Power generattion from thread mill new

POWER GENERATION FROM MANUAL TREADMILL

CONTENTS
CHAPTER NO TITLE
PAGE NO.
1 SYNOPSIS
2 Introduction
3 Literature review
4 Description of equipments
5 Design and drawing
6 Fabrication
7 Working principle
8 Merits & demerits
9 Applications
10 List of materials
11 Cost Estimation
12 Conclusion
13 Bibliography
14 photography

SYNOPSIS
An educational electrical generation kit includes a thread mill support which may
accommodate the driven shaft of thread mill, and wherein a generator engages the driven thread
mill to generate electricity. The kit also includes a display board with various electrical output
meters and/or electrical loads for monitoring and/or dissipating the electrical output from the thread
mill. The kit is designed to be readily portable and easily set up and torn down, and to allow a
spectator/participant to incorporate a thread mill of virtually any size into the thread mill support to
interactively generate electricity for use in the display board.
The modern challenge faced with the global energy situation is the growing energy demand
and the strong dependence on unsustainable fossil fuels. Another concurrent issue is the adverse
health and socio-economic implications of adult obesity. Human Power Generation, which uses
metabolized human energy to generate electrical power, could potentially address both these
challenges. The treadmill, one of the most popular exercise machines, presently consumes large
amounts of energy while dissipating a majority as heat. The purpose of this thesis project was to
design and develop a human powered treadmill generator and determine its power generation
potential. The developed treadmill was based on a manual flatbed treadmill using an
electromagnetic dynamo generator coupled to a front axle flywheel.
A heavy duty rechargeable battery pack was used to store the generated energy and
additional components to measure the generated power were included. The power generating
potential of the generator was determined for varying belt speeds and angles of inclination, and
compared with the American College of Sports Medicine (ACSM) metabolic walking and running
prediction equations to determine efficiency.
The generator was able to deliver 140W peak power for a short period of time.. Possible
applications for this concept include energy saving equipment in a gym, low-cost, simple to
operate, and low maintenance solutions for developing nations, and as a tool to educate energy
conservation. Also, the need for exercise in space with low gravity makes the treadmill generator a
possible source for secondary power in future extraterrestrial environments.

INTRODUCTION
The world‟s energy consumption is at an all time high with the demand continuously
increasing. This situation brings up several challenges that need to be addressed [1]: Depletion due
to finite availability of non-renewable energy sources, e.g. fossil fuels Environmental pollution, e.g.
with coal use in power plants Increasing population, especially in developing countries which lack
resources for clean energy Global warming with the related climate changes and adverse
implications Powering new technological applications, e.g. ultraportable electronics, wireless
sensor nodes, etc.
These challenges have been reason for much controversy in the developed world; however,
recent investigations have also shown a much more basic challenge of availability in the less
developed parts of the world. Data from the World Bank obtained as recently as 2009 estimated that
about 25.9% of the world‟s population (greater than 1.81 billion people) has no access to electricity
[2]. Larger numbers include those that have very limited access to electricity. Further, most
countries with the lowest values for percent of population with electricity also have low values of
urban population percentage, as seen in Table 1. 5 Table 1: Countries with least percentage of
population with electricity, compared with urban population percentage ‘Rank’ in least availability
of electricity access in 2009 (out of 87) [2] Country Percent of population with access to electricity
in 2009 [2] (%) Urban population as a percentage of total in 2009 [3] (%) 1 Uganda 9.0 13 2
Malawi 9.0 19 3 Congo, Dem. Rep. 11.1 35 4 Mozambique 11.7 38 5 Myanmar 13.0 33 39 India
66.3 30 74 China 99.4 44 A short comparison of the two most populous countries with known
booming economies also suggests an interesting relation between these two parameters.
Establishing a direct relationship would require a further, more comprehensive investigation
but it can be imagined that when the population is more diffused, less people are likely to have
access to electric power. Difficulties 6 such as the costly and time-consuming development of long
range power transmission to scattered remote areas can inhibit those regions from having
electricity.

