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CHAPTER TITLE PAGE NO

NO
SYNOPSIS

1 INTRODUCTION 3

2 LITERATURE SURVEY 6

3 DESCRIPTION OF EQUIPMENTS 9

4 DIAGRAM 25

5 WORKING PRINCIPLE 26

6 MECHANISM OF OPERATION 27

7 FACTORS DETERMINING THE CHOICE OF 29


MATERIALS

8 FABRICATION AND TESTING 32

9 ADVANTAGES AND DISADVANTAGES 33

10 CONSLUSION 35

11 PHOTOGRAPHY 37

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SYNOPSIS

Energy conservation is a topical issue and this design proffered an efficient method of doing so.
The design was originally conceived to meet the energy needs of those living in rural areas, due
to poor access to electricity and also as a model for gym centers and cycle workout studios. Most
persons living in these rural areas possess at least a cell phone but lack the means to charge them.
This study focused on the design and fabrication of a pedal operated power generator, for the
intents of burning fats while yet generating electricity. The power generator was designed to be
simple, cheap, durable and easily maintained. It was fabricated using locally sourced materials
and is intended to encourage local ingenuity and empower aspiring entrepreneurs especially in
developing countries. Its purpose is to efficiently transfer human foot motion less than 60 rpm
via a treadle and sprocket-chain step-up to drive a 12V DC permanent magnet generator. The
inverter converts the direct current (DC) into alternating current (AC) which is needed to charge
low voltage devices like mobile phones, laptops etc.

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CHAPTER 1

INTRODUCTION

In today’s world when the advancement in technology is at its peak and the
impact of these technology over the human health is also point of concern. As the
technology is advancing the physical activities are getting reduced. This in turn is
not a good sign. In Indian urban areas people use bicycle very rarely and also they
had become slave to their electronic gadgets. They are spoiling their health over
them. But if they use the portable cycle mob charger it would encourage them to
do more physical exercises through cycling. During cycling they can enjoy their
gadgets such as phone, tablets, GPS etc. In rural areas due to unscheduled power
cutoff people don’t have any mode of Communication so in that case this portable
cycle mob charger is the solution. Now, Why pedaling for electricity? The cost of
one KWh as your electricity company sells is Rs 5 in my place and earning this
through pedal power would take me 5 hours. Not much of an incentive to think
about pedal generators. Still the need for pedal power generation seems to exist, as
frequent e-mail requests tell me. Ill, pedal power can be made available anywhere,
it requires no fuel, is available both day and night, the equipment is inexpensive
and needs almost no maintenance. Addresses three key use cases: 1. Charging
batteries for small, portable devices while traveling on a bicycle 2. Generating as
much electrical Power as possible on a stationary pedal generator 3. Powering up
Electronic devices using the concept of cycle dynamo on stationary mode.

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There is one obvious challenge to offering mobile phones in emerging
markets: the availability of electricity to charge a mobile phone. You can’t expect
people to be driving around cars with chargers when most in the market might be
riding bicycles. That’s one reason that the biggest mobile manufacturing company
has announced the Nokia Bicycle Charger Kit. The kit not only allows a bicycle to
charge a phone while they ride it also could create a micro-business for individuals
who could offer mobile phone charging services for a fee using a bicycle. For those
in non-emerging markets, the solution also introduces a green way to keep your
mobile phone charged without having to plug it into the electrical grid. The kit
includes a holder, charger and a small electrical generator which utilizes the
movement of the bicycle’s wheels to charge the phone through a 2mm charging
jack used on most Nokia phones. The Nokia Bicycle Charger Kit is expected to be
available before the end of the year and will be available through select retail
locations and online.

The use of fossil fuels and other non-reusable sources of energy must be reduced in order to keep
emissions low and alleviate the use of diminishing resources. The idea of human powered
generation has been implemented in any 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 turn out to be an even
more fun experience for participants; it would provide them a means to exercise while indirectly
generating power.
The pedal operated power 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

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into pedal powered tools for sustainable development. Using human powered generation gives a
power source that is not directly derived from natural sources. An example is that a human
powered generator can be operated if there is no sun for solar generation, no wind for
wind generation, and no water for hydro generation. 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 devices, etc. It is important to visualize new ways to bring power to the
people as population continues to grow and power shortages continue to occur. Much of the
power that is provided to people today is done in very un-sustainable ways; new ideas are needed
to transit into a post cheap-petroleum era. This design relates to very compact and easily portable
power-generating unit, which besides being used as a power generator can also be used as cycle
exerciser. It serves dual purpose of power generation and helping the person to 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

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 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 20 century,but the arrival of cheap
electricity and fossil fuel abruptly stopped all 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.

