A mini Project Report on

“Fabrication of Mini Hydro turbine Using Rapid Prototyping”

Submitted by

Dhritvan Anjanappa - 1BM19IM005

Harikrishna VS - 1BM19IM015
Prithibi De Bhowmik - 1BM19IM026
Vineeth KR - 1BM19IM052
Nagarjuna SG - 1BM18IM029

In the partial fulfillment for III semester course

MINI PROJECT – I (19IM3DLMP1)

Under the guidance of:

Prof. Mayur Appaiah

Assistant Professor

Department of Industrial Engineering and Management

B.M.S College of Engineering, Bengaluru - 560019
2020-2021

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 CERTIFICATE
Department of Industrial Engineering & Management

B.M.S. COLLEGE OF ENGINEERING

Bengaluru – 560019

This is to certify that the MiniProject-1 (19IM3DLMP1) Phase-1 titled as

“MINI TURBINE” has been successfully completed by

NAME USN

Dhritvan Anjanappa 1BM19IM005

Harikrishna VS 1BM19IM015

Prithibi de Bhowmik 1BM19IM026

Vineeth KR 1BM19IM052

Nagarjuna SG 1BM18IM029

In the partial fulfilment for III semester course in the department of Industrial Engineering and
Management, Bachelor of Engineering, B.M.S. College of Engineering, an autonomous College
under VTU during the academic year 2020 – 2021

Under the Guidance of

Prof Mayur Appaiah

Guide Name Head of department

Prof Mayur Appaiah Dr. B. Ramesh Nayak

Name Signature with Date

Examiner No.1

Examiner No.2

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 Acknowledgment

Success is all about growing and learning with others. However, a number of people have motivated
and helped us to put these ideas well above the level of simplicity and into something concrete.
We would like to make use of this opportunity to thank everyone who has helped and encouraged
us to accomplish our Mini Project . Firstly, we would like to express our profound gratitude to our
Principal of B.M.S College of Engineering, Dr. B.V. Ravishankar.

Secondly, we would love to thank the head of the department of Industrial Engineering and
management Dr. B Ramesh Nayak for his direction and supervision for the project.

Next, we would like to thank our project guide Prof. Mayur Appaiah, Assistant Professor for all
his support, guidance and time which was extremely essential for the completion of this project.

Last but not least, we express our sincere thanks to Prof. Kavitha Rani N, Assistant Professor of
IEM Dept. who has helped us complete this project in a sophisticated and urbane way.
This project would not have been completed without her help .

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Tables of Contents

1. Introduction 5
1.1 What is Rapid Prototyping? 5
1.2 Why Rapid Prototyping? 6
1.3 Advantages and Disadvantages of Rapid Prototyping 7
1.4 Application of Rapid prototyping 8
1.5 Fused Deposition Method 9
1.6 3D Printing 10
1.7 Overview of the Project 11
1.8 What is a Turbine and how Does it Work? 13
1.9 Impulse Turbine 14
1.10 What is a Dynamo? 15

2. The Mini Turbine 16

2.1 Parts Specification 16
2.2 2D and 3D view of Parts 19
2.3 2D and 3D view of assembly 22
2.4 Calculation 23
2.5 Working Model 25
2.6 Applications of Mini Turbine 27

3. Conclusion 29
4. Reference 30

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 INTRODUCTION

1.1 What Is Rapid Prototyping?

Rapid prototyping is a group of techniques used to quickly fabricate a scale model of a physical
part or assembly using three-dimensional computer aided design (CAD) data. Construction of the
part or assembly is usually done using 3D printing or "additive layer manufacturing" technology.

The first methods for rapid prototyping became available in the late 1980s and were used to
produce models and prototype parts. Today, they are used for a wide range of applications, and
are used to manufacture production-quality parts in relatively small numbers if desired without
the typical unfavorable short-run economics. This economy has encouraged online service
bureaus. Historical surveys of RP technology start with discussions of similar production
techniques used by 19th-century sculptors. Some modern sculptors use the progeny technology
to produce exhibitions and various objects. The ability to reproduce designs from a dataset has
given rise to issues of rights, as it is now possible to interpolate volumetric data from one-
dimensional images

Fig 1.1 Rapid prototyped material of a cell phone

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1.2 Why Rapid prototyping?

1.2.1 : Thorough testing before production

The most important benefit of rapid prototyping is it allows you to thoroughly test your product
early on. You can create multiple prototypes in one go, detect some design flaws in your designs,
and create more refined ones in a short amount of time.
Detecting functional and design flaws early in your product can prevent huge costs later on if
flaws are identified during final production. Nowadays with 3D printing, you can also replicate
inner mechanical parts of your product with finer details. This helps you to work on both your
product’s aesthetics and functionality.

