PROJECT TITLE : INERTIA POWER WHEEL GENERATOR

OBJECTIVE OF PROJECT:

Design –Development of an free energy device ( inertia power wheel generator) that converts
intermittent or discontinuous form of energy input to continuous power output by using gravity as
spring

INTRODUCTION

RLEVANCE OF PROJECT :

TOTAL ENERGY

Our total energy use can be divided into three principal areas each of which consume
approximately equal amounts of energy on an annual basis:

 Electricity Generation
 Space Heating

 Transportation

This energy use has been roughly constant over the last 5 years and is dominated (90%) by
the use of fossil fuels.
Fossil Fuels come in 3 principal forms from which many other products are derived:

 Coal
 Natural Gas

 Crude Oil
Most traditional Energy production comes about via steam driven turbines so the heating of
water is what is essential.

 Coal Fired Steam Plants

 Nuclear Fired Steam Plants

 Oil/Natural Gas Fired Steam Plants

The Need for Alternative Energy

 Basic concept of alternative energy sources relates to issues of sustainability,

renewability and pollution reduction.
 In reality, Alternative Energy means any thing other than deriving energy via Fossil
Fuel combustion

 Basic Barrier to all forms of alternative energy lies in initial costs!

 Currently we have no significant production line alternative energy source operating

anywhere in the US!

The simple problem is that there are simply not enough fossil fuels left to sustain its usage as
the foundation of our energy production. Forget about global warming for the moment, the
issue is more basic than that.

We have about 50 more years of production from known reserves , after that we will either
have to discover more reserves are shift away from our fossil fuel based energy economy.
Forms of Alternative Energy:

 Solar:

Advantages: Always there; no pollution

Disadvantages: Low efficiency (5-15%); Very high initial costs; lack of

adequate storage materials (batteries); High cost to the consumer

 Hydro:

Advantages: No pollution; Very high efficieny (80%); little waste heat;

low cost per KWH; can adjust KWH output to peak loads; recreation
dollars

Disadvantages: Fish are endangered species; Sediment buildup and dam

failure; changes watershed characteristics; alters hydrological cycle

 Wind:

Advantages: none on large scale; supplemental power in windy areas;

best alternative for individual homeowner
 Disadvantages: Highly variable source; relatively low efficiency (30%);
more power than is needed is produced when the wind blows; efficient
energy storage is thus required

 Geothermal:

Advantages: very high efficiency; low initial costs since you already got
steam Disadvantages: non-renewable (more is taken out than can be put
in by nature); highly local resource

 Ocean Thermal Energy Conversion:

Advantages: enormous energy flows; steady flow for decades; can be

used on large scale; exploits natural temperature gradients in the ocean

Disadvantages: Enormous engineering effort; Extremely high cost;

Damage to coastal environments?

 Tidal Energy:

Advantages: Steady source; energy extracted from the potential

and kinetic energy of the earth-sun-moon system; can exploit bore
tides for maximum efficiency

Disadvantages: low duty cycle due to intermittent tidal flow; huge

modification of coastal environment; very high costs for low duty
cycle source

 Hydrogen Burning:

Advantages: No waste products; very high energy density; good

for space heating

Disadvantages: No naturally occurring sources of Hydogren;

needs to be separated from water via electrolysis which takes a lot
of energy; Hydrogen needs to be liquified for transport - takes
more energy. Is there any net gain?

 Biomass Burning:
 Advantages: Biomass waste (wood products, sewage, paper, etc)
are natural by products of our society; reuse as an energy source
would be good. Definite co-generation possibilities. Maybe
practical for individual landowner.

Disadvantages: Particulate pollution from biomass burners;

transport not possible due to moisture content; unclear if growing
biomass just for burning use is energy efficient. Large scale
facilities are likely impractical.

 Nuclear Fusion: --> Forget it, we aren't smart enough yet. But
suppose we become smart enough in a few hundred years. Can adoption
of sustainable energy technology get us to this point?