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From 1880 to 1900, there was a period of rapid development in electrical machines. Thus this
section reviews the works that has been done on human power generation.

2.2 Early Development


Studies in power generation shows that bicycling is one of the most efficient form of power
generation known, in terms of energy expended per person. McCullagh, (1977) gives us an
insight into the test conducted by Staurt Wilson using a 24V (at 1800rpm), 20A generator to
charge a 12V car battery. A belt-drive was used to connect a 15.5” diameter bike flywheel to a
2.5” diameter pulley that turned the generator. During this test, an average cyclist produced 75W
of sustainable electrical power 12V (900rpm) for a period of one hour.
In 1980, Carl Nowiszewski a mechanical student at the Massachusetts Institute of Technology
worked with Professor David Gordon Wilson on a design of a human powered generator which
when built will serve as an auxiliary control function in a sail boat in an Atlantic crossing. The
energy storage was primarily for automatic steering while the pilot sleep and the pedaling was a
way of keeping warm and avoid boredom. The overwhelming problem in the design was the
cramped quarters which Nowiszewski eventually solved. And then in 1988, George Alexander
Holt III designed a human powered generator using recumbent bicycle technology for use in a
sail boat using 6061-T6 aluminum; he built a light weight foldable apparatus. The human power
requirement was 120watt at 75rpm (George, 1988).

2.3 Recent Development


Mohd and others (2013) discussed charkha device in India, stated that spinning wheel
horizontally could be rotated by a cord encircling a large, hand-driven wheel where the fiber is
held in the left hand and the wheel slowly turned with the right. Holding the fiber at a slight
angle to the spindle produced the necessary twist. Jansen and Slob (2003) improved the power
generation system known as “Better Water Maker” (BWM) water disinfection system.
The BWM was designed for use where water is unsafe for drinking and electricity is scare. The
BWM utilizes a manual hand crank to provide power to its pump. They also studied one hand
cranking and found that 50w of power could be sustained for up to 30 minutes, which is more
than double the 17w required by the BWM.

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As early as 2007, fitness facilities around the world have begun researching applications for
converting human power to electricity. The California Fitness facility in Hong Kong was one of
the first gym establishments to incorporate human powered machines. Started by French inventor
Lucien Gambarota and entrepreneur Doug Woodring, the gym began a program called “Powered
by YOU” in which the excess energy generated by members on 13-step cycling and cross
training machines is diverted and converted to power lighting fixtures in the gym (Gerard, 2008).
Maha and Kimberly (2010), in the Proceedings of ASME 2010 4th International Conference on
Energy Sustainability made us to understand that other gyms in the United States began to
harness human power as well.
The Dixon Recreation Center at Oregon State University (OSU) is one of the many facilities
retrofitted between the years 2008 and 2009 by the Clearwater, Florida based company known as
ReRev. The company retrofitted 22 elliptical machines at OSU so that the excess energy
generated by patrons was diverted to the electric grid.
According to the company’s website, “An elliptical machine in regular use at a gym using ReRev
technology will generate one kilowatt-hour of electricity every two days.”

th

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CHAPTER 3

DESCRIPTION OF EQUIPMENTS

PEDAL

Figure No.3.4 Pedal

Pedal is the part of the rider push for foot to propel by the vehicle. Pedal
were initially Attached to crank connecting directly to the driven front plate. The
pedals were attached to a plate it is transmitting power to drum. Pedals usually
consist of a spindle that threads into the end of the crank and a body, on which the
foot rests or is attached, that is free to rotate on bearings with respect to the
spindle.

