This document describes the design and purpose of a pedal-powered generator and flour mill. The generator aims to produce electricity through pedaling to charge batteries and power devices, saving energy and reducing electricity bills. The flour mill is designed to grind wheat into flour using pedal power. Both systems use a bicycle mechanism and chain drive to transfer human power to the machines. The generator produces DC power to charge batteries while the flour mill uses rotating stone wheels to grind the wheat. The designs aim to provide off-grid power and milling solutions that are low-cost, easy to operate, and suitable for rural areas.

1. MADE BY :-------
PUSHPENDRA SINGH

2. 2
AIM OF THE PROJECT
• Producing our own electricity by pedaling an
exercise cycle.
• Saves energy which is used for charging the
batteries in conventional inverter system.
• Reduction in electricity bill.
• stationary pedal powered flour mill
• Provides a method for physical exercise
besides serving its main purpose.

3. BLOCK LAYOUT

5. INTRODUCTION
 The present design relates to very compact and
easily portable power-generating unit,
 which besides being used as a power generator.
 The power-generating unit is pedal operated.
 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
reading, watching TV etc. The user can relax
intermittently without stopping the motion of the rotor
unit abruptly.

6. COMPONENTS
(POWER GENERATION)
 DC Motor
 (capable of producing enough V to charge battery)
 Rubber Belt
 (capable of being fixed to rotor)
 Old Bicycle Rim
 Nails
 Scrap Wood
 NiMH Battery (4.8 V, 150 mAh)
 Copper Wire
 Diode
 Resistor (120 Ohm)
 Lengths of wire
 Alligator clips

7. 7
Alternator Battery
Inverter
CircuitPedaling 230v ac
BLOCK DIAGRAM
Voltage
Level
Indicator

8. 8
Our Design
(BATTERY CHARGER)
The whole system comprises of:
• An automobile alternator (12V ,35A )
which when pedaled gives dc output
which can be used to charge the battery.
• An inverter circuit draws 12v dc from the
battery and converts it into 230V ac.
• A battery level indicator is incorporated to
avoid overcharging of the battery.

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• Consists of a gear mechanism coupled to an
exercise cycle which helps to run the
alternator at around 3500rpm with least
effort.
• The alternator can charge the
Batteries by supplying 10Amp
current and 12V continuously.
• Thus the battery can be fully charged in about
3.5hours of pedaling

10. BLOCK LAYOUT
RECTIFIER
UNIT

11. WORKING CONCEPT
 The force applied to the pedals gets transmitted to the
rotor unit of power generating device (D.C MOTOR)
through chain-sprocket and gear train. The sizes of
sprockets and gears are so chosen to achieve suitable
rotating speed of the 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 rectifier unit and plurality of
electrical connectors in the rectifier unit provides electrical
power to various electrical devices.

12.  A DC motor is generally used in applications that require
accurate speed control. The motor is connected to a power
supply which provides electrical current to the windings (coils) in
the rotor. When a current is passed through windings, a
magnetic field is produced. This magnetic field causes the rotor
to spin therefore creating useful mechanical work.
 These windings may also be used to
induce a voltage if the reverse action is
taken (rotor is manually spun and the
DC motor acts as a generator).
 This can be explained by Faraday’s Law of Induction which in
short states that a voltage is induced by a changing magnetic
field. The presence of the magnetic fields makes it possible to
produce an electric current and generate power.

13. RURAL USE
 For schools (especially boarding schools),
meetings, NGO and movement offices, there will be many
people who can easily share the pedaling at night. Put
each CFL in a different room or region and people can
take turns pedaling. The lights will be ON only when you
pedal.
 Put one 11 W CFL in each house and connect all of
them in parallel to the pedal generator. At night each
family or household can take 30 minutes or 45 minutes
turns pedaling, lighting all houses as they pedal. If 3
houses are sharing a generator then 3 x 45 Minutes = 2
Hours, 15 Minutes lights for everyone, say from 7-9:15
PM.

14. URBAN USE
 If the usage is solely as an exercise cycle and to
demonstrate the principle of alternate energy in
urban schools, then instead of the more expensive
CFLs you can connect in parallel a few (say 3-4),
12 V, 20-30 W bulbs (that you can get from any
auto shop for a few rupees each).
 The ammeter indicates the current you are
supplying or the rate at which calories are being
burnt. You can also connect some CFLs in parallel
with the auto bulbs if you wish.