ALTERNATIVE ENERGY

Alternative energy is best defined by the followings terms :

 Energy fuelled in ways that do not use up natural resources or harm the
environment.
 Energy derived from sources that do not use up natural resources or harm
the environment.
 energy derived from nontraditional sources (e.g., compressed natural gas,
solar, hydroelectric, wind).
 Energy generated from alternatives to fossil fuel. Need not be renewable.

Many methods of alternative energy generation have been invented and

devised , one such method is discussed in this document and is an direct
application of energy to pumping.
PRINCIPLE OF OPERATION :
 The figure shows a free un-damped vibrations set up of two mass- two
spring system. As shown in the figure the input to the system is in the form of an
low energy intermittent input from any power source (excitation) , this results in
free un-damped vibrations are set up in the system resulting in the free to and fro
motion of the mass (m1)& (m2) , this motion is assisted by gravity and will
continue until resonance occurs, ie, the systems will continue to work long after the
input (which is intermittent) has ceased……Hence the term free energy is used

This to and fro motion of the upper mass (m1) is converted into useful fork
done by coupling it to an single cylinder piston pump.

(note : the upward motion of the mass(m1) effects the suction stroke of the pump
and downward motion causes delivery of the pumped fluid.)
PROBLEM DEFINTION

The figure below shows the nature of wind flow with respect to time…It should be noted that
Wind power available in wind changes erratically….hence the power produced by the wind turbine is
also erratic which is undesirable….which also reduces the overall efficiency of the wind power system,
hence there is a need of a device that can convert this non-continuous energy or power into a
continuous power production…which will increase the power produced and thereby efficiency of the
given wind power system

SOLUTION:

The Inertia Power Wheel Generator is a modified energy storage and conversion system that
receives a discontinuous power input and converts it into continuous power output in the use-able
and storable form.

The system is an cost-effective modified energy conversion system that utilizes the
gravitational energy along-with inertia (Newton’s first law) to keep on working long after the dis-
continous input was supplied thereby producing continuous power at constant rate.

Note : The Inertia power wheel is an device for enhancement of power production and no generator
on its own.
INERTIA POWER WHEEL GNERATOR(block diagram)
WORKING

The intermittent or discontinuous input energy is given to the top tray

system which rotates about the central hinge block, but due to the difference
in mass distribution the heavier tray will try to go down faster owing to
gravity…hence the angular momentum increases and thereby the inertia of
the system…which will keep mass system in motion….but in doing so the
system will tilt towards the left /right thereby bringing the balancing springs
in tension under action of the heavier tray……

When the tray moves in upward direction…the spring which was under
tension will try to come back to original position due to resilence of spring…
thereby pulling the heavy tray down …thus cycle continues…

The smaller tray acts as a counter weight that ensure the balance and
assists free rotation of device.

LITERATURE REVIEW :
 naturtechnik.de
Hello ~ definition ~ Würth technology ~ literature ~ left ~ exit

 
Würth - technology:

~ Perpetuum mobile? ~ bases ~ to which the whole? ~

~ laboratory model ~ reinforcement transmissions ~ centrifugal force pump ~

~ Declaration of Principle ~ turning asymmetry ~ announced patents ~

~ literature ~ Downloads ~ left ~

 
 
Description of the centrifugal force pump
(Träheitsaktives Schwungsystem)

Text download store

The course process of the eccentric cam weights

The varying speed of the eccentric cam weights in the circulation
Thus the acceleration of the eccentric cam weights in the circulation varies
Effect of centrifugal force on the eccentric cam weights
The controlling of the centrifugal force pump
Course comparison
State of rest

- Structure and function -

Two gear wheel rotors are swivelling stored on a main rotor shaft. The main rotor
shaft is for his part stored on the tax axle swivelling. The gear wheel rotors
reach into the tax gear wheel and unreel around this.
On the gear wheel rotors mirror-symmetrically eccentric cam weights are appropriate
to the tax axle.

