DESIGN AND FABRICATION OF PEDAL POWERED GENERATOR

Batch Number : 01 Batch Members: 1. S.Vinod 2. R.Sundar Rajan 3. R.Mukund 4. P.Anburaj Project Guide : Mr.T.Sankarlal

OBJECTIVE
According to Newtons law Energy can neither be created nor destroyed , it can be transformed from one form to another This design serves the main purpose of producing power. The power is generated through human energy. The basic idea involved is The Activation Of A Generator Through A PEDALED TRANSMISSION SYSTEM. This project has been fabricated so as to give the maximum efficiency and high quantity of power.

THEORY
The principle employed in our project is the transmission of motion using gears and chains. In precision machines wherein a definite velocity ratio is of importance, the requirements are satisfied only by the use of gear drives or toothed wheels.

A definite velocity ratio is required as in the case of our project and hence we used gears.

The motion and power transmitted by gears is kinematically the same as transmitted by friction wheels or discs.

FABRICATION DETAILS

The fabrication is satisfied by the use of four gears (different in diameters), a chain, a shaft and a motor.

Pedal Powered Generator Initial Transmission System Final Transmission System

Initial Transmission System

Initial Transmission System: The sprocket wheel and sprocket are involved in the construction of this system.

The pedal is bolted to sprocket wheel (driver) which in turn transmits power to the sprocket (driven) through a chain.
The entire system is called THE INITIAL TRANSMISSION SYSTEM the chain drive system.

Final Transmission Gear System

Final Transmission System: Driving gear and driven Gear constitute an integral part of this system.

These gears are mounted axially to each other.

Driving gear which is greater in diameter is made to mesh with driven gear which is the smallest gear in the entire system. Driven gear is secured onto the shaft of the electric motor.

OPERATIONAL DETAILS
The setup is similar to a bicycle and the working principle is very simple. When the pedaling operation is performed, the driving sprocket wheel rotates thereby causing driven sprocket to rotate. As described earlier, the motion is transmitted by means of a chain drive system employed in the setup. As a result of the activation of the initial transmission system, it is natural for the final transmission system to get activated as well. Thus driving gear and driven gear are subjected to rotation. In the event of driven gear being secured onto the shaft of the motor, the motor starts generating power.

DESIGN CALCULATION
Roller Chain Drive System: OBSERVATIONS: Diameter of the driving sprocket wheel (Ddsw) Number of Teeth in the driving sprocket wheel (Zdsw) Diameter of driven Sprocket (Dds) Number of Teeth in the driven sprocket (Zds) Number of Links in the chain (Lp) = 200 mm = 44 = 95 mm = 18 = 103

Pitch Angle () : For Driving Sprocket Wheel :

sw = 360 / Zsw sw = 360 / 44 sw = 8.182

For Driven Sprocket :

s = 360 / Zs s = 360 / 18 s = 20

Chain Pitch:
For Driving Sprocket Wheel : Sin (/2) = (Psw / 2) (D/2) Sin (8.182/2) = (Psw / 2) (200/2) Psw = 14.26 mm

 For Driven Sprocket : Sin (/2) = (Ps / 2) (D/2) Sin (8.182/2) = (Ps / 2) (200/2) Ps = 16.49 mm

Length Of Chain:
Length of Chain (L) = lp x P L = 103 x 14.26 L = 1468.78 mm

GEARS :
FOR DRIVEN GEAR
OBSERVATIONS: Diameter of the gear (d) = 23 mm Number of teeth (z) = 14
Calculation: Module (m) = d/z m = 1.64 m = 2 mm (standard value) Pitch Circle Diameter = (d)/2 PCD = ( x 23)/2 PCD = 5.16 mm

Addendum = 1 module = 1 x 2 mm = 2 mm Dedendum = 1.25 module = 1.25 x 2 mm = 2.5 mm Tooth Thickness = 1.5708 module = 1.5708 x 2 mm = 3.14 mm Minimum Clearance = 0.25 module = 0.25 x 2 mm = 0.5 mm

Backlash = Tooth Thickness Minimum Clearance = 3.14 mm 0.5 mm = 2.64 mm

 FOR DRIVING GEAR:

OBSERVATIONS: Diameter of the rim (d) Number of teeth in rim gear (z) = 400mm = 250

Calculation: Module (m) = d/z m = 1.6 m = 2 mm (standard value) Pitch Circle Diameter = (d)/z PCD = ( x 60.12)/250 PCD = 5.024 mm

Addendum

= 1 module = 1 x 2 mm = 2 mm = 1.25 module = 1.25 x 2 mm = 2.5 mm

Dedendum

Tooth Thickness = 1.5708 module = 1.5708 x 2 mm = 3.14 mm

Minimum Clearance = 0.25 module = 0.25 x2 mm = 0.5 mm

Backlash = Tooth Thickness Minimum Clearance = 3.14 mm 0.5 mm = 2.94 mm Theoretically, the backlash should be zero, but in actual practice some backlash must be allowed to prevent the jamming of the teeth due to tooth errors and thermal expansion.

 Speed Ratio : C = NdG = TDG NDG TdG Observations: Speed of the gear shaft (NdG) Speed of the rim gear (NDG ) Number of teeth in the gear shaft (TdG ) Number of teeth in the rim gear (TDG ) NGS = 250 10 14 NGS = 178.66 rpm

= NdG = 10 rpm (assumption) = 14 = 250

SPECIALITY OF THE DESIGN :

Hence, it implies that, if the rim gear rotates for 1 revolutions per minute (r.p.m), the gear shaft rotation is amplified to about 18 revolutions per minute (r.p.m).

Advantages Of Pedal Powered Generator :

It is pollution free. It is comparatively cheap in construction. It serves multiple purposes (exercising machine as well as power generator). It is movable unlike other power producing equipments. It is easier to maintain. It consumes less space. It is less prone to wear and tear of parts.

Disadvantages Of Pedal Powered Generator :

It is noisy in operation.

Lot of force is required to pedal.

It is a bulky. It requires constant lubrication.

USAGE PROSPECTS :
This eco-friendly power generating device can also be used as an exercise cycle to burn calories. The batteries used in two wheelers can be charged by connecting them to the generator.

It can be even used to power a computer for about twenty minutes (as an UPS). It has a capacity of 12 volts.

DRAFTED MODEL OF TRANSMISSION SYSTEM (designed in PRO-E)

ASSEMBLED DYNAMO AND GEAR

FINAL TRANSMISSION SYSTEM

ELECTRICAL CUT OUT