1.2.2: Cheaper and easy to operate

3D printing has been there since the 1980s. However, due to its huge cost and heavy machinery,
it was only affordable for big companies back then.
But that’s not the case today. Due to the rapid advancement in technology, 3D printers have
become much affordable and sport a compact design. Buying a 3D printer has become so
convenient that many tech enthusiasts own one in their home.

1.2.3: Faster realization of your product concept

Rapid prototyping tools simplify the process of generating new product ideas by allowing frequent
creation of visual replicas. Having a solid 3-dimensional replica in front of you helps you explore
new ideas and rework on them with ease.
You can work on your product step-by-step by creating the initial prototype and add the changes
until you are satisfied with the end results.
You can also share the progression of your product design with your colleagues, project partners,
and potential investors which is much better than sharing an imaginative concept. Rapid
prototyping lets you explore new possibilities to improve your product before transferring it into
the production line.

1.2.4: Speeds up the Manufacturing Process

Although prototyping is an important process in product design, it is considered as a bottleneck.
It takes a lot of time and effort to come up with a brand-new product idea and turn it into reality.
The most tedious part of product designing is working on the visuals and intricate details of your
product.

Fig 1.2 3D printer with the printer product

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1.3 Advantages of Rapid prototyping
Rapid prototyping provides engineer, design and development teams with distinct advantage such
as:

• The ability to explore and realize concepts more quickly. This efficiency in time and cost
allows teams to move beyond the mere visualization of a product, making it easier to grasp
the properties and design of a product.
• Apply repeated designs and incorporate changes that allow for the evaluation and testing
of the product. This iterative process provides a roadmap to developing and refining the
final product.
• Being able to communicate concepts concisely and effectively. Rapid prototyping takes
ideas, images and concepts from flat and 2 dimensional visuals to hands-on products that
clients, colleagues and collaborators can then see in action.
• The ability to thoroughly test and refine a concept. Being able to minimize design flaws
with a small volume rapid prototype run helps eliminate costly design flaws that might
not be evident during an early assessment.
• Save time and money since setup and tooling aren’t necessary. Because the same
equipment can be used to produce prototypes with different properties and materials, the
costs and time outlay are kept to a minimum.

Disadvantages of Rapid Prototyping

• When the focus is on a limited prototype, it can distract the product developers from doing
proper product analysis of the complete project. They may overlook a better solution, or
may not complete the specification that will result in poor engineered projects that can be
hard to maintain.

• If a prototype reached the customers, they might mistake it for the final product. If what
they see is a rough prototype, they will not understand that it is subject to further finishing
or polishing and may perceive that it is the actual performance or appearance of the final
product. Worse, they may find a prototype feature that will not be included in the final
product.

• Rapid prototyping techniques can also limit your option. There are many other options
available to make a prototype. Although they are not as fast, they have many good
features too like creating many moving parts that interlocks and work together. In
complicated projects, rapid prototyping may not be the best choice.

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1.4 Applications of Rapid Prototyping

Rapid prototyping is applicable to many materials and technologies, making it a versatile technique
that can be employed for numerous applications. A few ideas include the following:

• Concept models provide designers with the opportunity to validate both their ideas and
the assumptions that lie behind them. A physical concept model is an ideal way to explore
a concept, demonstrate its validity to stakeholders and/or create communication
surrounding it.
• Functional prototypes enable designers and developers to grasp the details that provide an
accurate representation of the finished product by allowing them to verify its validity
before it moves onto the next stage. The fit, design, manufacturability and function of the
product can be tested prior to moving it into full production mode — an infinitely costlier
process.
• Proving that a workable prototype is also going to be economically feasible to manufacture
is another application of rapid prototyping. Having a fantastic prototype that achieves a
satisfactory balance of functionality and aesthetics while also being cost- effective is
possible with rapid prototyping.

Fig 1.3 Rapid prototyped material

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 1.5 Fuse Deposition Method:
Fused Deposition Modeling is a solid-based rapid prototyping method that extrudes material
layer-by-layer to build a model. The system consists of a build platform, extrusion nozzle, and
control system. This is a fast and cost-effective process great for proving designs, fit and
function testing, small production runs, jigs, and fixtures.
Large material selection – including production-quality ABS and food-grade ABS Short

lead times, standard lead time - 3 to 5 days.