The course process of the eccentric cam weights (overview)

During a circulation of the rotors around the tax gear wheel move the eccentric cam
weights on a certain course, which runs eccentrically to the tax axle.

This course results from 2 rotations, which are “geschachtelt” into one another.
The eccentric cam weights turn around the axles of the gear wheel rotors and these
turn around the tax axle (supervision):
We divide this course mental into two sectors. In the first sector the eccentric
cam weight is consulted more closely to the tax axle (catching up phase). In the
second sector the Exzentwergewicht away from the tax axle turns outward
(hydroextracting phase).

Clarify yourselves the expirations with a small demo program!

The varying speed of the eccentric cam weights in the circulation (overview)

If the main rotor shaft with constant speed turns, the speed of the eccentric cam
weights varies during a course circulation.
If the eccentric cam weights outside are, the speed of the two into one another
geschachtelten rotations (supervision) adds itself:

If the eccentric cam weights inside are the speed of the Sub rotation disappeared
(supervision):
  

With the speed varies the acceleration of the eccentric cam weights in the
circulation (overview)

If the main rotor shaft with constant speed turns, the gear wheel rotors move by
the quadrants Q1, Q2, Q3 and Q4.
The position of the eccentric cam weights shows that the eccentric cam weight in
the catching up phase is braked and accelerated in the hydroextracting phase:

Speed is way per time.

By the movement of the gear wheel rotor in the quadrant Q1 by the eccentric cam
weight more way is put back than in Q2. The eccentric cam weight brakes on its way
from Q1 to Q2.

Accordingly the eccentric cam weight is slower in the quadrant Q3 than in Q4. It
accelerates on its way from Q3 to Q4.

 
 Effect of centrifugal force on the eccentric cam weights (overview)

With the turn of the main rotor shaft a centrifugal force field develops.
Centrifugal force grows with the number of revolutions squarely. Their influence on
the main rotor shaft system is speed-sensing.
We regard the moved eccentric cam weights on their course in the centrifugal force
field:

In the catching up phase the eccentric
force field and become heavy. Main and
shaft is pulled in this direction. The
implosive movement. The radius becomes
turning system takes up inertia energy
accelerates (Pirouetteneffekt).
cam weights move against the centrifugal
Subrotationsrichtung agree. The main rotor
eccentric cam weight describes a braking,
smaller, the course curvature closer. The
from the centrifugal force field and

In the hydroextracting phase the eccentric cam weights move increasingly in field
direction and become more with difficulty in the “case” outward. The radius
continues to become more largely, the course curvature. They unreel quasi into the
centrifugal force field and by centrifugal force are outward pressed
(hydroextracted without energy expenditure). Main and Subrotationsrichtung do not
agree.

If the directions of the two rotations agrees, the eccentric cam weight is heavier,
as if it does not agree.
The asymmetrical relative importance of the inertia values of the eccentric cam
weights in the two phases causes a course in main rotation direction. It supports
an acceleration of the main rotor shaft. After a Anschub the system remains
disproportionately for a long time in motion. If the turning rotor system developed
a certain centrifugal force field, it can run over a control by hold or accelerate.

The controlling of the centrifugal force pump (overview)

The control changes the speed and thus the acceleration of the eccentric cam
weights on its course. In addition it changes the courses and their curvature. It
continues to shift the inertia difference of the eccentric cam weights between the
two phases in the asymmetrical:

In the catching up phase the eccentric cam weight is braked by the control more
strongly and the course becomes closer to the tax axle (more strongly curvature and
stronger negative acceleration). The Piruetteneffekt in the catching up phase
thereby “more seriously” and the main rotor shafts accelerated more strongly. The
introduction of the weights takes place almost without work expended, because Sub
neutralize themselves and main rotation of centrifugal force fields mutually. In
the center a kind weightless zone develops.
The preference/advantage (acceleration) of the rotation pulls the Subrotoren on the
tax gear wheel along and the eccentric cam weights over the internal point of
tilting. At the point of tilting the Subrotations centrifugal force field breaks
down relative to the main rotation field. Main rotation centrifugal force presses
the eccentric cam weights again outward.

