Project Report 2018
GOVERNMENT POLYTECHNIC
RAJKOT
PROJECT REPORT
On
FLYWHEEL BASED BATTERY CHARGER
Prepared by:
GURJAR VIJAY D. :- 166200319534
PARMAR ALTAF H.:-166200319568
RATHOD HARDIK :- 166200319580
DERVALIYA ANIL :-166200319524
CHAUHAN VISHAL :-166200319516
Under guided:
H.D.KOTAK
For Partial fulfillment of subject of PROJECT – 1 Semester 5th date:-18/06/2018 to
20/10/2018
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CERTIFICATE
This is certify that, the following student is 6th semester of E.C Engineering
has partial fulfill the project work as a part or curriculum for The subject of
PROJECT-1 having a project title “FLYWHEEL BASED BATTERY
CHARGER” during the academic term from under my guidance Government
polytechnic, Rajkot under Gujarat Technical University.
SR. NO. NAME: EN.NO.
1. GURJAR VIJAY D 166200319534
Guided by:
H.D.KOTAK
Head of department
R.M.PARMAR
Mechanical. Engineering-Government polytechnic Rajkot-360003
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ACKNOWLEDGEMENT
This Project We have a make to guidance of H.D.KOTAK sir (lecture
of Mechanical. department) of the Government Polytechnic, Rajkot.
Guide teacher of our project. It helps to all the Steps of the project0.
We thankful to Shree R.M.PARMAR sir (HOD), Mr.H.D.KOTAK sir or
the entire teacher who advice in our project. We also thanks to our guide
teacher & our class mate friends to the best suggestion about our project.
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CONTENTS
S.r. no Title Page no.
1. INTRODUCTION 05
2. ABSTRACT 08
3. LITERATURE SURVEY 11
4. COMPONENTS SPECIFICATION 16
5. BACKGROUND OF FLYWHEEL CONCEPT 22
6. FLYWHEEL BASED BATTERY CHARGER 26
7. COMPONENTS OF PROJECT 31
8. ADVANTAGES & DISADVANTAGES 36
9. CONCLUSION 38
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CHAPTER-1
INTRODUCTION
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INTRODUCTION
The cost of fossil fuel is increasing day by day as well as government policy is
also towards the minimization of atmospheric pollution. Bicycle is an economical
and pollution free vehicle for controlling the atmospheric pollution, which is not
depending on crude oil. Government is also taking many steps to make use of
renewable resources.The use of fossil fuels and other non-reusable sources of
energy must be reduced to keep emissions low and alleviate the use of diminishing
resources. The idea of human powered generation has been implemented in many
different situations. Some examples include hand-crank radios, shaking
flashlights, and receiving power from gym equipment (William and Jeffrey, 2012).
The use of exercise equipment for a clean source of energy would be an even more
fun experience for participants and provide a means to exercise and generating
power. The flywheel based bicycle generator utilizes human energy to produce
electricity quickly and efficiently. The goal is to provide technological solution to
problem in the rural world by using detailed opportunity recognition, evaluation,
and development of prototype. The prototypes are then turned over to the
developing world for manufacturing, distribution and use. Less commonly, pedal
power is used to power agricultural and hand tools and even to generate
electricity. Some applications include pedal powered laptops, pedal powered
grinders and pedal powered water wells. Some third world development projects
currently transform used bicycles into pedal powered tools for sustainable
development. Human powered generation gives a power source that is not directly
derived from natural sources. An example is a human powered generator operated
in absence of solar irradiation, wind and water. The power generated from pedal is
perfect for remote areas, hilly regions, strategic location, Islands etc., where
electricity generation is scanty if not nil. In these situations, a small portable
power generating unit would be of great help to provide power supply to charge
battery-operated gadgets like mobile phones, lamps, radio, communication
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devices, etc. A new way to bring power to the people as population continues to
grow and power shortages continue to occur. This design relates to very compact
and easily portable power-generating unit, besides being used as a power
generator can also be used as cycle exerciser. It serves dual purpose of power
generation and helping the persont maintain physical fitness through exercise of
muscles of legs. It can be pedalled or cranked by hand/foot to charge 12 volt
batteries and run small appliances.