LITERATURE SURVEY
The usage of traditional power generation method such as burning of coal, wood, diesel
(generators) etc is continuously depleting our natural resources such as fossil fuels, which is the
demand for power has exceed the supply due to the rising population. In addition to this the
traditional methods cause pollution, encourage deforestation (cutting of trees) the consequences are
global warming, power shortage like we are facing in Tamilnadu.
GLOBAL WARMING:
Global warming is the increase in the average measured temperature of the Earth's near-
surface air and oceans since the mid-20th century, and its projected continuation. Global surface
temperature increased 0.74 ± 0.18 °C (1.33 ± 0.32 °F) during the 100 years ending in 2005. The
Intergovernmental Panel on Climate Change (IPCC) concludes that most of the increase since the
mid-twentieth century is "very likely" due to the increase in anthropogenic greenhouse gas
concentrations. Natural phenomena such as solar variation combined with volcanoes probably had a
small warming effect from pre-industrial times to 1950 and a small cooling effect from 1950
onward.
Climate model projections summarized by the IPCC indicate that average global surface
temperature will likely rise a further 1.1 to 6.4 °C (2.0 to 11.5 °F) during the twenty-first century.
This range of values results from the use of differing scenarios of future greenhouse gas emissions
as well as models with differing climate sensitivity. Although most studies focus on the period up
to 2100, warming and sea level rise are expected to continue for more than a thousand years even if
greenhouse gas levels are stabilized. The delay in reaching equilibrium is a result of the large heat
capacity of the oceans.
Increasing global temperature is expected to cause sea levels to rise, an increase in the
intensity of extreme weather events, and significant changes to the amount and pattern of
precipitation, likely including an expanse of the subtropical desert regions.. Other expected effects
of global warming include changes in agricultural yields, modifications of trade routes, glacier
retreat, mass species extinctions and increases in the ranges of disease vectors.
Remaining scientific uncertainties include the amount of warming expected in the future,
and how warming and related changes will vary from region to region around the globe. Most
national governments have signed and ratified the Kyoto Protocol aimed at reducing greenhouse
gas emissions, but there is ongoing political and public debate worldwide regarding what, if any,
action should be taken to reduce or reverse future warming or to adapt to its expected
consequences.

Global dimming, the gradual reduction in the amount of global direct irradiance at the
Earth's surface, may have partially mitigated global warming in the late 20th century. From 1960 to
1990 human-caused aerosols likely precipitated this effect. Scientists have stated with 66–90%
confidence that the effects of human-caused aerosols, along with volcanic activity, have offset some
of the global warming, and that greenhouse gases would have resulted in more warming than
observed if not for these dimming agents.
Ozone depletion, the steady decline in the total amount of ozone in Earth's stratosphere, is
frequently cited in relation to global warming. Although there are areas of linkage, the relationship
between the two is not strong.
POWER SHORTAGE:
Some developing countries and newly-industrialized countries have several hours of daily
power-cuts in almost all cities and villages because the increase in demand for electricity exceeds
the increase in electric power generation. Wealthier people in these countries may use a power-
inverter (rechargeable batteries) or a diesel/petrol-run electric generator at their homes during the
power-cut. The use of standby generators is common in industrial and IT hubs.
ULTIMATE AIM:
The ultimate aim of this project is to develop much cleaner cost effective way of power
generation method, which in turns helps to bring down the global warming as well as reduce the
power shortages.

DESCRIPTION OF EQUIPMENTS
DESCRIPTION OF EQUIPMENTS

These challenges have been reason for much controversy in the developed world; however,
recent investigations have also shown a much more basic challenge of availability in the less
developed parts of the world. Data from the World Bank obtained as recently as 2009 estimated that
about 25.9% of the world‟s population
(greater than 1.81 billion people) has no access to electricity [2]. Larger numbers include those that
have very limited access to electricity. Further, most countries with the lowest values for percent of
population with electricity also have low values of urban population percentage, as seen in Table 1.
5 Table 1: Countries with least percentage of population with electricity, compared with urban
population percentage ‘Rank’ in least availability of electricity access in 2009 (out of 87) [2]

Country Percent of population with access to electricity in 2009 [2] (%) Urban population as a
percentage of total in 2009 [3] (%) 1 Uganda 9.0 13 2 Malawi 9.0 19 3 Congo, Dem. Rep. 11.1 35 4
Mozambique 11.7 38 5 Myanmar 13.0 33 39 India 66.3 30 74 China 99.4 44 A short comparison of
the two most populous countries with known booming economies also suggests an interesting
relation between these two parameters. Establishing a direct relationship would require a further,
more comprehensive investigation but it can be imagined that when the population is more diffused,
less people are likely to have access to electric power. Difficulties 6 such as the costly and time-
consuming development of long range power transmission to scattered remote areas can inhibit
those regions from having electricity.
This lack of power in remote regions can hinder a country‟s ability to undergo overall
economic development. Hence, it is learned that electricity is still needed on the basis of availability
to a significantly large amount of the world‟s population. Further, means of delivering or producing
electricity in a way that is feasible and practical in remote regions, especially those of less
developed countries, are worth investigating. In terms of meeting the energy demand, data shows
the high dependence the world has overall on fossil fuels. Fossil fuels are known to be non-