3.5 Types of Pedal

3.5.1 Flat and Platform Pedal

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Figure No.3.5.1 Flat & Platform Pedal

Traditionally platform pedals were pedals with a relatively large flat area for
the foot to rest on, in contrast to the quill pedal which had very little surface area.
One form of the platform pedal had a large flat top area and flat bottom for use
with toe clips and toe straps. They were designed for greater comfort when using
shoes with less than rigid soles. They typically had a smaller cut away underside
giving greater cornering clearance, which was often needed for track cycling. They
were often marketed as being more aerodynamic than conventional quill pedal.
Attaching the shoes to the pedals gives the user more control over the pedal
movements.

There are two methods for attaching a cyclist's shoes to their pedals toe
clips, a basket and strap device which hold the foot in place and so called clippie’s
pedals, where specialized shoes with built in bindings attach to compatible pedals.

In mountain biking and platform pedals typically refer to any flat pedal
without a cage. Riders typically use plastic pedals made of nylon, polycarbonate,
or carbon reinforced plastic, although aluminum alloy and magnesium are not
uncommon pedal body materials. Mountain bikers tend to use aluminum or
magnesium because of the necessary use of metal studs to offer grip while the
pedals are wet muddy and slippery tend to prefer platforms to cage pedals because
they offer more support and grip for flexible shoes by using short metal studs.
Cage pedals are more popular in the low end mountain bike range. In general cage
pedals are uncommon in all types of biking, although there is a niche market within
mountain biking. Platform pedals are available in a wide variety of types and
prices, ranging from disposable plastic units used for test rides on new bicycles to
high end downhill models. Budget models may be made of steel or aluminum and

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incorporate reflectors for safer riding on streets at night. Less expensive platform
pedals are generally considered disposable and cannot be rebuilt when worn out.

3.5.2 Magnetic Pedal

Figure No.3.5.2 Magnetic Pedal

Magnetic pedals were introduced as early as 1897, and they Exist Magnet
flux road was available in 1996. Norbert Sadler and Wolfgang filed for a patent in
2005 and it has not been granted as of 2012. Cage pedals are more popular in the
low end mountain bike range. In general cage pedals are uncommon in all types of
biking, although there is a niche market within mountain biking.

Platform pedals are available in a wide variety of types and prices, ranging
from disposable plastic units used for test rides on new bicycles to high end
downhill models Established bicycle component manufacturer Magnetic,
introduced a magnetic pedal and dedicated shoe for casual riding in 2009. Others
have received mixed reviews.

3.5.3 Clip less Pedal

Clip less pedals require a special cycling shoe with a cleat fitted to the sole,
which locks into a mechanism in the pedal and thus holds the shoe firmly to the

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pedal. Most clip less pedals lock onto the cleat when stepped on firmly and unlock
when the heel is twisted outward, although in some cases the locking mechanism is
built into the cleat instead of the pedal. Clip less refers to the toe clip having been
replaced by a locking mechanism and not to platform pedals which would
normally not have to clips.

Figure No.3.5.3 Clip less Pedal

The clip less pedal was invented by Charles Hanson in 1895. It allowed the
rider to twist the shoe to lock and unlock and had rotational float (the freedom to
rotate the shoe slightly to prevent joint strain). The clip less pedal designed and
produced by his company in 1971. It used a plastic shoe cleat which slid into
grooves in the pedal and locked in place with a small lever located on the back side
of the pedal body. To release the shoe a rider had to reach down and operate the
lever, similar to the way a racing cyclist had to reach down and loosen the toes
trap. The lever was placed on the outside edge of the pedal so that in the event of a
fall the lever hitting the ground would release the foot.

The pedal was designed for racing, in particular track racing, and because of
the need to reach them to unclip they have been referred to as "death
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cleats".In1984, the French company Look applied downhill snow skiing binding or
cleat technology to pedals producing the first widely used clip less pedals. Initially
used by in order to facilitate faster transitions. Bernard's victory in Tour de
France in 1985 then helped secure the acceptance of quick release clip less pedal
systems by cyclists.

Those pedals and compatible models by other manufacturers remain in


widespread use today. The cleat is engaged by simply pushing down and forward
on the pedal, or, with some designs, by twisting the cleat in sideways. Then,
instead of loosening or pulling a lever, the cyclist releases a foot from the pedal by
twisting the heel outward.