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CHAPTER-2
ABSTRACT
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ABSTRACT
In remote areas, hilly regions, strategic location, border areas (army
deployment), Islands etc. generation of power is scanty if not nil. In these
situations a Small Manual Battery Charging Unit would be of great help to
provide power supply to battery chargers or battery operated gadgets like
mobile phone, communication devices, radio, lamp, fan, TV etc. This
product was conceived while studying various means to charge the
batteries of an energy efficient lamp. The present design relates to very
compact and easily portable power-generating unit, which besides being
used as a power generator and battery charger can also be used as cycle
exerciser. The power-generating unit is pedal operated. It serves dual
purpose of power generation and helping the person to maintain physical
fitness through exercise of muscles of legs and lower torso. The force
applied to the pedals gets transmitted to the flywheel rotor unit of power
generating device through chain-sprocket and gear train. The sizes of
sprockets and gears are so chosen to achieve suitable rotating speed of the
flywheel rotor for power generation. The shape and size of rotor is chosen
to act as a flywheel and impart suitable moment of inertia. The electrical
power so produced can be fed to a generator unit and plurality of electrical
connectors in the generator unit provides electrical power to various
electrical devices. As per the suitability of individual user the height of the
present design can be adjusted. The design enables hands free operation
and simultaneously the user can engage himself in other activities like
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reading, watching TV etc. The user can relax intermittently without
stopping the motion of the rotor unit abruptly.
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CHAPTER-3
LITERATURE SURVEY
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LITERATURE SURVEY
Throughout human history, energy has generally been applied
through the use of the arms, hands, and back. With minor exceptions, it
was only with the invention of the sliding-seat rowing shell, and
particularly of the bicycle, that legs also began to be considered as a
"normal" means of developing power from human muscles (Wilson,
1986). Over the centuries, the treadle has been the most common method
of using the legs to produce power. Treadles are still common in the low-
power range, especially for sewing machines. Historically, two treadles
were used for some tasks, but even then the maximum output would have
been quite small, perhaps only 0-15 percent Innovative Systems Design
and Engineering of what an individual using pedal operated cranks can
produce under optimum conditions. However, the combination of pedals
and cranks, which today seems an obvious way to produce power, was
not used for that purpose until quite recently. It was almost 50 years after
Karl von Krais invented the steerable foot-propelled bicycle in 1817 that
Pierre Michaud added pedals and cranks, and started the enormous wave
of enthusiasm for bicycling that has lasted to the present. Ever since the
arrival of fossil fuels and electricity, human powered tools and machines
have been viewed as an obsolete technology. This makes it easy to forget
that there has been a great deal of progress in their design, largely
improving their productivity. The most efficient mechanism to harvest
human energy appeared in the late 19th century pedaling. Stationary pedal
powered machines went through a boom in the turn of the 20th century,
but the arrival of cheap electricity and fossil fuel abruptly stopped all
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further development (Kris, 2011). Otto Von Guericke is credited with
building the first electrical machine in 1660. This form of electricity
precedes electromagnetic energy which dominates today. The landscape
for today's electricity usage practices bloomed from 1831 to 1846 with
theoretical and experimental work from Faraday, Weber and Gauss in the
relationship of current, magnetic fields and force. These theories enabled
the design modern motors and generators. From 1880 to 1900, there was a
period of rapid development in electrical machines. Thus this section
reviews the works that has been n human power generation.
KERS Bicycle
Mechanical kinetic energy recovery bicycle by use of flywheel was
done by Athlone Institute of Technology, Westmeath, Ireland. Maxwell
von Stein's Flywheel Bicycle stores the power that would otherwise be
wasted in the braking process. In order to help boost their range, many
electric and hybrid cars employ regenerative technology where braking
energy is stored in the battery instead of simply being wasted. Maxwell
von Stein, a student at New York City's Cooper Union for the
Advancement of Science and Art, thought of implementing a flywheel to
an existing bicycle, in order to harness the energy that's lost during
braking. That energy can then be used to boost the bike when needed. The
Flywheel Bicycle has a continuously variable transmission in the rear hub.