renewable, having formed over millions of years of decomposition of prehistoric biological forms
such as plant matter and the dinosaurs [4]. The rate at which modern society is consuming these
resources is far quicker, however, risking the depletion of this resource. Furthermore, the manner in
which the resource is consumed is known to produce pollutants (e.g. Carbon Monoxide (CO)) and
green house gases (e.g. Carbon Dioxide (CO2)) in our environment. Carbon Dioxide emissions
have been steadily growing through the combustion of fossil fuels as needed in transportation,
power generation and otherwise. One of the main reasons why this is a critical problem is that the
world heavily depends on these fossil fuels currently to feed its energy demands. Figure 1 illustrates
the level and trends of fossil fuel use as compared to total energy consumption over time in a few
countries and the world overall [5]. 7 Figure 1 Statistics shown here illustrate how the world on
average depends majorly on fossil fuels to supply energy. The trend in this parameter is also of
concern as the value has been stable around 80% for the past 15 years. The United States shows a
slow decline but is still above the world average. The trend of the most populous countries, China
and India, can also cause distress as the fossil fuel dependence is increasing at a rapid rate over
time. In the case of China, the value has superseded that of the United States as of 2006.
Therefore, it is established that with the various energy challenges faced today, renewable energy
sources must be seriously investigated. Particularly, the feasibility of low-cost, lowmaintenance and
simple methods of providing energy to remote areas should be studied. Such 0 10 20 30 40 50 60
70 80 90 100 1994 1999 2004 2009 Fossil fuel energy consumption (% of total) Year Fossil fuel
energy consumption trends in the US, China, India and World World United States China India 8
technology could not only help provide an alternative to fossil fuel in developed countries, but also
serve the growing needs of developing countries in a responsible way.
Purpose of Thesis Study
A Brief History of Human Power Generation Human power has been instrumental in
helping solve problems since ancient times. For example, all tools have historically been human
powered. It is believed that the first human powered device to generate rotary motion was the
potter‟s wheel, around 3,500 B.C.E. [12]. Later, devices such as Archimedes‟ screw allowed
efficient transfer of water from one level to another. The Chinese, after 200 C.E., were found to use
hand cranks to aid in textile manufacturing, metallurgy and agriculture. After the mid-15th century,
the technique of incorporating flywheels to produce smooth motion proliferated, allowing devices
such as the spinning wheel to gain popularity in Europe. Cranks and pedal power became one of the
most efficient means of coupling human power to applications. In the 19th century, the bicycle‟s
use of pedals allowed an efficient means of self-transportation [1]. In parallel with the invention of

the electric dynamo in the 19th century, it is speculated that pedal power was used to generate
electric power as early as then [13]. 10 However, with the burgeoning of the industrial revolution in
the 19th century and forward, human society found other ways of powering their engineered
applications. Particularly, the availability of cheap and plentiful electricity, powerful motors and
disposable batteries can be attributed to the decrease in popularity of using human strength [1].
Also, the ethical implications of having humans produce energy as punishment, as seen in some
prison mills, further diminished the popularity of human sourced power [12]. It would take until the
latter half of the 20th century for science to seriously reinvestigate this resource. Modern
Applications Today, human power has made sort of a comeback with many applications where it
can be of use and the reason to investigate alternative energy [1]. A novel feeling of empowerment
is recognized when people are able to do things for which they had to rely on machines previously
[12]. So much so, that the idea of powering solely from human energy exists as a technical
challenge. For example, the American Society of Mechanical Engineers (ASME) holds the Human
Powered Vehicle Challenge (HPVC) competition annually for encouraging higher education
students to construct and compete with single-driver prototypes power by the driver alone [14].
Further, the Royal Aeronautical Society has various challenges for the Kremer‟s prizes in human
powered flight [15]. The end goal of
this initiative is to qualify such an endeavor to be a competitive sport, possibly a part of the
Olympics. Human power has also been found to be uniquely good at providing energy generation in
isolated situations. For example, [16] shows the development of hand-operated axial flux generators
which can be useful for dismounted soldiers, search and rescue operation in case of 11 natural
disasters, relief workers in remote regions and field scientists. The study demonstrates how 60W
can be maintained from the generator for different applications while maintaining a lightweight
design for portability. Further, [17] provides a good example of applying human power in remote
areas of developing countries. In 1991, at the time of the study, many rural parts of India lacked any
access to electricity. Further, fossil fuel or solar/wind energy generation required skill in operation
and maintenance along with monetary resources that were unavailable. Human energy was
determined to be simple, dependable, required low capital, and reliable for the application of
desalinating local water. The successful implementation of a pedal powered system in the rural area

