Final Design Presentation

1. EMD342-Machine Design
Final Presentation
Title: Gyro-Flywheel Powered Car
Group: CKW2
Members:
1. Umesh A/L Ganesh 148397
2. Hon Zhi Jie 146735
3. Khoo Han Jian 147973
4. Muhammad Zuhairi bin Zuhan 146026

2. 1. Result Presentation Response
Issue Response
- Error on stress analysis - Redo and obtain the correct value of the stress
analysis
- Stability of the design - Use acrylic plate for the base or tying the box
holder to the car at four corner

3. Corrected Stress Analysis

4. 2. Assembly and Manufacturing design procedure

6. 3. Cost of components and off-the-shelve parts
No Part Quantity Price per part (MYR) Total price (MYR) Source
1 Flywheel 1 60 60 rozeem.com
2 Vacuum box 2 15 30 rozeem.com
3 Shaft 2 12.07 12.07 Shopee
4 Magnetic coupling 1 and 2 2 7 14 rozeem.com
5 Shaft connecter 2 6.39 12.78 Shopee
6 Mounted bearing 4 5.35 21.38 Shopee
7 Magnetic coupling holder, lock for holder 1 10 10 rozeem.com
8 Pneumatic one-way valve 1 6 6 Shopee
9 Box holder 2 5 10 rozeem.com
10 Lock for flywheel 1 0.50 0.50 rozeem.com
11 DC motor 1 100 100 Alibaba.com
12 Casing 2 45 45 rozeem.com
13 Neodymium magnet 21 0.92 19.20 Shopee
14 RC car 1 130 130 Shopee
TOTAL: 470.93
Cost for machine parts (assumed that we buy all components outside not considered from the school lab’s store)
Parts that obtained from school lab’s store

7. 4. Proposal for Pricing of the Machine
No Type Price
(MYR)
1 Machine parts 470.93
2 Labour cost 200
TOTAL: 570.93
No Type Price (MYR)
1 Total design price 570.93
2 Expected sale price 770.93
3 Profit 200
Expected Sales Price and Profit
Cost analysis

8. 5. Return of Investment analysis
ROI for 5 years, assume we sell 300 units
Fixed cost:
 Capital cost for 300 units
= RM 50 x 300 units
= RM 15 000
 Place for 5 years
= RM 10 000
Total = RM 25 000
Total = RM 175 779
OVERALL COST: RM 200 779
Total earning: RM 770.93 x 300 unit = RM 231 279
ROI = (Return on Investment /Cost of Investment) ×100%
= ((Final Value – Initial Value)/ Cost of Investment) x 100%
ROI = (RM231 279 – RM200 778)/ RM200 778 x 100%
= 15.19% over 5 years or average
Return of 15.19% / 5 =3.04% annual return
This business seems viable
Variable cost:
 Labour cost
= RM 100 x 300 units
= RM 30 000
 Transport
= RM 4 500 for 300units
 Components/parts
= RM 470.93/unit x 300
= RM 141 279

9. 6. Prototype Demonstration

10. 7. Machine Performance Validation
Simulation using SOLIDWORKS: Angular Velocity of Flywheel
Graph of Angular Velocity Vs Time
- Flywheel angular velocity: =100rpm = 600deg/sec

11. Validation: Angular Velocity
Analytical Method:
• Revolutions per minute (rpm) can be converted to angular velocity in degrees per second by
multiplying the rpm by 6
• 1 revolution = 360 degrees, 1 minute = 60 seconds
• We have used 100 rpm for the rotation of shaft connected to flywheel
• Hence, 100 𝑟𝑝𝑚 × 6 = 600 𝑑𝑒𝑔/𝑠𝑒𝑐, it is validated that the results from Motion Simulation
using SOLIDWORKS is the same as the analytical method