3.5.4 Attachment

The pedal spindle is threaded to match a threaded hole at the outboard end of
the cranks. Multispecies cranks have a 14.2875 mm hole with 20 Teeth (a diameter
per pitch combination fairly unique to this application). One-piece cranks use
a 12.7 mm by 20 hole. French pedal spindles use 14 x 1.25 (14 mm or 0.55 in
metric diameter with 1.25 mm or 0.049 in pitch) threads, and thread loosely into a
9/16 pedal hole.

The threading size is often stamped into the crank, near the pedal hole. The
right side (usually the drive-side) pedal spindle is right hand threaded, and the left
side usually the non drive side pedal spindle is left hand (reverse) threaded to help
prevent it from becoming loose by an effect called precession. Although the left
pedal turns clockwise on its bearing relative to the crank and would seem to tighten
a right hand thread, the force from the rider's foot presses the spindle against the
crank thread at a point which rolls around clockwise with respect to the crank, thus
slowly pulling the outside of the pedal spindle anticlockwise (counterclockwise)
because of friction and thus would loosen a right-hand thread.
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For a short time in the early 1980, Shimano made pedals and matching
cranks that had a 25.4 mm by 24 teeth per inch interface. This was to allow a larger
single bearing, as these pedals were designed to work with just one bearing on the
crank side rather than the conventional design of one smaller bearing on each side.

The pedal was invented by Charles Hanson in 1895. It allowed the rider to
twist the shoe to lock and unlock and had rotational float (the freedom to rotate the
shoe slightly to prevent joint strain). The clip less pedal designed and produced by
his company in 1971. It used a plastic shoe cleat which slid into grooves in the
pedal and locked in place with a small lever located on the back side of the pedal
body. To release the shoe a rider had to reach down and operate the lever, similar
to the way a racing cyclist had to reach down and loosen the toes trap.

VOLTAGE REGULATOR
A voltage regulator is designed to automatically maintain a constant voltage level.
A voltage regulator may be a simple "feed-forward" design or may include
negative feedback control loops. It may use an electromechanical mechanism, or
electronic components. Depending on the
design, it may be used to regulate one or more AC or DC voltages. Electronic
voltage regulators are found in devices such as computer power supplies where
they stabilize the DC voltages used by the processor and other elements. In
automobile alternators and central power station generator plants, voltage
regulators control the output of the plant. In an electric power distribution system,
voltage regulators may be installed at a substation or along distribution lines so that
all customers receive steady voltage independent of how much power is drawn
from the line. A popular three pin +12 V DC voltage regulator IC.
Measures of regular quality:

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The output voltage can only be held roughly constant; the regulation is specified by
two measurements: load regulation is the change in output voltage for a given
change in load current (for example: "typically 15 mV, maximum 100 mV for load
currents between 5 mA and 1.4 A, at some specified temperature and input
voltage"). · line regulation or input regulation is the degree to which output voltage
changes with input (supply) voltage changes - as a ratio of output to input change
(for example "typically 13 mV/V"), or the output voltage change over the entire
specified input voltage range (for example "plus or minus 2% for input voltages
between 90 V and 260 V, 50-60 Hz").
Other important parameters are: · Temperature coefficient of the output voltage is
the change with temperature (perhaps averaged over a given temperature range). ·
Initial accuracy of a voltage regulator (or simply "the voltage accuracy") reflects
the error in output voltage for a fixed regulator without taking into account
temperature or aging effects on output accuracy. · Dropout voltage is the minimum
difference between input voltage and output voltage for which the regulator can
still supply the specified current. A low drop-out (LDO) regulator is designed to
work well even with an input supply only a volt or so above the output voltage.
The input-output differential at which the voltage regulator will no longer maintain
regulation is the dropout voltage. Further reduction in input voltage will result in
reduced output voltage. This value is dependent on load current and junction
temperature. · Absolute maximum ratings are defined for regulator components,
specifying the continuous and peak output currents that may be used (sometimes
internally limited), the maximum input voltage, maximum power dissipation at a
given temperature, etc. · Output noise (thermal white noise) and output dynamic
impedance may be specified as graphs versus frequency, while output ripple noise
(mains "hum" or switch-mode "hash" noise) may be given as peak-to-peak or RMS
voltages, or in terms of their spectra. Quiescent current in a regulator circuit is the
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current drawn internally, not available to the load, normally measured as the input
current while no load is connected (and hence a source of inefficiency; some linear
regulators are, surprisingly, more efficient at very low current loads than switch-
mode designs because of this). · Transient response is the reaction of a regulator
when a (sudden) change of the load current (called the load transient) or input
voltage (called the line transient) occurs. Some regulators will tend to oscillate or
have a slow response time which in some cases might lead to undesired results.
This value is different from the regulation parameters, as that is the stable situation
definition. The transient response shows the behaviour of the regulator on a
change. This data is usually provided in the technical documentation of a regulator
and is also dependent on output capacitance.
· Mirror-image insertion protection means that a regulator is designed for use when
a voltage, usually not higher than the maximum input voltage of the regulator, is
applied to its output pin while its input terminal is at a low voltage, volt-free or
grounded. Some regulators can continuously withstand this situation; others might
only manage it for a limited time such as 60
seconds, as usually specified in the datasheet. This situation can occur when a three
terminal regulator is incorrectly mounted for example on a PCB, with the output
terminal connected to the unregulated DC input and the input connected to the
load. Mirror-image insertion protection is also important when a regulator circuit is
used in battery charging circuits, when externalpower fails or is not turned on and
the output terminal remains at battery voltage.
Electronic voltage regulator:
A simple voltage regulator can be made from a resistor in series with a diode (or
series of diodes). Due to the logarithmic shape of diode V-I curves, the voltage
across the diode changes only slightly due to changes in current drawn or changes
in the input. When precise voltage control and efficiency are not important, this
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design may work fine. Feedback voltage regulators operate by comparing the
actual output voltage to some fixed reference voltage. Any difference is amplified
and used to control the regulation element in such a way as to reduce the voltage
error. This forms a negative feedback control loop; increasing the open-loop gain
tends to
increase regulation accuracy but reduce stability (avoidance of oscillation, or
ringing during step changes). There will also be a trade-off between stability and
the speed of the response to changes. If the output voltage is too low (perhaps due
to input voltage reducing or load current increasing), the regulation element is