produced a sustainable 100W to power the desalination system. This let clean water be available to
the people locally, avoiding the need to walk 2km daily as done previously. This localized
generation of electricity has also made human power an excellent method for micro-power
generation. Theoretical analyses have been done to show that brisk walking motion can produce up
to 5-8W, adequate for basic wearable computing [18]. Recent research shows the performance of
three methods to perform this extraction. In [19], a summary of current progress in piezoelectric
generator technology shows power generation capabilities of up to 8400μW. Further, small-scale
electromagnetic generators are a little harder to manufacture but can produce power in the order of
mW. [20] shows the development of a electrostatic generator which uses microball movement
induced by low frequency human motion to generate at least 40μW. Such output power may seem
relatively negligible but it has potential in partially or completely removing the need for batteries,
making portable designs lighter, smaller and longer lasting. This is especially promising for
applications such as implantable and wearable 12 electronics, ambient intelligence, condition
monitoring devices, and wireless sensor networks [19]. These micro-electricity generators also
feature the unique aspect of passive electricity generation. That is, the generation requires no
deliberate human effort. This is recognized as an advantage in terms of psychological human
factors, prompting the study of power generation through child‟s play in [1]. This system used a
pneumatically actuated generator for safety and cost considerations and was able to produce about
5W. Further, [21] investigates energy generation from a dance club by developing floor tiles that
feature small-scale electromagnetic generators, allowing a single person to produce around 5-8W
for extended periods of time. The study went further to measure power output when multiple
humans are involved, as expected in a dance club environment. On average between 20-30W with
some peak values within 60-100W were produced in this scenario. Hence, it is demonstrated how
energy can be extracted from actions that are a regular part of human life, not requiring deliberate
effort. Moreover, there is potential in benefiting from the social nature of humans to multiply the
energy generated. The energy challenge as discussed earlier has generated interest in human
provided power as it is a renewable, carbon-free source. Pedal power generation has even been
established as a business with the presence of companies such as MNS Power (Mesa, AZ) which
sells DIY plans and equipment with which anyone can build a human powered generator [22]. Also,
ReRev (St. Petersburg, FL) has retrofitted at least 30 fitness facilities already to use existing
ellipticals in generating electricity [23]. Generating power via pedaling on a stationary bike has also
been investigated to find an output of 43-244W, depending on the load resistance [13]. 13 Hence, it
is seen that human power generation has multiple applications in modern society. It can be useful
when users are isolated as possible with natural disaster, military deployment or being in a remote
area. It also provides for an intuitive, easy to implement and relatively low cost design which is
particularly useful in rural areas of developing nations where skill in operating equipment and

investment capital is limited. Acquisition of energy via nondeliberate human effort is also possible
which could be useful for various novel portable electronics applications. Furthermore, it can allow
for power generation to be done socially, removing the feeling of deliberate effort while increasing
the power output significantly. The thought of using human energy as an alternative and renewable
energy source is gaining popularity to the level that businesses have formed around converting
exercise equipment such as stationary bikes and ellipticals to electricity generators.
BATTERY:
BATTERY CIRCUIT DIAGRAM:
CIRCUIT DIAGRAM DETAILS:
In our project we are using secondary type battery. It is rechargeable Type. A battery is one
or more electrochemical cells, which store chemical energy and make it available as electric
current. There are two types of batteries, primary (disposable) and secondary (rechargeable), both
of which convert chemical energy to electrical energy. Primary batteries can only be used once
because they use up their chemicals in an irreversible reaction. Secondary batteries can be
recharged because the chemical reactions they use are reversible; they are recharged by running a
charging current through the battery, but in the opposite direction of the discharge current.
Secondary, also called rechargeable batteries can be charged and discharged many times before
wearing out. After wearing out some batteries can be recycled.
Batteries have gained popularity as they became portable and useful for many purposes. The
use of batteries has created many environmental concerns, such as toxic metal pollution. A battery

