Design and Development of a Miniature Hydropower

System for Low-Power LED Application

Miles Alsado Colen Dana D. Decipulo
Mechanical Engineering Mechanical Engineering
Program, College of Christian V. Basog Program, College of
Engineering Education Mechanical Engineering Engineering Education
University of Mindanao Program, College of University of Mindanao
Davao City, Philippines Engineering Education Davao City, Philippines
m.alsado.537588@umindanao.e University of Mindanao c.decipulo.534515@umindanao.
du.ph Davao City, Philippines edu.ph
c.basog.537676@umindanao.edu
.ph
Marc Lawrence L. Salvador Justin Dave M. Sermese
Mechanical Engineering Mechanical Engineering
Program, College of Program, College of
Engineering Education Engineering Education
University of Mindanao University of Mindanao
Davao City, Philippines Davao City, Philippines
m.salvador.537748@umindanao. j.sermese.528750@umindanao.e
edu.ph du.ph

I. INTRODUCTION efficiency, low voltage requirements, and durability

[5]. Khan et al. [6] demonstrated that even pico-
Hydropower is one of the most established hydropower systems, utilizing water from
forms of renewable energy, providing a reliable and household taps or artificial channels, can generate
sustainable alternative to fossil fuel–based enough electricity to illuminate LEDs, making them
electricity generation. It harnesses the kinetic ideal as educational prototypes.
energy of flowing water and converts it into
mechanical and electrical power [1]. Globally, Prototypes play a critical role in demonstrating
hydropower accounts for nearly one-sixth of renewable energy conversion. Khan et al. [6]
electricity production, underscoring its significance developed a low-cost hydropower model designed
in the energy mix [2]. While large-scale hydropower for student projects, showing that simple systems
systems dominate global power generation, growing could effectively illustrate fundamental energy
interest has emerged in micro- and pico-hydropower principles. Likewise, Fernando et al. [7] designed a
systems due to their practicality in localized low-head micro-hydro setup using affordable
applications and their value as educational and materials, highlighting its potential for small-scale
demonstrative models. energy generation. These works illustrate that
hydropower prototypes are not only feasible but
Micro-hydropower systems are particularly also valuable for both research and education.
effective in supplying electricity to rural or off-grid
communities. Sharma et al. [3] reported that these Computer-aided design (CAD) tools, such as
systems provide reliable energy for basic loads such SolidWorks, have become integral in developing
as lighting, appliances, and small-scale equipment, renewable energy prototypes. Gupta et al. [8]
while reducing dependence on centralized demonstrated that SolidWorks enables precise
electricity grids. Similarly, Yadav and Singh [4] modeling of turbines and blades, improving energy
emphasized their importance in academic and conversion efficiency through optimized design.
technical fields, where scaled-down prototypes are Ahmed et al. [9] further showed that CAD-based
used to demonstrate renewable energy principles to optimization minimizes fabrication errors and
students and researchers. Their low cost, portability, reduces the time required to build functional
and minimal environmental impact make them prototypes. In the context of miniature hydropower,
suitable for both practical applications and these tools are essential for designing compact,
instructional purposes. accurate, and cost-effective systems.

One common configuration of micro-hydropower Simulation studies also support design refinement
systems involves coupling a water wheel or turbine by enabling virtual testing before fabrication.
to a direct current (DC) dynamo, which generates Fernando et al. [10] reported that variations in
sufficient power to operate small loads. Light- turbine blade geometry significantly affect system
emitting diodes (LEDs) are frequently employed as efficiency, and virtual modeling allows these
output devices due to their high luminous variations to be tested without material wastage.