commanded, up to a point, to produce a higher output voltage–by dropping less of
the input voltage (for linear series regulators and buck switching
regulators), or to draw input current for longer periods (boost-type switching
regulators); if the output voltage is too high, the regulation element will normally
be commanded to produce a lower voltage. However, many regulators have over-
current protection, so that they will entirely stop sourcing current (or limit the
current in some way) if the output current is too high, and some regulators may
also shut down if the input voltage is outside a given range (see also: crowbar
circuits).
Active regulators employ at least one active (amplifying) component such as a
transistor or operational amplifier. Shunt regulators are often (but not always)
passive and simple, but always inefficient because they (essentially) dump the
excess current not needed by the load. When more power must be supplied, more
sophisticated circuits are used. In general, these active regulators can be divided
into several classes:
· Linear series regulators
· Switching regulators
· SCR regulators
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Linear regulators
Linear regulators are based on devices that operate in their linear region (in
contrast, a switching regulator is based on a device forced to act as an on/off
switch). In the past, one or more vacuum tubes were commonly used as thevariable
resistance. Modern designs use one or more transistors instead, perhaps within an
Integrated Circuit. Linear designs have the advantage of very "clean" output with
little noise introduced into their DC output, but are most often much less efficient
and unable to step-up or invert the input voltage like switched supplies. All linear
regulators require a higher input than the output. If the input voltage approaches
the desired output voltage, the regulator will "drop out". The input to output
voltage differential at which this occurs is known as the regulator's drop-out
voltage.Entire linear regulators are available as integrated circuits. These chips
come in either fixed or adjustable voltage types.
Switching regulators
Switching regulators rapidly switch a series device on and off. The duty cycle of
the switch sets how much charge is transferred to the load. This is controlled by a
similar feedback mechanism as in a linear regulator. Because the series element is
either fully conducting, or switched off, it dissipates almost no power; this is what
gives the switching design its efficiency. Switching regulators are also able to
generate output voltages which are higher than the input, or of
opposite polarity — something not possible with a linear design. Like linear
regulators, nearly-complete switching regulators are also available as integrated
circuits. Unlike linear regulators, these usually require one external component: an
inductor that acts as the energy storage element. (Large-valued inductors tend to be
physically large relative to almost all other kinds of
componentry, so they are rarely fabricated within integrated circuits and IC
regulators — with some exceptions.[1][2]) Comparing linear vs. switching
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regulators The two types of regulators have their different advantages:· Linear
regulators are best when low output noise (and low RFI radiated noise) is required
· Linear regulators are best when a fast response to input and outputdisturbances is
required. At low levels of power, linear regulators are cheaper and occupy less
printed circuit board space.
· Switching regulators are best when power efficiency is critical (such as in
portable computers), except linear regulators are more efficient in a small number
of cases (such as a 5V microprocessor often in "sleep" mode fed from a 6V battery,
if the complexity of the switching circuit and the junction capacitance charging
current means a high quiescent current in the switching regulator).
· Switching regulators are required when the only power supply is a DC voltage,
and a higher output voltage is required.
· At high levels of power (above a few watts), switching regulators are cheaper (for
example, the cost of removing heat generated is less).
SCR regulators
Regulators powered from AC power circuits can use silicon controlled rectifiers
(SCRs) as the series device. Whenever the output voltage is below the desired
value, the SCR is triggered, allowing electricity to flow into the load until the AC
mains voltage passes through zero (ending the half cycle). SCR regulators have the
advantages of being both very efficient and very simple, but because they can not
terminate an on-going half cycle of conduction, they are not capable of very
accurate voltage regulation in response to rapidly-changing loads. An alternative is
the SCR shunt regulator which uses the regulator output as a trigger, both series
and shunt designs are noisy, but powerful, as the device has a low on resistance.

