UNIVERSITY OF SAN CARLOS

School of Engineering
Department of Mechanical and Manufacturing Engineering
Talamban, Cebu City

APPROVAL SHEET
Name of Candidates:

Surname

Fabian

Jake Floyd

G.

Paquibulan

Jason

S.

Saut
First Name

Bonifacio
M.I.

R.

Major : Bachelor of Science in Mechanical Engineering

Project Title

: Design, Fabrication and Testing of a Hybrid Solar

Powered Rotary Hydroponic Gardening System

Date of Defense

:
PROJECT EXAMINATION COMMITTEE

Dr. Edwin A. Carcasona, Ph D. PME

Committee Member

Dr. Michael E. Loretero, Ph D.

Committee Member

Engr Jose Arvin S. Tordillo

Committee Chair
Engr. Joey Pastoril, PME
Thesis Adviser

Dr. Ronald M. Galindo, Ph D.

Department Chairman
1

TABLE OF CONTENTS

TABLE OF CONTENTS................................................................................................................ii
LIST OF FIGURES ...................................................................................................................... vi
LIST OF TABLES ..................................................................................................................... viii
NOMENCLATURE ..................................................................................................................... ix
DEFINITION OF TERMS ........................................................................................................ ..xii
1. THE PROBLEM AND ITS SETTING................................................................... 1
1.1 INTRODUCTION......................................................................................................................1
1.2 STATEMENT OF THE PROBLEM ........................................................................................2
1.3 OBJECTIVES .......................................................................................................................... 3
1.4 SIGNIFICANCE OF THE STUDY .........................................................................................3
1.5 SCOPE AND LIMITATIONS OF THE STUDY ....................................................................4
1.5.1. SCOPE.4
1.5.2. LIMITATIONS....4
2. THEORETICAL BACKGROUND ................6
2.1 Hydroponics........................................................................................................................ 6
2.1.1 Hydroponic Techniques..........................6
2.1.1.1Wick System.............................6
2.1.1.2 Water Culture...................................6
2.1.1.3 Ebb and Flow- (Flood and Drain)............................7
2.1.1.4 Drip Systems Recovery/ Non-recovery...............................7
2.1.1.5. Nutrient Film Technique.............................7
2.1.1.6 Aeroponic.................................7
2.1.2. Hydroponic Growing Media..............................8
2.1.2.1 Coconut Coir................................8
2.1.2.2 Perlite...............................8
2.1.2.3 LECA...............................8
2.1.2.4 Rockwool.................................8
2.1.3 Lighting...............................9
2

2.1.4 Hydroponics Nutrient Solution...............................9

2.1.5. Aeration..................................9
2.2 Water and Soil Drawbacks in conventional Farming........................10
2.3 Starting Dimension................................11
2.4 Stress Analysis...............................11
2.4.1 Shear-Moment Diagrams..............................11
2.4.2 Flexural Stress...............................13
2.5 Motor......................................................................13
2.6 Chain Drive................................................................16
2.7 Fluid Flow..........................17
2.8 Pump......................................18
2.8.1 Pipeline with Pump...............................18
2.9 Grow Lights...............................................................19
2.10 Mass and Density Relationship................................................20
3. REVIEW OF RELATED LITERATURE
3.1 Soil Degradation in the Philippines...........................................21
3.2 State of Water Availability in the Philippines...........................21
3.3 Plant Nutrient Requirements......................................................22
3.4 Dissolved Oxygen......................................................................22
3.5

Pechay

Production......................................................................23
3.6Comparison

of

Plant

Requirements

............................................23
3.7

Rotary

plant

growing..................................................................24
3.8

Nutritional

and

Sensory

Qualities

of

Hydroponic

and

Soil-grown

Produce...................24
3.9

Economic

Impact

Hydroponics..............................................25

of

4. METHODOLOGY ................................................................................................................... 27
4.1 Research Process Flow Scheme..
27
4.2

Design

of

Hybrid

Solar

Powered

Rotary

Hydroponics

Gardening

System...29
4.2.1 Design Conception....29
4.2.1.1 Conceptualization of the Entire Hybrid Solar Powered Rotary Hyrdroponics
Gardening System..30
4.2.1.2

Conceptualization

of

the

Rotary

Hydroponic

Garden

Unit...32
4.2.1.3 Conceptualization of the Irrigation System..40
4.2.1.4 Conceptualization of the Housing.43
4.2.2 System Operation..44
4.2.3 Strength Analysis..45
4.3 Material Selection and Procurement..48
4.3.1 Rotary Cylindrical Unit Material..48
4.3.2

Support

Material...

