Group 1 Honda Generator-Design Revisions

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Design Revisions

The following are 3 design changes for the product at the system level. These changes address one or more of the following: global, societal, economic, or environmental concerns.

Revision 1

Two Pistons Instead of One

The piston is moved via the crankshaft. The piston is attached to the crankshaft via a piston rod, which connects the piston to the crankshaft, which converts the circular motion of the crankshaft into the up and down motion of a piston. The piston starts at the top, and then moves downwards to allow the engine to take in a cylinder full of a mixture of air and gasoline, this is also known as the intake stroke. The piston then moves back up to compress the fuel and air mixture to make the ignition more powerful. When the piston returns to its top position, the spark plug ignites the mixture by creating a spark. The mixture in the cylinder explodes forcing the piston to move downwards.

An additional piston would allow more gasoline to be ignited within a certain time frame, and therefore increase the output potential of the generator.

In order to make this design revision the crankshaft would most likely need to be reinforced to withstand the additional stress an additional piston connection rod would place on the crankshaft. We suspect that the crankshaft is comprised of primarily steel due to its texture, color, feel, and its low cost. Steel has an extremely high strength when compared to its cost. Steel has a tensile modulus of 29,000,000psi while only costing 580 cents per metric ton. We briefly looked at other materials, which could replace the steel used to construct the crankshaft, but very few materials have a higher tensile modulus. Beryllium, Tungsten, and Osmium are all materials, which have high tensile strengths when compared to steel, but to due their extreme costs are not feasible to use on a generator constructed for widespread use. Beryllium has a tensile modulus of 42,000,000 psi, which is high than that of steel’s, but costs $317,000 per metric ton, which if used to construct the crankshaft would make the generator unaffordable.

This design revision would have drastic impacts on the economic, societal, environmental, and global implications of this product.


This design revision would result in more electrical output energy being produced from the generator with a lower cost to the operator, since the crankshaft is turning not one piston, but two, which allows more gasoline to be ignited in the same time span resulting in a larger output of work in the form of electrical energy. Furthermore, since an additional piston is being added to the generator this will increase the overall cost of the generator to pay for its materials and construction.


This design revision would increase the potential demographic market, which would be interested in purchasing this generator because it would have a larger energy output, and could be used in more situations.


This design revision would be have numerous environmental impacts. One negative aspect of this design revision is the additional gasoline exhaust from burning additional fuel. This would result in the generator leaving a larger carbon footprint. The positive environmental impact of this design revision is that since the generator would be creating more electrical energy with the same amount of gasoline input. Consumers would require less gasoline per watt, which would ultimately result in fewer green house emissions per watt of electricity generated.

Revision 2

Addition of a Catalytic Converter

A catalytic converter helps to decrease the amount of toxic chemicals released by a internal combustion engine, these include Carbon Monoxide (CO), Nitrogen Oxides (2NOx), and unburnt hydrocarbons (CxH2x+2). The addition of a catalytic converter is not necessary by the standards of the EPA, but would be an environmentally friendly improvement. Catalytic converters are shown to reduce the toxicity of exhaust by up to 90%.


Catalytic converters are available to the consumer at around $150 on average, according to Froogle. considering that these are meant for large car engines and ours is only a small one cylinder engine our converter would be much smaller, so assuming one quarter the cylinders means the cylinder would be only one quarter the size this would make materials one quarter the cost, plus labor an educated guess of the price addition would only be about $50, or about 3.8% increase.


The addiction of a Catalytic Converter would also greatly increase the safety of the generator. this generator is not rated for inside use, but it hasn\'t been said in the directions that it is necessary to keep the generator away from open windows, thus some of the exhaust could be inhaled. also many times generators are placed between floors on a construction site, though the buildings are still skeletal the ventilation might not be perfect. with a Catalytic Converter installed the safety concerns in both these cases are virtually removed, because you would need to spend 10 times as long in contact with the exhaust in order to intake a dose that could adversely affect your health. the addition of a catalytic converter might also allow the use of running the generator safely in not well ventilated areas such as a garage. but this would require testing to prove.


The use of a catalytic converter would greatly reduce the pollution levels of the Generator. though it would not reduce the carbon footprint of the generator. rather it might increase it. also the disposal of the catalytic converter may release some chemical, but this will be minimal.

Revision 3

Change to Common Nut Size

Throughout the disassembly and reassembly process a constant problem arose, it was the constant switching of bolt, nut and screw sizes. In several cases of using small nuts, bolts, and screws, striping regularly occurred which led to the reassembly to be less than perfect. The design revision proposed is to make all nuts, bolts, and screws of universal sizes of around medium build. This revision would slightly change the outer size of the generator to fit bigger nuts, screws, and bolts in which smaller ones were used. The additional material used in the outer casing and the nuts, bolts, and screws will raise the cost of the amount of material used but will lead to quicker assembly in the shop and the ability to only have to order a small variety of nuts, bolts, and screws. This will allow for quick repairs when problems occur. Due to more materials being used the weight of the generator will grow in size. The additional weight of the generator will be greater.the e additional cost for the revision of the product will be higher but will reduce overhead of additional sizes of nuts, screws, and bolts along with assembly time. In the long run there will be less warranty repairs due to stronger connections. This will also expand the life of the product from the ability to take more punishment during use in heavy machining areas. Also, personal serviceability will be easier with the quick use of only one tool for most repairs. With the product now more durable, this will lead to Honeywell name to grow in respectability for their products.