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Similarly, Mao et al. [11] highlighted that digital three-dimensional modeling, and the physical
simulations enable engineers to predict system materials such as a turbine, shaft, DC dynamo, and
performance under different conditions, providing LED bulb.
valuable insights into hydropower optimization.
The process involves designing the turbine and
Despite these advances, limited research has housing components in SolidWorks, fabricating the
focused on miniature hydropower systems prototype using locally available materials, and
specifically designed to power low-wattage devices testing its performance under varying water flow
such as LED bulbs. Existing studies predominantly conditions. SolidWorks is used for precise modeling
emphasize large-scale hydropower or community- and motion analysis to ensure that the turbine
based micro-hydro projects. Furthermore, the transfers sufficient torque to drive the dynamo.
integration of SolidWorks-assisted design, Fabrication is carried out based on the finalized
affordable materials, and prototype fabrication design, and testing evaluates the system’s capacity
tailored to educational use has not been extensively to generate electricity and power an LED bulb. The
explored. This gap underscores the need for outcome of the process is a functional miniature
systematic research on small-scale hydropower hydropower prototype that demonstrates the
systems for instructional and demonstrative principles of energy conversion and serves as an
applications. educational tool for renewable energy awareness.
This study aims to design and develop a miniature
hydropower system capable of powering an LED
bulb using a small DC dynamo. Specifically, the
objectives are: (1) to design the system and turbine Input Process Output
components using SolidWorks; (2) to fabricate the
prototype utilizing locally available and affordable Gathering Data
materials; and (3) to test the prototype under
varying flow conditions to assess its performance. Designing and
Turbine and simulation of Miniature
The significance of this study lies in its contribution Shaft the Hydropower
to renewable energy education and sustainable mechanisms System
technology development. The prototype offers a Water Flow Prototype
low-cost, eco-friendly, and replicable model for Fabrication of Powering LED
demonstrating energy conversion principles. DC Dynamo Prototype Bulb
Moreover, integrating CAD tools in the design stage and LED
bridges theoretical knowledge with practical Testing and
engineering application, thereby enhancing Evaluation
technical learning and awareness of renewable
energy solutions.
Figure 1. Conceptual Framework Diagram
The scope of this study is limited to the design,
fabrication, and testing of a miniature hydropower B. Materials and Resources
system intended to power an LED bulb. It does not
extend to large-scale hydropower applications or The researchers will utilize SolidWorks
integration with power grids. The prototype is software to create a detailed 3D model of the
intended solely for small-scale educational and miniature hydropower system. The features of
demonstration purposes. SolidWorks, such as Finite Element Analysis
(FEA), Computational Fluid Dynamics (CFD), and
II. MATERIALS AND METHODS Motion analysis, will also be employed to simulate
the turbine and dynamo interactions, ensuring
A. Conceptual Framework efficiency and structural reliability prior to
fabrication.
The conceptual framework outlines the
processes involved in the design and development Testing the electrical output and mechanical
of a miniature hydropower system. This study performance of the prototype is essential. A digital
employs the capstone research methodology to multimeter will be used to measure the voltage and
integrate theoretical knowledge of renewable energy current generated by the DC dynamo during
with practical prototype development. Figure 1 operation. A digital laser tachometer will monitor
presents the research framework, which illustrates the rotational speed of the turbine and shaft in
the relationship among key components of the revolutions per minute (RPM). Flow meters or
system. Inputs include the principles of energy controlled water sources will be used to regulate and
conversion, the use of SolidWorks software for measure water flow rates applied to the turbine. In

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addition, the brightness of the LED bulb will serve c. Concept Design
as a visual indicator of the system’s effectiveness in
converting hydraulic energy into electrical energy. The concept design of the miniature hydropower
system is based on the configuration of a Francis
C. Methods and Procedures turbine, scaled down for laboratory and educational
use. Water from a faucet flows through a small
This section outlines the systematic approach to housing that directs the stream toward the curved
designing, fabricating, and testing the miniature turbine blades, causing rotation. The rotating turbine
hydropower system prototype. The process shaft is coupled to a small DC dynamo, which
integrates the design criteria, design constraints, converts the mechanical energy into electrical
concept design, simulation, fabrication procedure, energy. The generated power is sufficient to light an
and testing procedures. This helps ensure the LED bulb, serving as a clear visual indicator of
prototype’s effectiveness, efficiency, and reliability successful energy conversion. The system is
in generating electricity from water flow and designed to allow continuous water flow after
powering an LED bulb. passing through the turbine, ensuring that the output
can be safely discharged while maintaining efficient
a. Design Criteria energy extraction. This conceptual setup
demonstrates the basic principles of hydropower
The design must address several critical criteria generation in a simple and accessible manner.
to ensure the miniature hydropower system is
suitable for educational and demonstration
purposes. The system must be capable of
consistently generating enough electrical power
from water flow to illuminate an LED bulb, thereby
proving its functional reliability. It should prioritize
efficiency by maximizing energy conversion
through optimized turbine design while maintaining
a compact and portable structure for ease of
handling. The system must also be user-friendly,
allowing straightforward assembly, operation, and
monitoring of performance, making it accessible for
students and educators. Additionally, it should
incorporate safety features such as stable housing
for electrical components and protective covers for
moving parts to prevent accidents during
demonstrations.