In the hydroextracting phase the course curvature becomes additionally further and
the radius larger. The eccentric cam weight is pushed by the control into the
“case” in the centrifugal force field (positive acceleration) and receives to
additional area its won kinetic energy in motion to convert. The “case” is less
braked straight lines and thus. The main rotation centrifugal force field develops
the Subrotations Fliehkraftfeld again.

By the control we receive a plus at rotational energy in both phases.

The control is realized by and a ago movement of the tax gear wheel (stroke). In
the appropriate course segment teeth are to it-given in each case or taken off.
 

Course comparison (overview)

It is thus crucially into which direction the tax gear wheel at a certain time in
the course process of the eccentric cam weights is moved. In the illustration the
tax gear wheel in the catching up phase counterclockwise, in the hydroextracting
phase with the clockwise direction moves.
The number of revolutions of the main rotor shaft determines the frequency of the
phase changes. The speed of lift of the control must be co-ordinated with the
number of revolutions of the main rotor shaft.
The control out of phase claimant comes the rotor to to stand (braking of the
rotor).

The rotary system absorbs torque and the inertia of the system (the momentum) rises
with increasing centrifugal force. Without control the machine runs out with same
rotation impulse longer than rigid system of same mass. With control the system
accelerates.

State of rest (overview)

In a state of rest the rotor system remains standing if the control is operated.
The rotors move back and forth, but the oh carrier hardly moves.
There is not strength-closing connection or translation between the tax gear wheel
and the rotor system.

 
DESIGN METHODOLOGY

DESIGN OF INERTIA POWER WHEEL GENERATOR

In our attempt to design a special purpose machine we have adopted a very a

very careful approach, the total design work has been divided into two parts
mainly;

 System design
 Mechanical design
System design mainly concerns with the various physical constraints and
ergonomics, space requirements, arrangement of various components on the main
frame of machine no of controls position of these controls ease of maintenance
scope of further improvement; height of m/c from ground etc.

In Mechanical design the components are categoriesed in two parts.

 Design parts
 Parts to be purchased.
For design parts detail design is done and dimensions thus obtained are compared
to next highest dimension which are readily available in market this simplifies the
assembly as well as post production servicing work.

The various tolerances on work pieces are specified in the manufacturing

drawings. The process charts are prepared & passed on to the manufacturing
stage .The parts are to be purchased directly are specified &selected from standard
catalogues.
SYSTEM DESIGN

General considerations

In system design we mainly concentrate on the following parameter

1.System selection based on physical constraints:-

While selecting any m/c it must be checked whether it is going to be used

in large scale or small scale industry In our case it is to be used in small scale
industry So space is a major constrain .The system is to be very compact. The
mechanical design has direct norms with the system design hence the foremost job
is to control the physical parameters.

2. Arrangement of various components:-

Keeping into view the space restriction the components should be laid such
that their easy removal or servicing is possible moreover every component should
be easily seen & none should be hidden every possible space is utilized in
component arrangement.

3. Components of system:-

As already stated system should be compact enough so that it can be

accommodated at a corner of a room. All the moving parts should be well closed &
compact A compact system gives a better look & structure.

Following are some example of this section

 Design of machine height

 Energy expenditure in hand operation
 Lighting condition of m/c
8. Chances of failure:-

The losses incurred by owner in case of failure of a component are

important criteria of design. Factor of safety while doing the mechanical design is
kept high so that there are less chances of failure. Periodic maintenance is required
to keep the m/c trouble free.