High strength
Extremely durable
Concept models
Engineering models
Functional testing
Consumer products
High-heat applications
Initial prototypes

Fig 1.4 Fused Deposition Method

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1.6 3D Printing:
1.6.1 Part Size Most 3D printers work with a closed build platform. This makes it possible to print
several parts simultaneously. The smaller your objects, the more you can combine in one single
build, saving operating expenses, material and time. On the other hand, it limits the size of the parts
that can be printed. Large objects can easily be split up into sections, but that might require
extensive assembly afterward, which conflicts with producing fast parts, integrating the
functionality and reducing the number of components, some of the 3D printing’s main advantages.
In general, our guideline is that every part the size of a football surely has the potential to be
produced in a cost-effective way using 3D Printing.
1.6.2 Part Complexity One of the biggest advantages of 3D Printing is the freedom of design. A
product with a complex geometry will be harder – if not impossible – and more expensive to make
with traditional production techniques. With the right approach to design and engineering, there
simply is no other cost-effective technique to address design challenges, such as incorporating
difficult undercuts and integrating functionality. In Additive Manufacturing, complexity is free.
1.6.3 Project Value The total commercial value of the device or equipment your parts fits in, is
something to take into consideration. 3D Printing a component can add value to your product in
terms of customization, functionality, time to market, etc., but that’s not necessarily the case. And
if it’s not adding value, it’s probably just adding costs. For price-sensitive consumer goods, these
costs will be much harder to justify than for high-end industrial solutions.
1.6.4 Series Size The quantity that makes 3D Printing a considerable production method is
different in every single project. What’s clear is that there are no fixed costs, like molds, that
influence your part’s price. The cost per part will always remain the same in 3D Printing, no matter
what the total quantity might be. A balanced volume/price ratio highly depends on the other 4
parameters in this list. For example, although the price per part does not decrease for bigger
quantities, a large series still can be relatively cost-effective because you might save on assembly:
with 3D Printing you can print one piece that might otherwise consist of five.
1.6.5 Purpose What is the purpose of your object? Does it have a function, or does it only need to
look good? Or both perhaps? Nowadays, everything is possible in terms of post-processing and
finishing to enhance the surface quality of 3D-printed parts: painting, smoothing, dying, coating,
metal plating, you name it. But as with everything in life, “the more you want, the more you pay”
is also true in this case.

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 1.7 Overview of the project

In the field of engineering and designing the process of creating a prototype is a very necessary
and essential one.
It provides the engineers and product developers a clear scope and idea of what the product will
look like and the concept with a flourish in it.
However, this process was also very expensive and took up a lot of resources which is not the
most effective way towards productions. This is where rapid prototyping becomes more
plausible and effective in every way.
In the rapid prototyping, there is no need for expensive modeling of the prototyping, instead,
there are several techniques that can be used to create 3D models of the product part of the
assembly.
This process is easy and requires much lesser time and resources as compared to the past
techniques, and also provides freedom in designing and prototype.

1.7.1 Tolerances for standard resolution:

X/Y planes: +/- .005” for the first inch, plus +/- .002” for every inch thereafter
Z plane: +/- .010” for the first inch, plus +/- .002” for every inch thereafter
Using engineering-grade thermoplastics such as ABS and polycarbonate materials, this
technology builds parts in an additive process that enables complex geometries that are often
difficult to duplicate with traditional manufacturing methods such as CNC machining.

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 1.7.2 Selective Laser Sintering:
The main laser parameters include wavelength, power, scanning speed, hatch distance, scan pattern,
vector length, ratio of length to width, scan angle, beam spatial distribution, beam spot size, point
overlapping, and continuous or pulsed laser operation.

Fig 1.5 Selective Laser Sintering

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1.8 What is a turbine? How does it work?

A turbine is a device that harnesses the kinetic energy of some fluid - such as water, steam, air, or
combustion gases and turns this into the rotational motion of the device itself. These devices are
generally used in electrical generation, engines, and propulsion systems and are classified as a type of
engine. They are classified as such because engines are simply technologies that take an input and
generate an output. A simple turbine is composed of a series of blades and allows the fluid to enter the
turbine, pushing the blades. These blades then spin and eject the fluid which now has less energy it
did than when it entered the turbine. Some of the energy is captured by the turbine and used.