This is linked to a 6.8 kilogram (15 lb) flywheel from a car engine
mounted in the middle of the frame. When the cyclist wishes to slow
down, such as when they're going down a hill or coming to a stop, they
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shift the transmission to maximize the flywheel-speed-to-bike-speed ratio.
This "charges" the flywheel with kinetic energy - effectively a mechanical
version of what happens in an EV where a battery stores the scavenged
energy. Once they want to accelerate or climb a hill, they do the opposite -
they shift the transmission to minimize the ratio. This lets the energy
stored in the flywheel drive the transmission, giving the bike and its rider a
boost.
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BASIC CONFIGURATIONS OF BICYCLE GENERATOR
The basic configuration of a bicycle generator consists of rider input
where rider releases energy through pedals. This input energy from rider is
further passed to gears and drive wheel of the bicycle. The flywheel which
is connected to rotor of generator starts rotating. Once generator meets
sufficient speed, it starts to generate voltage. This generated is sent to
booster circuit which provides sufficient constant voltage to the battery to
charge as shown in Fig 1.
Fig-1:Block diagram showing the Energy conversion loop
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CHAPTER-4
COMPONENTS SPECIFICATION
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COMPONENTS SPECIFICATION
Generator:
Permanent Magnet DC Generator is used in the
experiment. Ratings of this generator are 16V, 2A, 1000RPM. This
generator gets almost constant amount of speed as input to rotor since
flywheel is used.
Flywheel:
A flywheel is a mechanical device specifically designed to
efficiently store rotational energy. Flywheels resist changes in rotational
speed by their moment of inertia. The amount of energy stored in a
flywheel is proportional to the square of its rotational sped. Flywheels are
also used to provide continuous power output in systems where the energy
source is not continuous. The flywheel used is of 17cm Dia, 0.8cm Width
and 2.5kg weight.
LI-PO Battery bank:
A Lithium-Polymer battery is rechargeable battery of lithium-ion
technology using a polymer electrolyte instead of more common liquid
electrolyte. Here 12V, 4.4AH battery bank is being used.
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Belt Drive System:
A belt is a loop of flexible material used to link two or more
rotating shafts mechanically. Belts are used to transmit power more
efficiently. Belts need not to be axially aligned.
DESCRIPTION OF BICYCLE GENERATOR:
For the experimental investigation bicycle
generator with a Permanent Magnet Direct Current (PMDC) generator is
mounted above the rear wheel of the bicycle with flywheel connected to
generator shaft is as shown in Fig.2. This Flywheel is driven by pulleys
drive system. The generator produces 30w of power when the bicycle is
rode at 10kmph. This generated power is stored in the lithium polymer
battery bank of 12v 4.4ah. The battery bank is protected by battery
management system (BMS), which protects battery from over charge, over
discharge and short circuit. These charged batteries can be used to light
homes, to charge electronic devices and can also be used to pedal assist
while riding in uphill. While moving up-hill, the rider has to pedal with
more power in order to run the cycle upwards in this situation running
generator simultaneously is impossible, so a clutch system is used where it
separates the flywheel and generator system from rare wheel.
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Fig.2: Bicycle generator with a Permanent Magnet Direct Current (PMDC) generator
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INVESTIGATION OF GENERATED VOLTAGE AND CURRENT
The experimental prototype, rider is made to ride bicycle in downhill
(15KMPH) and straight road(10KMPH), the corresponding values of
generated voltage and current when connected to a battery bank of 12V
4.4AH are in given in Table.
1. TABLE-1:GENERATED VOLTAGE AND CURRENT FOR A
BATTERY BANK OF 12V 4.4AH
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CHAPTER-5
BACKGROUND OF FLYWHEEL CONCEPT
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BACKGROUND OF FLYWHEEL CONCEPT
Energy storage can take several forms; fuels, batteries, and flywheels
(kinetic energy) . Flywheels have been in existence since time immemorial
serving as devices for mechanical energy storage. Flywheel energy storage
functions through high-speed acceleration of the flywheel (a rotor) while
maintaining the rotational energy in the entire system . The subsequent
extraction of energy from the system decreases the rotational speed of the
rotor as a consequential outcome of the energy conservation principle.