9. Servicing facility:-

The layout of components should be such that easy servicing is possible

especially those components which required frequent servicing can be easily
dismantled.

10. Height of m/c from ground:-

Fore ease and comfort of operator the height of m/c should be properly
decided so that he may not get tired during operation .The m/c should be slightly
higher than that the level also enough clearance be provided from ground for
cleaning purpose.

11. Weight of machine:-

The total wt of m/c depends upon the selection of material components as

well as dimension of components. A higher weighted m/c is difficult for
transportation & in case of major break down it becomes difficult to repair.
 SYSTEM DESIGN

Assumptions

m1 = Mass of empty pan in kg = 3.6 Kg

θ = Angle of inclination of the conveyor track = 50

M1 X 197 = M2 X (172/COS5)

M2 =4.12 KG….

This is balancing load….which will allow the tray to revolve freely through 180
degrees , bt we expect the tray to make a complete revolution, hence increasing
valu of mass by 15% m2 = 4.8 kg
MECHANICAL DESIGN
DESIGN OF MAIN SHAFT
The main shaft carries the entire load of the material transfer system , as well as it
is subjected to torsion and direct shear under given system of forces, hence the
main shaft will be designed considering all the above criterion.

a) Design of main shaft in compression

Design of Main shaft considering pure axial load in the form of dead weight of
system which will cause compressive stress in the shaft material .

The Weight system is as follows:

Low mass tray = 3.2 kg = 32 N

High mass tray = 4.8 kg = 48 N

Note : The shaft is fitted with ball bearing 6004 ZZ which are held in the bearing
bush mounted on this shaft.

MATERIAL SELECTION : - Ref :- PSG (1.10 & 1.12) + (1.17)

DESIGNATION ULTIMATE TENSILE YEILD STRENGTH

STRENGTH N/mm2 N/mm2

800 680
EN 24

The load acting on shaft is summation of the weights of the pans , arm , part weight
, counter weight , bearing housing, bearing bush which is maximum upto
(approximately ) 10 kg = 100 N
The smallest section on shaft = 20 mm

Compressive stress= Force

area

= 100

/4 x (d2 )

= 100 x 4

 x (20) 2

shear stress = 0.318 N/mm 2

Shaft is safe under compressive load

b) Design of main shaft in torsion

Using ASME code of design ;

Allowable shear stress;

Fsall is given stress ;

Fsall = 0.30 syt = 0.30 x 600

=180 N/mm2

Fsall = 0.18 x Sult = 0.18 x 720

= 130 N/mm2

Considering minimum of the above values ;

fsall = 130 N/mm2

Considering pure torsional load;

Tdesign =  fsact d3

16
Torque is owing to the movement of dead weight or pan with part, which is given
by,

T = 48 X 197 = 9456 N-mm

Assuming 100 % overload

Tdesign = 2 T = 18912 N-mm

Fsact = 16 x Tdesign

 d3

fsact = 12.03 N/mm2

As fsact < fsall

The shaft is safe in torsion

c) Check for direct shear of main shaft

Shear stress = shear force

Shear area

The shaft supports the entire material transfer system and vertical component of
force which is same as the force as angle is small ie, 100 N

= 100

/4 x (d2 )

= 100 x 4

 x (20) 2

shear stress = 0.318 N/mm 2

Shaft is safe in shear

 .

SELECTION OF BEARING 6004ZZ

Shaft bearing will be subjected to purely medium radial and axial loads; hence we
shall use ball bearings for our application.

Selecting ; Single Row deep groove ball bearing as follows.

Series 60

IsI No Bearing of d D1 D D2 B Basic

basic capacity
design No
(SKF)
20AC0 6004 20 23 42 36 12 4500 7350
4

P = X Fr + Y F a

For our application F a =Dead weight load =100 N

P = X Fr+ Y F a

As; F a/ Fr < e  X =1,Y=1

In this case the radial load is negligible hence;

P = Fa = 100 N

 P= 100 N

Calculation dynamic load capacity of brg

L= ( C ) p , where p= 3 for ball bearings

When P for ball brg

For m/c used for intermittent operation hence,

LH = 2000Hr

But ; L- 60 n LH

10 6

L=1.2 mrev

Now;1.2 = (C) 3
 100

C= 106.26 N.