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DYNAMO
A dynamo is an electrical generator that produces direct current with the use of a
commutator. Dynamos were the first electrical generators capable of delivering
power for industry, and the foundation upon which many other later electric-power
conversion devices were based, including the electric motor, the alternating-current
alternator, and the rotary converter. Today, the simpler
alternator dominates large scale power generation, for efficiency, reliability and
cost reasons. A dynamo has the disadvantages of a mechanical commutator. Also,
converting alternating to direct current using power rectification devices (vacuum
tube or more recently solid state) is effective and usually economic. The word
dynamo (from the Greek word dynamis; meaning power) was originally another
name for an electrical generator, and still has some regional
usage as a replacement for the word generator. A small electrical generator built
into the hub of a bicycle wheel to power lights is called a hub dynamo, although
these are invariably AC devices.

"Dynamo Electric Machine" (end view, partly section, U.S. Patent 284,110)

Description:
The dynamo uses rotating coils of wire and magnetic fields to convert mechanical
rotation into a pulsing direct electric current through Faraday's law of induction. 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. The motion of the wire within the magnetic
field causes the field to push on the electrons in the metal, creating anelectric
current in the wire. On small machines the constant magnetic field may be
provided by one or more permanent magnets; larger machines have the constant

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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 essentially a rotary switch. It consists of a set of contacts mounted on the
machine's shaft, combined with graphite-block stationary contacts, called
"brushes", because the earliest such fixed contacts were metal brushes. The
commutator 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.
Discovery of electric motor principles
While not originally designed for the purpose, it was discovered that a dynamo can
act as an electric motor when supplied with direct current from a battery or another
dynamo. At an industrial exhibition in Vienna in 1873, Gramme noticed that the
shaft of his dynamo began to spin when its terminals were accidentally connected
to another dynamo producing electricity. Although this wasn't the first
demonstration of an electric motor, it was the first practical one. It
was found that the same design features which make a dynamo efficient also make
a motor efficient. The efficient Gramme design, with small magnetic air gaps and
many coils of wire attached to a many-segmented commutator, also became the
basis for the design of all practical DC motors. Large dynamos producing direct
current were problematic in situations where two or more dynamos are working
together and one has an engine running at a lower power than the other. The
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dynamo with the stronger engine will tend to drive the weaker as if it were a motor,
against the rotation of the weaker engine. Such reverse-driving could feed back
into the driving engine of a dynamo and cause a dangerous out of control reverse-
spinning condition in the
lower-power dynamo. It was eventually determined that when several dynamos all
feed the same power source all the dynamos must be locked into synchrony using a
jackshaft interconnecting all engines and rotors to counter these imbalances.
Dynamo as commutated DC generator:
After the discovery of the AC Generator and that alternating current can in fact be
useful for something, the word dynamo became associated exclusively with the
commutated DC electric generator, while an AC electrical generator using either
slip rings or rotor magnets would become known as an alternator. An AC electric
motor using either slip rings or rotor magnets was referred to as a synchronous
motor, and a commutated DC motor could also be calledan electric motor though
with the understanding that it could in principle operate as a generator.
Rotary converter development:
After dynamos and motors were found to allow easy conversion back and forth
between mechanical or electrical power, they were combined in devices called
rotary converters, rotating machines whose purpose was not to provide mechanical
power to loads but to convert one type of electric current into another, for example
DC into AC. They were multi-field single-rotor devices with two or more sets of
rotating contacts (either commutators or sliprings, as required), one to provide
power to one set of armature windings to turn the device, and one or more attached
to other windings to produce the output current.
The rotary converter can directly convert, internally, any type of electric power
into any other. This includes converting between direct current (DC) and
alternating current (AC), three phase and single phase power, 25 Hz AC and 60 Hz
22
AC, or many different output voltages at the same time. The size and mass of the
rotor was made large so that the rotor would act as a flywheel to help smooth out
any sudden surges or dropouts in the applied power.
The technology of rotary converters was replaced in the early 20th century by
mercury-vapor rectifiers, which were smaller, did not produce vibration and noise,
and required less maintenance. The same conversion tasks are now performed by
solid state power semiconductor devices. Rotary converters were still used for the
West Side IRT subway in Manhattan into the late 1960s, and possibly some years
later. They were powered by 25 Hz AC, and provided DC at
600 volts for the trains. Dynamos still have some uses in low power applications,
particularly
where low voltage DC is required, since an alternator with a semiconductor
rectifier can be inefficient in these applications.
Hand cranked dynamos are used in clockwork radios, hand powered flashlights,
mobile phone rechargers, and other human powered equipment to recharge
batteries.

23
Chain

A chain is a series of connected links which are typically made of metal. A chain may
consist of two or more links.

 Those designed for lifting, such as when used with a hoist; for pulling; or for
securing, such as with a bicycle lock, have links that aretorus shaped, which make
the chain flexible in two dimensions (The fixed third dimension being a chain's
length.)

 Those designed for transferring power in machines have links designed to mesh
with the teeth of the sprockets of the machine, and are flexible in only one
dimension. They are known as roller chains, though there are also non-roller
chains such as block chain.

Two distinct chains can be connected using a quick link which resembles a carabiner with
a screw close rather than a latch.

24
CHAPTER 4

DIAGRAM

25
CHAPTER 5

WORKING PRINCIPLE

Principle of Dynamo An electrical generator is a device that converts


mechanical energy to electrical energy, generally using electromagnetic induction.
The source of mechanical energy may be a reciprocating or turbine steam engine,
water falling through a turbine or waterwheel, an internal combustion engine, a
wind turbine, a hand crank, or any other source of mechanical energy. The
Dynamo was the first electrical generator capable of delivering power for industry.
The dynamo uses electromagnetic principles to convert mechanical rotation into an
alternating electric current. A dynamo machine consists of a stationary structure
which generates a strong magnetic field, and a set of rotating windings which turn
within that field. On small machines the magnetic field may be provided by a
permanent magnet; larger machines have the magnetic field created by
electromagnets. The energy conversion in generator is based on the principle of the
production of dynamically induced emf. Whenever a conductor cuts magnetic flux,
dynamically induced emf is produced in it according to Faraday's Laws of
Electromagnetic induction. This emf causes a current to flow if the conductor
circuit is closed. Hence, two basic essential parts of an electrical generator are (i) a
magnetic field and (ii) a conductor or conductors which can so move as to cut the
flux.

26
CHAPTER 6

MECHANISM OF OPERATION

The Pedal Operated Power Generator (POPG) is a type of generators in which the
source of mechanical power is provided by the human effort while spinning a
shaft, with its corresponding angular speed (ωhuman) and torque (Thuman). Usually, a
sort of mechanical transmission system is needed to adapt these variables into the
generator’s required ones (ωgen and Tgen). Then, this mechanical power is turned
into electric power by the generator (Pout gen). Eventually, Poutgen is converted
with the aim of being stored (Pin storage), without damaging the storage system.
The principle of using your pedal motion to create the same motion as a motor can
be translated to almost any device, and the parts needed are all the same, and in the
case of the pedal powered electrical device, the components include:

A stationary bike or exercise bike, belt and pulley system, chain drive
system, generator,blocking diode, fuse, battery and inverter system

27
The voltage induced across the terminals of a wire loop when the magnetic flux
passing through the loop varies can be calculated using the following equation:

Where: E = the voltage induced across the terminals


of the wire loop, expressed in volts (V).

is the number of turns of wire in the loop.