b. Design Constraints Figure 2. Miniature Hydropower Design

The design of the miniature hydropower system

must meet specific constraints to ensure its d. Design Procedure
effectiveness and practicality. Efficiency constraints
include the requirement to generate sufficient power The design procedure for the miniature
from low water flow rates, reflecting real-world hydropower system follows a structured and
conditions of micro-hydropower applications. The methodical approach. Key components such as the
prototype must utilize a low-voltage DC dynamo Francis-type turbine, DC dynamo, shaft coupling,
compatible with small-scale renewable energy and housing are integrated to achieve the project’s
demonstrations, ensuring safe operation. For objectives of efficiency, affordability, and
sustainability, the design should prioritize the use of educational value. The process begins with
locally available and affordable materials, such as conceptualizing the turbine geometry and overall
acrylic, aluminum, or plastic components, to reduce layout, followed by 3D modeling and simulations in
costs and support replicability in academic settings. SolidWorks to analyze stress distribution, water
Size and weight limitations must also be considered, flow behavior, and rotational motion. After
ensuring the system remains lightweight and validation, materials are selected based on
portable without compromising durability. Lastly, in availability, cost, and durability to ensure that the
terms of cost, the total material and fabrication system remains lightweight yet functional. The
expenses must remain affordable for students and finalized design serves as the basis for the
small institutions, making the system financially fabrication and assembly of the prototype, ensuring
viable as a teaching and demonstration tool. proper alignment between the turbine and dynamo

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to generate sufficient power for lighting the LED
bulb. e. Fabrication Procedure

d.1. Runner The fabrication of the miniature hydropower

system involves the use of 3D-printed components
The runner was designed to efficiently convert for the runner, nozzle, casing, and drainage system,
the kinetic energy of water flow into rotational produced using durable filament materials such as
mechanical energy. Its blades follow a Francis-type PLA+, PETG, or ABS. The turbine runner is printed
configuration, allowing water entering from the with precise blade curvature to maximize water
nozzle to strike the curved surfaces at the optimal flow efficiency, while the nozzle is designed to fit
angle, ensuring smooth and continuous rotation. The securely with a standard faucet connection. The
component was 3D-printed using durable filament casing is fabricated to house the turbine, nozzle, and
materials such as PLA+ or PETG, chosen for their shaft assembly, ensuring proper alignment and
strength, water resistance, and ease of fabrication. water flow, while the drainage system provides
The runner’s dimensions were carefully scaled to controlled discharge of water. A steel or aluminum
match the flow rate of a household faucet, providing shaft is inserted into the runner and coupled to a
sufficient torque to drive the DC dynamo. Blade low-voltage DC dynamo, which is mounted onto the
curvature and spacing were optimized to maximize casing with support brackets. The LED bulb is
energy capture while reducing turbulence and connected as the electrical load, with proper wiring
hydraulic losses. for safety and performance testing. After
fabrication, all components are assembled, aligned,
d.2. Nozzle and sealed to prevent water leakage and ensure
smooth operation.
The nozzle was designed as the input point
where the faucet is inserted to direct water flow f. Testing Procedure
toward the turbine runner. Its geometry was
optimized to focus and accelerate the water stream, The testing phase of the miniature hydropower
ensuring consistent impact on the runner blades for system is designed to evaluate its efficiency,
maximum efficiency. The nozzle was fabricated functionality, and reliability under different water
using 3D-printed filament materials such as PLA+ flow conditions. The procedure ensures that the
or PETG, selected for their durability, precision, and prototype meets the study’s objectives of generating
ability to withstand continuous water exposure. Its sufficient power to light an LED bulb while
dimensions were tailored to fit standard household demonstrating renewable energy principles in a
faucets, providing a snug connection to minimize simple and educational manner. Each testing phase
leakage. The alignment of the nozzle with the validates the effectiveness of the system, its
runner was carefully positioned to deliver smooth adaptability to varying water flow, and its durability
flow, reduce turbulence, and enhance the overall under repeated operation.
performance of the system.
f.1. Setting Performance Goals
D.3. Casing
Performance goals for the miniature hydropower
The casing was designed to enclose and protect system are established to ensure functionality and
the turbine runner, nozzle, and shaft assembly, efficiency. The system must be capable of
ensuring safe and efficient operation of the producing enough electrical power from water flow
miniature hydropower system. Its main function is to illuminate an LED bulb continuously. The turbine
to direct the water flow toward the runner while runner must rotate smoothly under household faucet
minimizing leakage and splashing. The casing was flow rates, with minimal turbulence and mechanical
3D-printed using durable and water-resistant vibration. The system must maintain structural
filament materials such as PLA+ or PETG, chosen integrity during operation, and all components,
for their strength, ease of fabrication, and resistance particularly the 3D-printed parts, must withstand
to continuous water exposure. The dimensions were repeated water exposure without degradation. The
optimized to maintain compactness for portability prototype must also demonstrate portability,
while allowing adequate clearance for internal affordability, and safety for use in educational
components to function without obstruction. The demonstrations.
modular design of the casing also enables easy
assembly, maintenance, and replacement of parts. f.2. Initial Performance Testing
Additionally, transparent sections may be
incorporated to allow visual observation of the Initial performance testing is conducted by
turbine’s motion during operation, further placing the miniature hydropower system under a
enhancing its educational and demonstrative value. standard faucet to evaluate turbine response and