is a device that converts chemical energy directly to electrical energy it consists of one or more
voltaic cells. Each voltaic cell consists of two half cells connected in series by a conductive
electrolyte.
One half-cell is the positive electrode, and the other is the negative electrode. The electrodes
do not touch each other but are electrically connected by the electrolyte, which can be either solid
or liquid. A battery can be simply modeled as a perfect voltage source which has its own resistance,
the resulting voltage across the load depends on the ratio of the battery's internal resistance to the
resistance of the load.
When the battery is fresh, its internal resistance is low, so the voltage across the load is
almost equal to that of the battery's internal voltage source. As the battery runs down and its
internal resistance increases, the voltage drop across its internal resistance increases, so the voltage
at its terminals decreases, and the battery's ability to deliver power to the load decreases.
DYNAMO:
Dynamo is an electrical generator. This dynamo produces direct current with the use of a
commutator. Dynamo were the first generator capable of the power industries.The dynamo uses
rotating coils of wire and magnetic fields to convert mechanical rotation into a pulsing direct
electric current. A dynamo machine consists of a stationary structure, called the stator, which
provides a constant magnetic field, and a set of rotating windings called the armature which turn

within that field. On small machines the constant magnetic field may be provided by one or more
permanent magnets; larger machines have the constant magnetic field provided by one or more
electromagnets, which are usually called field coils.
The commutator was needed to produce direct current. When a loop of wire rotates in a
magnetic field, the potential induced in it reverses with each half turn, generating an alternating
current. However, in the early days of electric experimentation, alternating current generally had no
known use. The few uses for electricity, such as electroplating, used direct current provided by
messy liquid batteries. Dynamos were invented as a replacement for batteries. The commutator is a
set of contacts mounted on the machine's shaft, which reverses the connection of the windings to
the external circuit when the potential reverses, so instead of alternating current, a pulsing direct
current is produced.
MOTOR:
D.C.MOTOR PRINCIPLE:
A machine that converts direct current power into mechanical power is known as D.C
Motor. Its generation is based on the principle that when a current carrying conductor is placed in a
magnetic field, the conductor experiences a mechanical force. The direction if this force is given by
Fleming’s left hand rule.
WORKING OF A DC MOTOR:
Consider a part of a multipolar dc motor as shown in fig. when the terminals of the motor are
connected to an external source of dc supply;
(i) The field magnets are excited developing alternate N and S poles.
(ii) The armature conductors carry currents. All conductors under N-pole carry currents in
one direction while all the conductors under S-pole carry currents in the opposite
direction.
Suppose the conductors under N-pole carry currents into the plane of paper and those under
S-pole carry current out of the plane of paper as shown in fig. Since each armature conductor is
carrying current and is placed in the magnetic field, mechanical force acts on it.
Applying Fleming’s left hand rule, it is clear that force on each conductor is tending to
rotate the armature in anticlockwise direction. All these forces add together to produce a driving
torque which sets the armature rotating. When the conductor moves from one side of the brush to
the other, current in the conductor is received and at the same time it comes under the influence of
next pole which is of opposite polarity. Consequently the direction of force on the conductor
remains same.

PRINCIPLES OF OPERATION:
In any electric motor, operation is based on simple electromagnetism. A current-carrying
conductor generates a magnetic field; when this is then placed in an external magnetic field, it will
experience a force proportional to the current in the conductor, and to the strength of the external
magnetic field. As you are well aware of from playing with magnets as a kid, opposite (North and
South) polarities attract, while like polarities (North and North, South and South) repel. The internal
configuration of a DC motor is designed to harness the magnetic interaction between a current-
carrying conductor and an external magnetic field to generate rotational motion.