As the required dynamic capacity of brg is less than the rated dynamic capacity
of brg;

DESIGN OF DAMPER SPRING

Damper spring is provided at the stopper end to stop the revolving tray the second
station, the object of the spring is to absorb the shock owing to the arrest of the
revolving tray

Specifications of spring

Wire diameter d = 2 mm

Mean coil diameter D = 18 mm

No of turns n = 10

 c = D/d =18/2 = 9

Maximum deflection of spring:-

Deflection  = 25 mm

Where;

 = 25 mm
Now;

 = 8 W C3 n

Gd

9 = 8 x W x (9)3 x 10

0.89 x 105 x 2

W = 27.5 N

The weight of the empty pan is approximately 3Kg, hence the spring will easily
deflect under the load weight of pan+ weight of material in tray, hece the
damping action is achieved.
DESIGN OF THE DRIVER arm
MATERIAL SELECTION : -

Ref :- PSG (1.10 & 1.12) + (1.17)

DESIGNATION ULTIMATE YEILD

TENSILE STRENGTH

STRENGTH N/mm2

N/mm2
EN 9 650 480

Cross section of link may be determined by considering lever in bending ;

The linkage has an section of (20 x 20 )mm

Let; t= thickness of link

B= width of link
 Bending moment;

Section modules; Z= 1/6 t b2

Fb=m/z = PL

1/6 t B2

= 6PL

tB2

Maximum effort applied by hand( P)= 100 N

fb= 6 x 100 x 120

20 x 20 2

fb =9 N/mm2

As fbact< fball

Thus selecting an (20 x20) cross-section for the link.

DESIGN OF SPUR PINION & GEAR
Stage 1: Drive as GEAR and pinion arangement

Maximum load =Maximium torque / Radius of gear

Maximum torque = 48 x 197 =9456 N

Radius of gear by geometry = 120mm

Maximum load = 9456 / 120 =48.8

b = 10 m

Sult pinion = Sult rack = 600 N/mm2

Service factor (Cs) = 1.5

The gear and pinion arrangement where as pinion has 12 teeth and gear sector has
120 teeth share the entire tooth load…

ÞPt = 48.8 N.

Peff = 48.8 N (as Cv =1 due to low speed of operation)

Peff = 48.8 N --------(A)

Lewis Strength equation

WT = Sbym
Where ;

Y= 0.484 – 2.86

Þ yp = 0.484 - 2..86 = 0.341

20

yg = 0.484 – 2.86 = 0.484

80

Þ Syp = 68.2

Syg = 89.6

As Syp < Sys Þ pinion is weaker

WT = (Syp ) x b x m

=68.2 x 10m x m

WT= 682 m2----------(B)

Equation (A) & (B)

682 m2 = 48.8

Þm=0.26 mm

selecting standard module = 2 mm ----for ease of construction as we go for single

stage gear box…making size compact …achieving maximum strength and proper
mesh.

Hence gear dimensions are as follows,

DESIGN OF BOOM
The BOOM carries the entire load of the material transfer system , under given
system of forces, hence the main shaft will be designed considering all the above
criterion.

a) Design of Boom in compression

Design of boom considering pure axial load in the form of dead weight of system
which will cause compressive stress in the shaft material .