Correspondingly, increasing the speed of the rotor requires addition of
energy to the framework.Potter’s wheel, the first version of flywheel,
exemplifies the functioning of, and illustrates the basic structure of a
flywheel. In this case, the potter proffers the requisite force for rotation of
the wheel. Subsequently, while the potter molds the wheels using her
hands, she repeatedly kicks the wheel to normalize the rotation speed vis-
à-vis the frictional forces that work against the acceleration of the wheel.
Friction in the potter’s wheel come from both the wheel bearings and
working the clay. To this end, it is noteworthy that the weight of the wheel
determines the uniformity of the rotational velocity and the ultimate.
The modern flywheel features tiny, but entirely significant,
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modifications depending on the specific application of the flywheel
system. Essentially, the contemporary flywheel for electrical energy
storage comes complete with a rotating mass whose function is to regulate
the voltage of the lines attached to the flywheel. The rotating mass is often
made of metal but can encompass other suitable materials in accordance
with the features of the entire system and the general use. Since the
rotating mass forms part of an electrical motor , it draws its spinning force
from the electric motor. However, due to the such forces as friction, the
flywheel occasionally losses energy, thus, necessitating the existence of a
mode of charging for increased energy. On that note, charging the
flywheel entails sequential injection of electrical current pulses to the
fixed coils (the stator). The electric currents generate magnetic fields that
exert force on the flywheel setting it in a rotational motion. Speeding up
the rotor stores energy while slowing it down provides energy- this sums
up the operation principle of the flywheel. The control system couples
with the voltage system of the setup to control the entire operation of the
flywheel.
On the same vein, it would be erratic to assume that the flywheel only
has two states (speeding up or slowing down), it remains idle in the
absence of the former state. At this point, the flywheel rotates at a
constant speed given that the friction losses in the bearings are negligible .
As such, it can take a relatively longer time to slow down.The improved
or contemporary flywheel’s primary parts include a power converter,
stator, rotor, controller and bearings. The rotor is a combination of the
rotating sections of the power generator and the bearings. Below is a
schematic diagram for flywheel subsystems.
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The power converter attaches to a Direct Current (DC) source.
According to Castelvecchi (2007), it generates the pulses of current
whose cumulative force speeds up the flywheel (rotor). The resulting
current has both varying voltage and frequency.The function of the
controller is to determine and regulate the frequency in a manner that the
rotor receives the push just in time. Permanent magnets for man inalienable
parts of the rotor.The bearings provide a minimal-drag support for the
rotor with a net effect ofless energy loss. The entire system operates
alongside the necessary cooling fans, fuses and contractors to improve
safety and efficiency. On the overall, the flywheel system is useful in
supplying the required energy when the need arises or dissipating the
excess energy when necessary. Such mode of operation can be critical for
a flywheel based battery charger
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CHAPTER-6
FLYWHEEL BASED BATTERY CHARGER
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FLYWHEEL BASED BATTERY CHARGER
Essentially, a flywheel system is a simple mechanical battery. As such,
with the earlier mentioned components, one can easily modify the basic
structure of a flywheel for such applications as a flywheel-based battery
charger. Thefollowing figure is an illustration of a possible flywheel design
for such a battery charging flywheel system.
Figure : Setup of Flywheel Based Battery Charger
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System Description
The Figure 2 offers a pictorial outlook of a battery charger that incorporates a
flywheel and its operation principle. The basic design of this battery charger
model comprises flywheel that consist of a medium-density fireboard, steel,
and iron among other materials. In most cases, the flywheel is forms from any
two of the components to cater for issues of cost saving and durability. While
the flywheel model described in the introductory section of this paper uses
electrical currents to acquire a rotational force, this design is unique in the
sense that it will use human power just like the potter’s wheel. Using the
human power in this case is aimed at making the system more energy-saving
in the sense that it will not require any electricity or whatever form of energy
to run. Besides, then, it means that the system will hardly experience
downtimes given that the minimal human power required will always be
present. The human power finds its way through the mechanical framework
with the help of paddles, chain, sprocket, and the freewheel structure.The
mechanical human power from the flywheel system then propagates to the
electricity generator. The process uses the mode of energy transmission that
multiplies the velocity of the rotor (flywheel) before its transmission to the
electricity
Following a successful assembly of the entire system, it is put into an
iron-cabinet which should also be portable and not prone to disintegration.