.50
4.3.3 Reservoir Material.
51
4.3.4 Piping Material..51
4.3.5 Housing Materials.53
4.3.6

Fabrication

Equipment

and

Materials..

..55
4.4 Equipment Selection and Procurement...
57
4.4.1

Aerator

Unit..

.58
4.4.2 Central Light Source..
58
4.4.3 Motor.59
4

4.4.4 Chain Drive: Roller chain and Sprocket....

.64
4.4.5

Piping

System...

.67
4.4.6 Pump.....67
4.4.7 Roller.71
4.4.8 Other Machine Elements...72
4.4.8.1 Springs....72
4.4.8.2 Bearings..73
4.4.8.3 Screw..73
4.4.8.4 Bolt and Nut
73
4.4.9

Solar

Power

set..74
4.4.9.1 Solar Panel..74
4.4.9.2

Storage

Battery..

..75
4.4.9.3

Wiring

and

Extension..75
4.4.10 Measuring Instruments....75
4.4.10.1

Thermometer...

..75
4.4.10.2 Psychrometer....75
4.4.10.3
Ruler..75
4.4.10.4 Weighing Scale.75
4.5 Fabrication and Assembly..75
4.5.1 Rotary Hydroponics Garden Unit and Mechanism
75
4.5.2 Irrigation System Piping
81
5

4.5.3 Housing.83
4.6 Installation of Rotary Hydroponics Gardening System.86
4.7

Testing

of

Gardening

System..86
4.7.1

Testing

of

the

Rotary

Garden

Unit.86
4.7.2

Testing

of

the

Irrigation

System.86
4.8 Crop Growing...86
4.8.1

Biological

Significance

of

Environmental

Parameters..86
4.8.2 Growing Procedure
88
4.9 Morphological Data Collection.
91
4.9.1 Qualitative Morphological Analysis..
91
4.9.1
Morphometry...104
4.10

Expected

Output..

..104

LIST OF FIGURES
Figure 2.1. (a) Supported beam carrying distributed loading; (b) free-body diagram of a finite
beam
segment..12
Figure 2.2.Free-body diagram of an infinitesimal beam element carrying a concentrated force PA
and a concentrated couple..12
Figure 2.3. Mottor motion profile..13
Figure

3.1.

Rotary

hydroponic

system..

..24
Figure 4.1 Research Process Flow Scheme.......27
Figure 4.2 Solar Powered Hydroponics Gardening System Main Components....29
Figure 4.3 Hydbrid Solar powered rotary hydroponic gardening system..31
Figure 4.4 Rotary hydroponic garden unit.32
Figure 4.5 Exploded view of rotary hydroponic garden unit.33
Figure 4.6 Planting area capacity...35
Figure 4.7 Grow tray assembly..36
Figure 4.8 Locking Mechanism.37
Figure 4.9 Drive Mechanism.38
Figure 4.10 Support Frame39
Figure 4.11 Irrigation system only without the support structure (e.g. wheels) ...40
Figure 4.12 Irrigation system with emphasis on the gate valve 41
Figure 4.13 Housing...43
Figure 4.14 Timeline of System Operation44
Figure 4.15 Loading on the support ..46
Figure

4.16

Rotary

hydroponic

garden

unit

materials

...48
Figure 4.17 Fiberglass components...49
Figure 4.18 Piping materials..51
Figure 4.19 Housing materials...53
7