Let's start by looking at a simple 2-pole DC electric motor (here red represents a magnet or
winding with a "North" polarization, while green represents a magnet or winding with a "South"
polarization).
Every DC motor has six basic parts -- axle, rotor (armature), stator, commutator, field
magnet(s), and brushes. In most common DC motors, the external magnetic field is produced by
high-strength permanent magnets. The stator is the stationary part of the motor -- this includes the
motor casing, as well as two or more permanent magnet pole pieces. The rotor (together with the
axle and attached commutator) rotate with respect to the stator. The rotor consists of windings
(generally on a core), the windings being electrically connected to the commutator. The above
diagram shows a common motor layout -- with the rotor inside the stator (field) magnets.
The geometry of the brushes, commutator contacts, and rotor windings are such that when
power is applied, the polarities of the energized winding and the stator magnet(s) are misaligned,
and the rotor will rotate until it is almost aligned with the stator's field magnets. As the rotor
reaches alignment, the brushes move to the next commutator contacts, and energize the next
winding. Given our example two-pole motor, the rotation reverses the direction of current through
the rotor winding, leading to a "flip" of the rotor's magnetic field, driving it to continue rotating.
In real life, though, DC motors will always have more than two poles (three is a very
common number). In particular, this avoids "dead spots" in the commutator. You can imagine how
with our example two-pole motor, if the rotor is exactly at the middle of its rotation (perfectly
aligned with the field magnets), it will get "stuck" there. Meanwhile, with a two-pole motor, there is
a moment where the commutator shorts out the power supply. This would be bad for the power
supply, waste energy, and damage motor components as well. Yet another disadvantage of such a
simple motor is that it would exhibit a high amount of torque "ripple" (the amount of torque it could
produce is cyclic with the position of the rotor).

So since most small DC motors are of a three-pole design, let's tinker with the workings of
one via an interactive animation (JavaScript required):
A few things from this -- namely, one pole is fully energized at a time (but two others are
"partially" energized). As each brush transitions from one commutator contact to the next, one coil's
field will rapidly collapse, as the next coil's field will rapidly charge up (this occurs within a few
microsecond). We'll see more about the effects of this later, but in the meantime you can see that
this is a direct result of the coil windings' series wiring:

There's probably no better way to see how an average DC motor is put together, than by just
opening one up. Unfortunately this is tedious work, as well as requiring the destruction of a
perfectly good motor. The guts of a disassembled Mabuchi FF-030-
PN motor (the same model that Solarbotics sells) are available for (on 10 lines / cm graph paper).
This is a basic 3-pole DC motor, with 2 brushes and three commutator contacts.
The use of an iron core armature (as in the Mabuchi, above) is quite common, and has a
number of advantages. First off, the iron core provides a strong, rigid support for the windings -- a
particularly important consideration for high-torque motors. The core also conducts heat away from
the rotor windings, allowing the motor to be driven harder than might otherwise be the case.
Iron core construction is also relatively inexpensive compared with other construction types.
But iron core construction also has several disadvantages. The iron armature has a relatively high
inertia which limits motor acceleration. This construction also results in high winding inductances
which limit brush and commutator life. In small motors, an alternative design is often used which
features a 'coreless' armature winding.
This design depends upon the coil wire itself for structural integrity. As a result, the
armature is hollow, and the permanent magnet can be mounted inside the rotor coil. Coreless DC
motors have much lower armature inductance than iron-core motors of comparable size, extending
brush and commutator life.

The coreless design also allows manufacturers to build smaller motors; meanwhile, due to the lack
of iron in their rotors, coreless motors are somewhat prone to overheating. As a result, this design is
generally used just in small, low-power motors. Beamers will most often see coreless DC motors in
the form of pager motors.
Again, disassembling a coreless motor can be instructive -- in this case, my hapless victim was a
cheap pager vibrator motor. The guts of this disassembled motor are available (on 10 lines / cm
graph paper). This is (or more accurately, was) a 3-pole coreless DC motor.
BEARING:
A bearing is a device to permit constrained relative motion between two parts, typically
rotation or linear movement. Bearings may be classified broadly according to the motions they
allow and according to their principle of operation. Low friction bearings are often important for
efficiency, to reduce wear and to facilitate high speeds. Essentially, a bearing can reduce friction by
virtue of its shape, by its material, or by introducing and containing a fluid between surfaces. By
shape, gains advantage usually by using spheres or rollers. By material, exploits the nature of the
bearing material used. Sliding bearings, usually called bushes bushings journal bearings sleeve
bearings rifle bearings or plain bearings. Rolling-element bearings such as ball bearings and roller
bearings. Jewel bearings, in which the load is carried by rolling the axle slightly off-center.
Fluid bearings in which the load is carried by a gas or liquid. Magnetic bearings in which
the load is carried by a magnetic field. Flexure bearings, in which the motion is supported by a load
element which bends. Bearings vary greatly over the forces and speeds that they can support.
Forces can be radial, axial (thrust bearings) or moments perpendicular to the main axis. Bearings

very typically involve some degree of relative movement between surfaces, and different types
have limits as to the maximum relative surface speeds they can handle, and this can be specified as
a speed in ft/s or m/s. The moving parts there is considerable overlap between capabilities, but plain
bearings can generally handle the lowest speeds while rolling element bearings are faster,
hydrostatic bearings faster still, followed by gas bearings and finally magnetic bearings which have
no known upper speed limit.