Fig 1.6 water Turbine

Water turbines are generally divided into two categories:

1)Impulse Turbine

2) Reaction Turbine

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 1.9 Impulse Turbine

1.9.1 Impulse turbines change the direction of flow of a high velocity fluid or gas jet. The
resulting impulse spins the turbine and leaves the fluid flow with diminished kinetic energy. There
is no pressure change of the fluid or gas in the turbine blades (the moving blades), as in the case
of a steam or gas turbine, all the pressure drop takes place in the stationary blades (the
nozzles).Before reaching the turbine, the fluid's pressure head is changed to velocity head by
accelerating the fluid with a nozzle. Pelton wheels and de Laval turbines use this process
exclusively. Impulse turbines do not require a pressure casement around the rotor since the fluid
jet is created by the nozzle prior to reaching the blades on the rotor. Newton's second law describes
the transfer of energy for impulse turbines. Impulse turbines are most efficient for use in cases
where the flow is low and the inlet pressure is high.

Fig 1.7 Pelton Wheel

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 1.10 What is a Dynamo?

A dynamo is an electrical generator that creates direct current using a commutator. Dynamos were the
first electrical generators capable of delivering power for industry, and the foundation upon which
many other later electric-power conversion devices were based, including the electric motor, the
alternating-current alternator, and the rotary converter.

Today, the simpler alternator dominates large scale power generation, for efficiency, reliability and
cost reasons. A dynamo has the disadvantages of a mechanical commutator. Also, converting
alternating to direct current using rectifiers (such as vacuum tubes or more recently via solid
state technology) is effective and usually economical.

Fig 1.8 Dynamo

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 THE MINI TURBINE

2.1 PARTS SPECIFICATION

2.1.1 Casing
The casing has an outer diameter of 60mm and inner diameter of 50mm. It consists of an open side
and closed side. It has a circular hollow cavity inside which the runner is housed. The casing has
two holes on opposite sides of the walls which are the inlet and outlet holes for the water, both
holes have a diameter of 10mm. The closed side of the casing has a smaller hole of 4mm to allow
dynamo to be connected to the runner. The nozzle fits into the inlet hole of the casing.
Care must be taken to ensure that the blades of the runner do not come into contact with the sides
of the casing.

Fig 2.1 Casing of the turbine 3D printed

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 2.1.2 Runner
The runner is essentially the main component of the turbine and it is the only moving. This is where
fluid power is transformed into the
rotational force that drives the generator. Regardless of the runner type, its buckets or blades are
responsible for capturing the most possible energy from the fluid. The curvature of each surface,
front and rear, determines how the water will push its way around until it falls away. The runner
consists of 8 curved blades of 4mm height each. A DC dynamo is attached to the back of the runner
in order to convert the mechanical energy into power. The runner body has a diameter of 20mm and a
2mm hole in the center to connect the dynamo.

Fig 2.2 Runner of the turbine 3D printed

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 2.1.3 Nozzle
A nozzle is a device designed to control the direction or characteristics of a fluid flow (especially to
increase velocity) as it exits (or enters) an enclosed chamber or pipe.

A nozzle is often a pipe or tube of varying cross-sectional area, and it can be used to direct or modify
the flow of a fluid (liquid or gas). Nozzles are frequently used to control the rate of flow, speed,
direction, mass, shape, and/or the pressure of the stream that emerges from them. In a nozzle, the
velocity of fluid increases at the expense of its pressure energy.

The nozzle is a cylindrical component having outer diameter of 25mm and inner diameter of 21mm
for the bigger hole to which the water source is attached and 5 mm diameter for the smaller end hole
which is fitted to the casing. The difference in hole sizes is so that the velocity of the water will increase
and the amount of power generated.

Fig 2.3 Nozzle of the turbine 3D printed

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 2.2 2D and 3D View Parts

2.2.1 Casing

Fig 2.4 Solidworks Diagram of Casing

Fig 2.5 Solidworks Diagram of Casing 2D

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 2.2.2 Runner

Fig 2.6 Solidworks Diagram of Runner

Fig 2.7 Solidworks Diagram of Runner 2D

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 2.2.3 Nozzle

Fig 2.8 Solidworks Diagram of Nozzle

Fig 2.9 Solidworks Diagram of Nozzle 2D

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 2.3 2D and 3D View of the assembly (Mini Turbine)

Fig 2.10 Solidworks Diagram of Assembly

Fig 2.11 Solidworks Diagram of Assembly 2D

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2.4 CALCULATIONS

Observation
Current I = 0.03 A
Voltage V = 6 volts
RPM = 1200-1500
Mass flow rate = 0.14 kg/s
Velocity of water from tap C0 = 0.425 m/s
Velocity of water from nozzle to runner = C1
Velocity of water coming out of runner = C2
Radius of runner = 2x10-2 m

Output Power
Power = VxI
= 6 x 0.03
= 0.18 W

Torque of runner
T= Force x Radius of runner

F=Mass flow rate x (velocity of water going out(cosX2) + velocity of water coming(cosX1) )
F= m(C2(cosX2) + C1(cosX1) ------------------------------------------------ Eqn 1

X2= 90 degrees, therefore Cos X2=0, and C2(Cos X2)=0.