Figure 4.20 Fabrication materials and equipments55

Figure 4.21 Equipments.57
Figure 4.22 Motion profile of the AC compact motor...60
Figure 4.23 Free Body Diagram at the contact of the roller and wheel.61
Figure 4.24 Other Machine Elements Used...72
Figure 4.25 Solar Power Set..74
Figure 4.26 Exploded view of the rotary hydroponic garden77
Figure 4.27 Locking Mechanism exploded view...80
Figure 4.28 grow tray isometric exploded view80
Figure 4.29 Irrigation system.81
Figure 4.30 Housing with retracted shading mechanism...83
Figure 4.31 Housing with shading mechanism..85
Figure 4.32 Germination....89
Figure 4.33 Seeds introduced into the holes on the Rockwool cube.89
Figure 4.34 Position of plants from (a) 6 am to 5 pm....90
Figure 4.35 Position of plants from 5 pm to 6 am.90
Figure 4.36 Rotary garden unit..92
Figure 4.37 Desire Speed...92
Figure 4.38 Pechay (Brassica rapa) Qualitative Morphology...93
Figure 4.39 Pechay (Brassica rapa) Morphometry...93

LISTOF TABLES
Table 2.1. Roller Chain Dimensions..
.17
Table 4.1 Data for space maximization...
35
Table 4.2 Summary of Strength Analysis on Support Frame.47
Table 4.3 Summary of Strength Analysis on Trays47
Table 4.4 Summary of Grow Lights Sizing
59
Table

4.5

Summary

of

Preliminary

Motor

Sizing...62
Table

4.6

Summary

of

Roller

Chain

and

Sprocket

Selection..66
Table
4.7
Summary
of
Sizing.70
Table

4.8

Pump

Summary

Selection..71

and
of

Pipe
Roller

10

Nomenclature
2

A
c
C
d
D
fb
f
Ft
Fn
g
H
hf
Ll
Lr
hp

=
=
=
=
=
=
=
=
=
=
=
=
=
=
=

Area (m );
Distance from the neutral axis to the outermost surface (m);
Center distance (pitches);
Shaft diameter (in);
Pitch diameter (in);
Flexural stress (Pa);
Friction factor;
Tangential force (N);
Normal force between roller and the unit (N);
Acceleration due to gravity (m/s2);
Total head (m);
Friction loss (m);
Raw lumens of the lamp (lumens);
Lumens reach the surface to be illuminated (lumens);
Total pumping head (m);

hK

Minor losses (m);

hL

Head loss (m);

I
J
K
L
m
M
N
T1
T2
P
Pdesign

=
=
=
=
=
=
=
=
=
=
=

Centroidal moment of inertia (m4);

Polar moment of inertia (kgm.m2);
Minor loss coefficient ;
Length (Pitch);
Mass (kg);
Moment (Nm);
Rotational speed (rpm);
Number of teeth of the smaller sprocket (teeth);
Number of teeth of the larger sprocket (teeth);
Power (W)
Design power (W);

Prated

Rated power of the driver (W);

F service

Service factor

p
pr
Q

=
=
=
=

Pitch (in);
Pressure (Pa);
Volume flow rate (m3/s);
Reynolds number

Ro
Ri
r drive

=
=
=

Outer radius of cylindrical unit (m);

Inner radius of cylindrical unit (m);
Drive ratio

T
T acc

=
=

Torque (Nm);
Torque to accelerate the cylinder (Nm);

T roll

Torque needed to overcome rolling friction (Nm);

T rot

Torque needed to rotate the wheel (Nm);

t
vm
v
V
Vs
W

=
=
=
=
=
=

Time (seconds);
Linear speed of the chain (m/s);
kinematic viscosity (m2/s); 11
Velocity (m/s);
Shearing force (N);
Weight (N);

DEFINITION OF TERMS

AC Motor is an electric motor driven by an alternating current.

Aeration is the process of introducing and integrating oxygen into a liquid or other substance.
Aerator is an air pump used to oxygenate the water.