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power generation. Parameters such as water flow
rate, turbine rotational speed, and dynamo voltage User experience evaluation focuses on assessing
output are recorded. The LED bulb serves as the the ease of setup, operation, and maintenance of the
primary indicator of electrical generation, where its miniature hydropower system. Feedback from users
brightness reflects the effectiveness of power is collected to determine how easily the prototype
output. Multiple test runs are conducted under can be attached to a faucet, aligned for proper water
different faucet flow rates to evaluate system flow, and connected to the LED bulb. Operator
adaptability. Observations are used to identify interaction is measured by observing how quickly
issues such as leakage, misalignment, or insufficient users can start and stop the system, as well as their
power generation, with adjustments made to ability to monitor LED brightness as an indicator of
optimize performance. performance. Ergonomics and handling are
considered to ensure portability and safety, while
f.3. Data Collection the accessibility of components for cleaning and
reassembly is also evaluated to promote user-
During testing, both qualitative and quantitative friendly operation and maintenance.
data are collected for analysis. Quantitative data
include turbine rotational speed (RPM), dynamo
voltage and current output, and water flow rate,
measured using a tachometer, multimeter, and flow f.7. Efficiency Testing Using Overall Equipment
gauge. Qualitative observations include the stability Effectiveness (OEE) and Power Conversion
of the turbine rotation, smoothness of water flow Efficiency
through the casing, and the consistency of LED
illumination. Repeated test runs are performed to The Overall Equipment Effectiveness (OEE)
ensure accuracy, and all data are recorded formula is applied to determine the system’s
systematically to monitor the performance trends of operational efficiency. This formula integrates
the prototype. availability, performance, and quality to
comprehensively assess the effectiveness of the
f.4. Statistical Analysis miniature hydropower system. The formula is
expressed as:
The data collected from the test runs are
subjected to statistical analysis to ensure reliability OEE= Availability x Performance x Quality → E qn . 1
and consistency of results. Descriptive statistics,
including mean, median, and standard deviation, are Availability = Ratio of actual operating time to
calculated for turbine speed, dynamo output, and planned operating time (%).
LED brightness levels. Performance variations Performance = Ratio of actual rotational speed of
between test runs are analyzed to identify patterns the runner to the designed rotational speed (%).
and validate improvements after system Quality = Ratio of stable LED illumination cycles to
adjustments. This analysis ensures that the the total number of operational cycles (%).
miniature hydropower system meets the design
objectives of efficiency, functionality, and The Power Conversion Efficiency is also
reliability for educational demonstration purposes. calculated to measure the effectiveness of
converting hydraulic energy into electrical energy.
f.5. Stress Testing This is defined as:

Stress testing involves operating the miniature P electrical

hydropower system continuously under flowing Npower= ×100 → Eqn . 2
water to evaluate durability and reliability. The
P Hydraulic
focus is on monitoring the wear and tear of 3D-
printed components such as the runner, nozzle, and Where P electrical is the measured output power of
casing, as well as the stability of the shaft and the dynamo (W) and P hydraulic is the hydraulic
dynamo connection. Performance consistency is power input, computed as:
assessed to ensure that the turbine maintains stable
output and continuous LED illumination even after Phydraulic= pgQH → Eqn . 3
extended operation. Water leakage, vibration, and
misalignment are carefully checked to prevent with ρ as water density (kg/m³), g as gravitational
performance losses. This testing ensures that the acceleration (m/s²), Q as water flow rate (m³/s), and
system can withstand prolonged and repeated usage H as effective head (m).
in various flow conditions.
These equations provide a comprehensive
f.6. User Experience Evaluation evaluation of the miniature hydropower system’s

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effectiveness, enabling identification of factors that
influence performance and guiding further
optimization for educational and demonstration
purposes.

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