∆ is the variation in intensity of the magnetic flux


passing through the wire loop, expressed in
Webers (Wb).

∆ is the time interval during which the magnetic flux variationoccurs,


expressed in seconds (s)

28
CHAPTER 7

FACTORS DETERMINING THE CHOICE OF MATERIALS

The various factors which determine the choice of material are discussed
below.

1. Properties
The material selected must possess 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

 Physical
 Mechanical
 From manufacturing point of view
 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, torsion and buckling load, fatigue resistance, impact
resistance, elastic limit, endurance limit, and modulus of elasticity, hardness, wear
resistance and sliding properties.

29
The various properties concerned from the manufacturing point of view are,

 Cast ability
 Weld ability
 Surface properties
 Shrinkage
 Deep drawing etc.

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

30
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.

31
CHAPTER 8

FABRICTION AND TESTING

STUDY

FINDING DEMERITS OF OLDER PROCESS

FINDING THE SOLUTION FOR PROBLEMS


FGGGGS

IMAGINARY PLAN

COLLECTING THE MATERIAL

FABRICATION

WORKING & ANALYSING

RESULT AND SCOPE OF FUTURE WORK

32
CHAPTER 9

ADVANTAGES & DISADVANTAGES

Portable- it is a portable device which is easily detachable and attachable.

1. No operating cost- it requires only mechanical work so free of any


operating cost.

2. Economical- it is free source of electricity, though it require some


mechanical work which can be done in any leisure time so it is economical

3. Health improving- Cycling makes one to be fit and healthy.

4. Eco-friendly- Doesn’t emit any kind of harmful substances so it is eco


friendly.

5. Robust and simple circuit- This circuit requires only five components
which are small in size and robust. This makes it simple in design.

6. Very low maintenance-No need of maintenance as devices are very cheap.

7. Better performance on Li-ion battery: In today’s time the most of the


phones use Li-ion battery in their phones so this is necessary for us to give better
performance in those but still it’s a disadvantage that it doesn’t give optimal
performance on other batteries.

8. Frictional losses: The frictional losses occur because of friction between


motor wheel & cycle wheel. 9. High speed disadvantage

33
APPLICATIONS
Since the Pedal operated cell phone charger is more efficient it is used for mobile
charger.

All mobile charging applications.

LIMITATIONS
 Less efficiency when compressed to other device.

 Leakage of air affects the working of the unit.

34
CHAPTER 10
CONCLUSION
In conclusion, this project was designed to serve as a model/prototype to meet specific need in
our locality. The device can also serve as an alternative power source in extreme case scenario
even in urban centers. Since the device is manually operated, it can be used in areas where there
is no power supply and would always be readily available.
The device is environmentally friendly as it produces no waste in the process of its operation,
and the device work with little or no noise. The system proved efficient since even with a
minimum pedaling speed, the system produced enough voltage required to charge the battery in
order for the system to be usable by almost anybody at anytime.

35
BIBLIOGRAPHY

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
 Atkinson, C. J. and Brooks, L. (2005) In the Age of the Humanchine, In Proceedings of
International Conference on Information Systems (ICIS), AIS, Las Vegas, USA.
 Bryant, C. G. A. and Jary, D. (1991) Giddens' theory of structuration : a critical
appreciation, Routledge, London.
 Callon, M. and Latour, B. (1981) Unscrewing the Big Leviathan: how actors
macrostructure reality and how sociologists help them to do so, In Advances in Social
Theory and Methodology: Toward an Integration of Micro- and Macro-Sociologies.(Eds,
Knorr-Cetina, K. D. and Cicoure, A. V.) Routledge and KeganPaul, Boston, Mass, pp.
277-303.
 Penston, J. (2007) Patients' preferences shed light on the murky world of guideline-based
medicine, Journal of Evaluation in Clinical Practice, 13 154-159.

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PHOTOGRAPHY

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