X1=0 degree, therefore Cos X1=1, and C1(Cos v)=C1.

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 We know that,
A0C0= A1C1
C1=A0C0/A1

A0 = Cross sectional area of nozzle entry= 3.14X10-4

A1 = Cross sectional area of nozzle exit = 3.14 x 0.625x10-6
C1= 0.425 x 3.14x10-4/3.14 x 0.625x10-6
C1 = 72.32 m/s

Substituting in Eqn 1:
F= 0.14 x 72.32
= 10.12 N

Therefore T = 10.12 x 2x10-2

= 0.2024 Nm

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 Working Model

Fig 2.12 Top View of Working Model

Fig 2.13 Side View of Working Model

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 Fig 2.14 Front View of Working Model

Fig 2.15 Working of Mini Turbine

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 Application of Mini Turbine
The mini turbine research is aimed at designing and constructing a hydroelectric power plant model
that can generate electric power, which can be used at the domestic level to power electrical
appliances. There are three main sections for the hydro turbine, the feedback system for the
continuous flow of water. The result shows that the construction of mini hydro turbine plants is
feasible and there were no major problems apparent at the design and implementation stages of the
mini hydro turbine.

Fig 2.16 3D printer with the printer product (Nozzle)

In addition to electrical production, they may also be used for pumped storage, where a reservoir is
filled by the turbine (acting as a pump) driven by the generator acting as a large electrical motor during
periods of low power demand, and then reversed and used to generate power during peak demand.
These pump storage reservoirs act as large energy storage sources to store "excess" electrical energy
in the form of water in elevated reservoirs. This is one of a few methods that allow temporary excess
electrical capacity to be stored for later utilization.

Fig 2.17 Final Assembly of the Product

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Mixed flow turbine is also used in irrigation water pumping sets to pump water from ground for
irrigation. It is efficient over a wide range of water head and flow rate.

There is an effective use of water pressure and velocity.

It has a low price, and good regulation
Its efficiency is proportional to rate of flow of water hence a high efficiency can be obtained by
increasing the speed of water flow
Generating Clean Electricity.
A primary use of hydropower energy is to produce electricity.
Benefits for Business.
Offering Recreational Facilities.
Flood Risk Management.
Hydropower is completely renewable, which means it will never run out unless the water stops
flowing.
Emission Free.
Reliable.
Adjustable.

Fig 2.18 3D printer with the printer product (Casing)

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3 Conclusion
We finally would like to conclude that “Mini Turbine” can be an important addition to our day to
day life. There are many real-life applications that can be accomplished with the Mini Turbine
which have been reported above. We also would like to conclude that during this project we get to
find out our practical abilities and could co-relate to the theoretical knowledge that has been taught
to us.

We would also conclude that this project has given a clear perspective of Rapid Prototyping and
what potential it holds as a manufacturing element is the present and also in the near future,
compared to that of the normal/outdated manufacturing processes that are still used to date.

We would also add that this project has given us a basic understanding of how the projects are
worked on and also has taught us to face deadlines and come up with real time solutions for real
time problems. This project also taught us to think out of the box, and improvise according to the
situation.

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4 Reference
4.1 Websites
• https://engineeringproductdesign.com/knowledge-base/rapid-prototyping-techniques/
• https://en.wikipedia.org/wiki/Rapid_prototyping
• https://fractory.com/what-is-rapid-prototyping/
• https://www.3erp.com/blog/rapid-prototyping-advantages-applications/
• https://rapidsrepro.com/advantages-disadvantages-prototyping/
• https://en.wikipedia.org/wiki/Turbine
• https://www.sciencedirect.com/topics/engineering/impulse-
turbine#:~:text=The%20impulse%20turbine%20is%20the,thermal%20energy%20into%
2 0kinetic%20energy.

4.2 Journals
• N. J. Lee, J. W. Choi, Y. H. Hwang, Y. T. Kim, and Y. H. Lee, in 26th
IAHR Symposium on Hydraulic Machinery and Systems, Beijing,
2012 (Institute of Physics, London, 2012), pp. 1–8
• H. C. Chen and V. C. Patel, “Near-wall turbulence models for complex
flows including separation,” AIAA Paper No. 87-1300, 1988.
• P. Huang, P. Bradshaw, and T. Coakley, “Skin friction and velocity
profile family for compressible turbulent boundary layers,” AIAA
J. 31, 1600 (1993).

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