DESIGN OF EQUIPMENT AND DRAWING

DESIGN OF EQUIPMENT AND DRAWING
COMPONENTS
FABRICATION OF POWER GENERATION FROM SPEED BREAKE consists of the
following components to full fill the requirements of complete operation of the machine.
1. Battery
2. Motor
3. Rack and pinion gear
4. Dynamo
5. Speed break arrangement
6. Bearing
BASE:
Length of the base = 500mm
With of the base = 450mm
Height of the base = 50mm
Material = M.S
Quantity = 1
VERTICAL COLUMN:
Base Length of the column = 200mm
Base With of the column = 200mm
Upper length of the column =80mm
Upper width of the column = 80mm
Height of the column = 600mm
Material = M.S
Quantity = 1
FLANGE:
Length of the flange = 79mm
Outer Diameter of the flange =80mm
Inner diameter of the flange =20mm
Material = C.I
Quantity = 1
SPUR GEAR
Rack
Length : 500 mm
Module : 6 mm
No. of teeth : 96

Pinion
Outer diameter of the gear (d2): 30mm
Inner diameter of the gear: 10mm
No of teeth: 24
BEARING HOUSING:
Length of the housing = 75mm
Outer diameter of the housing = 55mm
Inner diameter of the housing = 50mm
MACHINE SPECIFICATION:
Size of machine (L x H) :500mmx----mm
DESIGN CALCULATION:
Formula:
P= 2πnt/60
Where N - speed of the motor in rpm
P – Power in watts
T – Torque transmitted in N.M
T = Px60/ 2πN
= 18 x 60/ 2πx30
= 1080/188.5
T = 5.73N.M
GEAR:
DRIVING GEAR
L-500mm
T1 -96
N1 -30rpm
DRIVEN GEAR
D2 -30mm
T2 -24
N2 - 60rpm
WE KNOW,
Velocity Ratio, N1/N2 = D1/ D2
N2/30 = 125/ 30
N2 = 125x30/30
N2 = 125rpm
Therefore the speed of the pinion or driven gear is 125 rpm. This gear is coupled to the dynamo. So
the dynamo also rotates at the same speed.

FABRICATION OF POWER GENERATION FROM MANUAL THREADMILL

FABRICATION
METHOD OF FABRICATION:
In this project the components of this machine such as bearing housing, flange, and motor
shaft are turned and faced in the center lath as per the dimension of drawing. Holes in the flange are
drilled using in the drilling machine. The parts such as vertical column, base plate are fabricated
from m.s plate of 2mm thickness by cold working (hammering) the ms plate to the required shape
and dimensions. On the base plate the vertical column is welded. On the top of the vertical column
the motor is fixed with the help of bracket. The motor shaft is couple to the flange shaft. The blades
are fixed on the flange, the flange shaft and the motor shaft are couple with the bearing by means of
bearing housing.

WORKING PRINCIPLE
The conventional manual treadmill without Electricity Generator is shown in Fig. 1.When
someone walks runs on the walking belt flywheels runs at 200 r.p.m. This fly wheel rotation is used
to generate the electricity. For mounting the Electricity Generator a support is welded on left
upright as shown in Fig. 2.An Electricity Generator is mounted on this support and a v-pulley is
fixed on the generator shaft as shown in Fig. 2. A walking belt is wrapped around roller 1 and roller
2.Roller 1 is mounted on the left and right upright and roller 2 is mounted on lower end of the base
frame. A V-grooved flywheel is mounted on the left side of the roller 1 and another flywheel is
mounted on the right and of the roller 1 as shown in Fig 3
The V-Grooved Flywheel is connected with the-Pulley mounted on Generator shaft through
a V-belt. When someone walks / runs on the walking belt roller 1 and 2 rotate. As the V-grooved
flywheel is mounted on roller 1 and there is no relative motion between the flywheel and roller 1.
Thus V-grooved fly wheel rotates with roller 1. The diameter of V-grooved flywheel is kept 5 times
more than the diameter of the v-pulley mounted on the shaft of the generator. If flywheel rotates
at200 r.p.m. the generator shaft will rotate at1000 r.p.m. and electricity will be generated which
may be used to charge the battery or it may be used to run the MP3 player, low voltage CFL etc