The above flywheel based battery charger system is projected to vary
between 1.5 to 12- voltbattery charging. In a commercial sense, this design is
highly promising. The commercial potential of this design is particularly
perspicuous given the fact that load sheddinghas, in the recent past, been a
weighty issue [1] in both remote urban and rural areas. The system has the
ability to give massive positive returns for home use and small scale
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agricultural use. In an urban set up, this flywheel based battery charging
system can find application in the exercise machines. To this end, the
dynamic device is multifaceted in
the sense that it can perform several roles both in and out of the home.
Another advantage of this design is that it can be modified to serve both
large and small scale operations. In addition, in a world that is constantly
looking for means to save energy, this system seems to be the right choice
given its mechanical nature. Finally, just like the normal generators, this
system proffers the ability to incorporate stationary driving machines. In
this manner, a simple step-up of the engine capacity through multiplication
of the available power enables the system to charge larger batteries.Even
with such high levels of efficiency and effectiveness, the system still uses
bearings whose complexity may increase energy loss. Besides, the limits of
mechanical fatigue and stress of the components may prevent the system
from superseding the sensible levels of efficiency and performance in large
scale operations. Samineni (2003) approximates the speed limit of the
materials at 700M/sec which is relatively low for larger batteries. Even
then, the possibility of adjustments makes a case for this system.
System Testing
In as much as the design of the system looks simple superficially,
testing is still critical and plays a central role in determining the feasibility
of the system and its plausibility in various application settings. The
degree of interdependence and integration of the various components of
the flywheel seemed relatively high. However, the actual performance of
the various components, especially the external subsystems, can only be
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ascertained when they are part of the flywheel framework [5]. For
instance, the characterization of a bearing is only possible when it is used
in a flywheel that is rotating at its maximum speed and
power. Among the attributes that notable during the system testing
include output voltage, step load transient response, start-up and charging
time, power versus time, standby power consumption, energy recovery
efficiency, and duty factor.
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CHAPTER-7
COMPONENTS OF PROJECT
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COMPONENTS OF PROJECT
1. Speedometer:
2. Flywheel
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3. Generator
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4. LI-PO Battery
5. Belt Drive
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6. Stand
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CHAPTER-8
ADVANTAGES & DISADVANTAGES
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Advantages
- Low maintenance.
- Long life (more than 2-3 years)
- Low environmental impact.
- Excellent load following characteristics.
- No fuel, water or any resource consumption.
Disadvantages
- Add weight to cars expecielly problematic in
raceing cars.
- Highcost as compare to PHS and batteries.
- Cost 1400s/kw³
- Cannot hold power for long durations.
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CHAPTER-9
CONCLUSION
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Conclusion and Recommendations
This particular design of the flywheel based battery charger has not
yet been rolled out for commercial use. The stated commercial
applications are mere projections of it potentiality. However, while
this design can be used for further research that would see pivotal
improvements incorporated into this design, it could also be adopted
gradually. Scalability is one major concern of this design. Here, size
matters. As a matter of fact, large scale adoption of this design
requires a relatively larger system with numerous modifications and
adjustments. Such an endeavor comes with equally numerous
iterations before the system meets the scale requirements. It is also
noteworthy that the battery charger will, at some point, cease to be
portable in large scale application. Apart from scalability, system
efficiencyis an issue of concern. Even then, the issue of efficiency
grows more critical with increase in scalability. Thus, in large scale
applications, the flywheel based battery charger must be highly
efficient. It is, therefore, fortunate that this design is highly flexible
and can be tweaked depending on the nature of application and the
needs of the consumers. Since this design is not yet commercialized,
it is recommended that business incubators work in close cooperation
with the developers to oversee the success of this device . Besides,
several field experiments are necessary in determining the actual,
rather than theoretical, feasibility of this design. Finally, the fact that
this design uses human power limits its scalability and performance,
thus, electrically powered flywheel based battery chargers would
be more suitable at such high scales. The design in this discussion
remains highly suitable for small scale operations, but with room for
modification to meet the high-scale thresholds.
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