12

Agriculture is a broad term used to describe cultivation of plants, livestock, fungi, and other
life forms to serve human interests in the form of resources.
Basin a container with a greater width than depth, becoming smaller toward the bottom.
Bearing - is a machine element that constrains relative motion to only the desired motion, and
reduces friction between moving parts.
Buckling - is characterized by a sudden sideways failure of a structural member subjected to high
compressive stress.
Cation - A positively charged ion. Plant nutrient examples include calcium (Ca++) and potassium
(K+).
Chain drive - is a way of transmitting mechanical power from one place to another.
Chlorophyll is the green pigment in plant responsible for trapping light energy for
photosynthesis.
Evaporation - is type of vaporization of a liquid that occurs from the surface of a liquid into a
gaseous phase that is not saturated with the evaporating substance.
Evapotranspiration is the process by which water is transferred from the land to the
atmosphere by evaporation from the soil and other surfaces and by transpiration from
plants.
Housing - The housing is a structure with walls and roof made chiefly of transparent material,
such as glass or net, in which plants are enclosed and protected from pests and diseases.
Growing Medium is a materials that are sometimes used in hydroponic growing to support the
plant's roots and, sometimes, to hold nutrient.
Grow Light - is an artificial light source, generally an electric, designed to stimulate plant growth
by emitting an electromagnetic appropriate for photosynthesis.

13

Horticulture is a branch of the science of agriculture that relates to cultivating gardens and
orchards, including the growing of vegetables, fruits, flowers, and ornamental shrubs and
trees.
Hydroponics - A method of growing plants without soil. Plants usually are suspended in water or
inert growing media, and plant nutrients are supplied in dilute solutions. Visit
atlantishydroponics.com for hydroponic equipment, tools, and gardening tips.
Irrigation - is the method in which water is supplied to plants at regular intervals for agriculture
Luminance Flux - measure of the perceived power of light
Macronutrient is a major minerals that are used by plants in large amounts, consisting of
nitrogen (N), phosphorus (P), potassium (K), sulfur (S), calcium (Ca), and magnesium
(Mg).
Micronutrient is a nutrient used by plants in small amounts, less than 1 part per million.
Micronutrients include boron, chlorine, copper, iron, manganese, molybdenum, and zinc.
These are also called trace elements.
Morphometry is the process of measuring the external shape and dimensions of landforms,
living organisms, or other objects.
Morphology is a branch of biology dealing with the study of the form and structure of
organisms and their specific structural features.
Motion Profile - is the movement from point A to point B on a single axis. It describes the
rotational motion of the motor during its operating period.
Nutrient- Any substance, especially in the soil, that is essential for and promotes plant growth.
Pathogen - Any organism that causes disease which are generally applied to bacteria, viruses,
fungi, nematodes, and parasitic plants.

14

pH -A scale measuring the acidity or alkalinity of a sample.

Photosynthesis - The formation of carbohydrates from carbon dioxide (CO2) and a source of
hydrogen (H) such as water in chlorophyll containing cells exposed to light involving a
photochemical release of oxygen through the decomposition of water.
Pipe Network is hydraulics network, containing several or many interconnected branches.
Reservoir is the container in a hydroponic system which holds nutrient solution in reserve for
use.
Respiration is the process within plants where sugars and starches are converted into energy.
Roller Chain is a type of chain drive most commonly used for transmission of mechanical
power.
Soil degradation - is defined as the process which lowers the current or future capacity of the soil
to produce goods or services.
Soil salinity - is measure of the total soluble salts in a soil.
Soilless Growing - is based on the concept that plants do not require soil to grow.
Spring A machine with elastic characteristics used to store mechanical energy.
Sprocket is the toothed wheel upon which a chain rides.
Submersible pump is a pump that is used to water the plants and transport nutrient solution
from reservoir to the basin
Substrates - refer to as growing mediums. Substrates are necessary in hydroponic systems in the
absence of soil, as plants still require support.
Timer - is used in automated hydroponic systems to control growing conditions, allowing users
to set nutrient application intervals, etc.
Transpiration is the process of losing water in the form of vapor through stomata.

15

Stress- measures the deforming force per unit area of the object
Strain- measures the relative change in length caused by a deforming force.
Shear-Moment Diagram is an analytical tool used in conjunction with structural to help
perform structural design by determining the value of shear force and bending moment at
a given point of a structural element such as a beam.

16