12. Conclusion of Validation
• Only can use SOLIDWORKS to perform analysis.
• Failure due to several causes

13. Failure Causes
• Shaft fabricated are not really straight causing the assembly process become harder and imperfect. (flywheel,
coupling shaft)
• The motor selection is not suitable. Motor requires same or higher power supply to make it move/ The selected
component can only act as generator and not motor, thus cannot work if electricity is supplied.
• The dimension of the overall box are not precisely measured. An unmeasured part to be assemble caused the
design barely fits.
• 3D printed product are sensitive, cannot be stored just anywhere and need to be placed at a cool places.
• Magnetic coupling does not align correctly. The magnet should be first aligned with an appropriate distance to
make it work efficiently.
• Stability for the box holder is not efficient. The assemble is easily dislocated.
• The vacuum box is not functioning. The 3D printing process have a possibility to contain a micro-size leakage
causing the air to enter the box.

14. 8. Reflection on the developed machine prototype
The first two objective of our project is: Design gyro-flywheel engine ( FESS &
Gyroscope); and Design a mechanism to utilize the gyroscopic concept to assist
the movement of the car. The engine of the remote control car should be
replaced by our gyro-flywheel system that can provide electricity to drive the
remote control car.
Next, the gyroscopic concept is utilized by placing all the components and
parts into a gyro-flywheel box which is later placed on the remote control car.
When the car turns to either left or right, the entire gyro-flywheel box will turn
to assist the movement of the car.

15. Unfortunately, the third objective (Design a suitable coupling system to reduce
waste of energy) is not met. This is due to the resistance in between the coil
wire and magnet of the motor-generator is too strong. As a result the magnetic
coupling fails to turn the shaft of motor-generator. The possible solution to
this problem may be reducing the numbers of magnet in the motor-generator
so that the resistance can be reduced or using other stronger coupling system
such as fluid coupling.

16. 9. Reflection on
management of design

17. Design Project Management Planned Outcome
Brainstorming design ideas Have chosen the best out of 4 design
Materials and components identification 1. Material used for casing: PLA
2. Box holder: Iron bar
3. Motor-generator provided: Double-layer Disc
Generator with Iron Core Multi-pole Strong
Magnetic Three-phase AC Power Generation
4. Shaft: Steel bar
5. Magnetic coupling
Holder: PLA
Magnet: Neodymium magnet
6. Vacuum box: PLA.
7. Flywheel: Aluminium

18. Design Project Management Planned Outcome
Part Design using SOLIDWORKS 1. All the parts we fabricate ourselves are designed
2. Tolerance analysis is done
3. They are sent to fabrication for CNC milling
and 3D printing process
Part Assembly using SOLIDWORKS 1. Visualise the assembly of the parts
2. BOM is done
Simulation using SOLIDWORKS 1. Motion analysis is done
2. 3D rendering and function simulation are
produced
3. Structural analysis for shaft, flywheel and casing
are done
Fabrication of parts 1. All the parts fabricated by ourselves are finished
successfully

19. Design Project Management Planned Outcome
Assembly of prototype 1. The dimension of casing is not enough precise
2. The casing should not be made by polylactic
acid (PLA) due to poor in withstand heat
3. Box holder is not enough stable
4. Selected motor-generator is not suitable. Only
functions as generator, cannot operate by DC
power supply
5. Fabricated shafts are not straight
6. Magnetic coupling is possible if the alignment
and distance between the coupling is more
accurate
7. There might be micro-sized hole on the vacuum
box surface which results in air entering the
box. Super glue is applied onto the surface.
8. Fail to test run the prototype

20. 10. Conclusion
1. The GYRO-FLYWHEEL POWERED CAR project is partially success and partially not workable.
2. Learned more about fabrication processes that used for our project. (Ex. CNC machining, 3D printing, turning
process, MIG welding, wire cutting process, milling machining process, soldering etc)
3. The gyro concept success, which the overall box will rotate and assists the car turning direction.
4. The flywheel cannot spin smoothly because of the incorrect alignment between two mounted ball-bearing, shaft
hole of ball bearing is not straight and shakes whenever the shaft spin.
5. The DC motor not working.
• Reason 1: The wire connection in 3 phase bridge rectification board not correct.
• Reason 2: The DC motor cannot use as motor to spin the flywheel, only can use as generator for electricity
generation as the online seller said.