachers) verifying the effectiveness of the
proposed methodology process. In addition, IoT
accessories were used to measure the variables of
interest in the system, which are versatile and
inexpensive, such as Arduino systems, with
which can be used to visualize the data measured
in real time.
Undoubtedly power generation systems are not
new, Durrani. A.M [14] et al. used wastewater to
drive a micro-hydroelectric power plant where a
low head screw turbine was used to generate
power and Uchiyama.T [13] et at. developed
micro hydro turbine with excellent performance
in passing foreign matter included in the water
flow. Some studies on pico- hydro power have
been conducted such as Williamson, S. J [49] et
al. where they study pico- hydro power at low
head deriving six key experimental parameters
for a Turgo turbine and demonstrating that these
systems can be used efficiently at low head in a
variety of site conditions, Bozorgi, A [46] et al.
numerically studied invertible low drop potential
pico-hydro systems concluding that an axial
pump can function properly as a turbine in low
head pico-hydro power plants and Gaiser. K [42]
et al. studied the optimal parameters for the
empirical design of a low-cost pico-hydro power
plant for distributed power generation
applications. The most developed area currently
is design where Yahya, A. K [44] et al. developed
a pico-hydro generation system which is the
effective way to help remote communities by
generating electricity using water as the main
source to be used for small capacity equipment
such as motors and light bulbs, Cobb, B.R. [47]
et al. built a laboratory scale test device to test the
operational performance characteristics of
impulse turbines. The results highlight the
importance of proper system design and
installation and increase the knowledge base on
Turgo turbine performance that can lead to better
practical implementation in pico-hydro systems,
Zainuddin, H [48] et al. describe the design and
development of a pico-hydro generation system
using distributed household drinking water by
developing a small-scale hydroelectric
generation system using distributed household
drinking water as an alternative source of
electrical power for residential use and Gallego.
E [44] et al. designed a low-cost Turgo turbine
for a low head hydro system and experimentally
evaluated the operating parameters.
Most of the works that report pico-hydraulic
systems, these works are totally field,
Revista de Ciencias Tecnológicas (RECIT). Volumen 6 (4): e325.
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experimental, or totally theoretical
implementations that in general seek the design
of new turbines, optimization of design or
operating parameters. In the case of this study, it
is the design of a pico-hydraulic power
generation system that responds to the new
current context of distance education by COVID
19 and the use of renewable energies that are
required in academic programs in Mexico. The
methodology used can be reproduced by other
people who need to have a system like the one
presented for educational activities. Within the
capabilities of the pico-hydraulic power
generation system designed, there are endless
teaching and training topics in the areas of
mechanics, energy, and instrumentation, where
the system can play an important role in learning.
The satisfaction of the users of the pico-hydraulic
power generation system with respect to the
practice was measured through the questionnaire
shown in table 11. All the participants involved
in the project answered the questionnaire
obtaining as a result that most of the participants
totally agree or agree with the capabilities offered
by the system to support the practical distance or
face to face training, and that the requirements
established as design parameters are met.
Table 11. User satisfaction
Question
Totally Agree
Agree
Neutral
Disagree
Totally Disagree
The system was easy to use, and the virtual connection was adequate for the practice
9
14
5
0
0
Remote use of the system allows you to expand your knowledge in different areas of the
program curriculum
20
4
2
1
1
The picohydraulic generation system used in practice allows the practical learning by doing
in the current COVID-19 pandemic condition.
25
2
1
0
0
The picohydraulic generation system used in practice allows a more complete
understanding of hydraulic generation issues, internet of things and instrumentation through
data analysis in the cloud.
11
10
3
4
0
The practice was more accessible for data visualization and processing.
26
1
0
1
0
The picohydraulic generation system used in practice allows to reproduce processes
through its reconfigurable condition in the range of pressures and flow rates.
12
10
3
2
1
The practice carried out at a distance as training was significant
22
3
1
1
1
4.1. Principal contributions
The authors consider that the designed system
contributes to the expansion of infrastructure and
improvement of technology to provide clean and
more efficient energy to help the environment
through the training of professionals who are
trained in the generation of energy at small scale
and related parameters such as pressure, flow,
energy demand, monitoring, visualization. In
addition, the same micro-hydraulic systems are
used to store energy from renewable energies.
We believe that well trained professionals in the
above topics will have a great impact on the
inclusion of sustainability in society and its
execution in the development and
implementation of projects.
4.2. Research scope and limitations
A pico hydroelectric power generation system
was obtained for teaching and training purposes
that operates manually and with access to
parameter measurement through LCD displays.
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For the implementation of the system was
economical by using common materials, sensors,
and instruments. The designed system can be
easily restructured to simulate different cases or
conditions of pressure, flow or load demand. In
addition, it was found that a major limitation is
the manual operation of the hydraulic circuit
control valves, and there is still no data storage
and monitoring system through cloud platforms.
4.3. Applicability for teaching and training
With the support of the MS Teams platform, a
virtual session was held to show the operating
parameters of the pico-hydraulic energy
generation system, such as pressure, flow, and
voltage obtained in the electric generator, to
students and professors from the five
participating universities. The designed pico-
hydraulic power generation system is functional,
low cost and can be easily reproduced to be used
for teaching purposes.
The above limitations may be considered in
future work or improvements to the proposed
system.
4.4. Main findings
1) The result shows that the proposed approach
can achieve greater client satisfaction (students
and teachers), and that technical contradictions in
the development of the system can be overcome
by optimizing resources, costs, and the degree of
functionality.
2) The implemented IoT has an architecture that
can be adapted to different case studies through
simple modifications of the Arduino code and
hardware.
3) The implementation of the pico-hydraulic
power generation system can be done with
commercial, open source and relatively low-cost
cards, allowing students to redesign the
architecture of the platform to create different
configurations or load cases of complex systems.
4) The satisfaction of the users (students and
teachers) on the use of the designed system
shows the advantage of including it as part of the
practical activities of the subjects to improve the
‘ability to manage, analyze and develop projects
in energy generation, transformation, and
transmission systems'
5. Conclusions
With the integration of QDF and TRIZ tools it
was possible to design and build a pico-hydraulic
power generation system for teaching and
training purposes considering the requirements
of both the client and the engineering
requirements through a work team made up of
students and professors from four universities.
6. Authorship acknowledgment
Josefa Morales Morales and Pedro Cruz
Alcantar: Conceptualization, Project
administration, Review and Editing. Horacio
Bautista Santos, Rafael Figueroa Díaz, César
Manuel Valencia Castillo, Mauricio Leonel Paz
Gonzalez: Methodology, Review and Editing,
Supervision. Isaac Compeán Martinez: Review
and Editing, Supervision, Project
Administration.
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Derechos de Autor (c) 2023 Josefa Morales Morales, Horacio Bautista Santos, Rafael Figueroa Díaz, César Manuel Valencia Castillo,
Mauricio Leonel Paz González, Isaac Compeán Martínez, Pedro Cruz Alcantar
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