MERITS
 Reliability
 Use of renewable energy
 Easy implementation

APPLICATIONS
 For Home appliances usage
 Industries, agricultural
LIST OF MATERIALS

LIST OF MATERIALS
FACTORS DETERMINING THE CHOICE OF MATERIALS
The various factors which determine the choice of material are discussed below.
1. Properties:
The material selected must posses the necessary properties for the proposed application. The
various requirements to be satisfied can be weight, surface finish, rigidity, ability to withstand
environmental attack from chemicals, service life, reliability etc.
The following four types of principle properties of materials decisively affect their selection
a. Physical
b. Mechanical
c. From manufacturing point of view
d. Chemical
The various physical properties concerned are melting point, thermal Conductivity, specific heat,
coefficient of thermal expansion, specific gravity, electrical conductivity, magnetic purposes etc.
The various Mechanical properties Concerned are strength in tensile, Compressive shear,
bending, torsional and buckling load, fatigue resistance, impact resistance, eleastic limit, endurance
limit, and modulus of elasticity, hardness, wear resistance and sliding properties.
The various properties concerned from the manufacturing point of view are,
 Cast ability
 Weld ability
 Surface properties
 Shrinkage
2. Manufacturing case:
Sometimes the demand for lowest possible manufacturing cost or surface qualities
obtainable by the application of suitable coating substances may demand the use of special
materials.
3. Quality Required:
This generally affects the manufacturing process and ultimately the material. For example, it
would never be desirable to go casting of a less number of components which can be fabricated
much more economically by welding or hand forging the steel.
4. Availability of Material:

Some materials may be scarce or in short supply. It then becomes obligatory for the
designer to use some other material which though may not be a perfect substitute for the material
designed. The delivery of materials and the delivery date of product should also be kept in mind.
5. Space consideration:
Sometimes high strength materials have to be selected because the forces involved are high and
space limitations are there.
6. Cost:
As in any other problem, in selection of material the cost of material plays an important part
and should not be ignored.
Some times factors like scrap utilization, appearance, and non-maintenance of the designed
part are involved in the selection of proper materials.
S.No DESCIRPTION QTY Material
1 Working Belt 1 rubber
2 dynamo 1 aluminum
3 V-Grooved flywheel 1 C.I
4 Flywheel 1 C.I
5 Battery 1 plastic
6 Generator Support and frame 1 MS

COST ESTIMATION
1. MATERIAL COST.
S.No DESCIRPTION QTY Material Price (Rs)
1 Working Belt 1 rubber 1400.00
2 dynamo 1 aluminum 950.00
3 V-Grooved flywheel 1 C.I 300.00
4 Flywheel 1 C.I 500.00
5 Battery 1 plastic 950.00
6 Generator Support and frame 1 MS 1000.00
2. LABOUR COST:
Lathe, drilling, welding, grinding, power hacksaw, gas cutting cost =Rs 800.00
3. OVERGHEAD CHARGES:
The overhead charges are arrived by “manufacturing cost”
Manufacturing Cost =Material Cost +Labour Cost
= Rs 5900 + Rs 1000.00
= Rs 6900.00
Overhead Charges =20%of the manufacturing cost
= Rs 350.00
4. TOTAL COST:
Total cost = Material Cost +Labour Cost +Overhead Charges
= Rs 5900 + Rs 1000.00+ Rs 700.00
=7600 /-
Total cost for this project (Rs) =7600 /-

CONCLUSION
 This manual treadmill with Electricity Generator is simple in design.
 The manual treadmill with Electricity Generator is simple in design.
 This manual treadmill with Electricity Generator is sustainable.
 A wide range of health problems can be managed using this manual treadmill.
 This treadmill with Electricity Generator is useful for such are as where electricity is
not available.
 Electrical energy can be saved by using this manual treadmill with Electricity Generator
 Green House Gases can be reduced up to some extent by this manual treadmill with
Electricity Generator.
 Strength of muscles can be improved by using this manual treadmill with Electricity
Generator

BIBLIGRAPHY
1. Design data book - P.S.G.Tech.
2. Machine tool design handbook - Central machine tool Institute, Bangalore.
3. Strength of Materials - R.S.Kurmi
4. Manufacturing Technology - M.Haslehurst.
5. Design of machine elements - R.s.Kurumi

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