15. 4C: OTHER USES OF PEDAL
GENERATOR
 You can run any 12 V device such as mike system,
radio, tape recorder, laptop through 12 V adapter
and TV (of 12 V).
 If you want to run lower voltage
equipment (such as 6 V radio) then use
your hands to turn the pedals and do
not use the 12 V battery.
 To charge lower voltage batteries, use your hand
and turn the pedals slowly.

17. INTRODUCTION
 A simple rule is that most people engaged in delivering
power continuously for an hour or will be more efficient
when pedaling rate is in the range of 50-70 rpm.(Wilson
D.G. VITA volunteer).
 Keeping these limitations of
human capabilities in mind the
proposed machine consists of
three sub systems:
(1) The energy unit,
(2) Transmission mechanism
(3) The process unit.

18. INTRODUCTION
 The energy unit basically consists of conventional
bicycle mechanism; the transmission mechanism
consists of chain drive running over a pair of
sprockets and belt drive running over pulley and
stone wheels.
 The process unit is a pair of stone wheels mounted
over one another where the wheat gets crushed
into powered form to produce wheat flour. All these
units are assembled on bicycle like structure(seat,
saddle, handle etc).

19. COMPONENT
(FLOUR MILL)
 Bicycle chain -one and a half
 V-belting
 Cardboard
 Mortar (16kgs sand and 8kgs cement)
 Rim tape (rubber strip or tape)
 Cotter pins (6)
 The Chain Assembles
 Flywheel
 Chassis OF STEEL
Hand Mill

20. OUR DESIGN
(HAND FLOUR MILL)
Drive unit:
 This is first stage of transmission. The transmission of
power from human to processing unit is carried out in two
stages namely chain drive and belt drive. The operators
uses his feet & legs to rotate pedal around the crank axel.
 1-Front Chain Sprocket , 2-Pedal ,3-Chain ,4-Rear
 chain sprocket 5-Bearings for belt drive shaft ,
 7-CrossV Belt, 8-Stonewheels

21. OUR DESIGN
(HAND FLOUR MILL)
Processing Unit:-
 In second stage this power is transmitted to stone
wheels from pulley with the help of cross belt
drive.
 Process unit is the one where actual crushing of
wheat kernels take place. This process unit
basically consists of stone wheel, hopper &the
hemispherical collector.

22. BLOCK LAYOUT
Figure…..Energy unit, Transmission unit, Process unit

23. WORKING CONCEPT
 In conventional stone wheel mechanism
the intermittent flow is required to get fine
output. The same type of arrangements of
flow is made in Pedal operated flour mill.
 It consists of Hopper mechanism in which the grains are
stored. It is having a flow control unit, which is connected by
means of mechanical spring to the left hand brakes.
 By breaking, the flow may control. The output of the stone
wheel mechanism is collected between a hemispherical
collector which is located below the stone wheel mechanism.

24. RURAL & URBAN USE
 The main objective behind development of pedal
operated flour mill was on producing cheap, easy to
operate system which can be easily fabricated by
readily available material and
thus we proposed a simplistic design
that can deliver efficient, productive
and reliable flour mill which can be
used in rural as well as urban areas.
 This equipment can be easily operated by semi
rather low skilled operator. Further this equipment
can easily find its place where there is no or limited
power supply.

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ATTRACTIONS OF OUR PROJECT
• Can be used in rural areas where electricity is out of
reach
• Any time charging, even during power failure
• Power Saving
• Reduces electricity bill
• Modified versions can be used for running house hold
applications like television and other appliances.
• Low cost
• Simple in construction
• Easily operated HAND FLOUR-MILL.

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CONCLUSION
The above proposed project named “THE PEDAL POWERED
GENERATION ” & “THE PEDAL POWERED FLOUR
MILL” has been designed and materialized on the objective of
providing an alternative source of electricity as well as an
effective mode of FLOUR MILLING. We believe that this
project, if effectively used may be considered as an innovative
and a good solution for the energy crisis as far as a developing
nation like India is concerned.