The Weight system is as follows:

Low mass tray = 3.2 kg = 32 N

High mass tray = 4.8 kg = 48 N

MATERIAL SELECTION : - Ref :- PSG (1.10 & 1.12) + (1.17)

DESIGNATION ULTIMATE TENSILE YEILD STRENGTH

STRENGTH N/mm2 N/mm2

600 480
EN 9

The load acting on shaft is summation of the weights of the pans , arm , part weight
, counter weight , bearing housing, bearing bush which is maximum upto
(approximately ) 10 kg = 100 N

The smallest section on shaft = 20 mm

Compressive stress= Force

area

= 100

/4 x (d2 )

= 100 x 4

 x (502-402)

shear stress = 0.14 N/mm 2

Boom is safe under compressive load

 MATERIAL SPECIFICATION : EN9
PART NAME : BASE PLATE
RAW MATERIAL SIZE:  220X 12
Sr. Description of Tools Time in minutes
Operation
No

Jigs & M/c Cutting Measuring Setting M/c Total

Fixture Instrument
Tools Tools Time Time Time

1 Clamp stock Three jaw Lathe - - 20 - 20

chuck

2 Facing Both side to Three jaw Lathe Facing Vernier - 5 5

total length 6mm chuck
tool

3 Turning OD Ø 206 Turning 5 10 15

mm through length tool

4. Drilling Ø 15 Fixture --”-- Twist Vernier 15 10 25

through thickness drill

5.. Boring Ø 80hrough --”-- --”-- Boring Vernier 15 10 25

thickness tool
 MATERIAL SPECIFICATION : EN9
PART NAME : BOOM BASE DISK
RAW MATERIAL SIZE:  220X 12

Sr. Description of Tools Time in minutes

Operation
No

Jigs & M/c Cutting Measuring Setting M/c Total

Fixture Instrument
Tools Tools Time Time Time

1 Clamp stock Three jaw Lathe - - 20 - 20

chuck

2 Facing Both side to Three jaw Lathe Facing Vernier - 5 5

total length 6mm chuck
tool

3 Turning OD Ø 206 Turning 5 10 15

mm through length tool
 MATERIAL SPECIFICATION : EN9
PART NAME : BOOM HOLDER
RAW MATERIAL SIZE:  80X 90

Sr. Description of Tools Time in minutes

Operation
No

Jigs & M/c Cutting Measuring Setting M/c Total

Fixture Instrument
Tools Tools Time Time Time

1 Clamp stock Three jaw Lathe - - 20 - 20

chuck

2 Facing Both side to Three jaw Lathe Facing Vernier - 5 5

total length 80mm chuck
tool

3 Turning OD Ø Turning 5 10 15
66mm through tool
length

4. Drilling Ø 15 Fixture --”-- Twist Vernier 15 10 25

through thickness drill

5. Boring Ø 50hrough --”-- --”-- Boring Vernier 15 10 25

thickness tool
 MATERIAL SPECIFICATION : EN9 RAW
PART NAME : BOOM HOLDER MATERIAL SIZE: PIPE  60X040 760

QUANTITY :- 01 NO’S.

Sr. Description of Tools Time in minutes

Operation
No

Jigs & M/c Cutting Measuring Setting M/c Total

Fixture Instrument
Tools Tools Time Time Time

1 Clamp stock Three jaw Lathe - - 20 - 20

chuck

2 Facing Both side to Three jaw Lathe Facing Vernier - 5 5

total length 750mm chuck
tool

3 Turning OD Ø Turning 5 10 15
50mm through tool
length
 MATERIAL SPECIFICATION : EN9
PART NAME : MAIN SHAFT
RAW MATERIAL SIZE:  60 X 50

Sr. Description of Tools Time in minutes

Operation
No

Jigs & M/c Cutting Measuring Setting M/c Total

Fixture Instrument
Tools Tools Time Time Time

1 Clamp stock Three jaw Lathe - - 20 - 20

chuck

2 Facing Both side to Three jaw Lathe Facing Vernier - 5 5

total length 37mm chuck
tool

3 Turning OD Ø Turning 5 10 15
53mm through tool
length

4. StepTurning OD to Lathe Turning Vernier - 14 14

Ø 40 mm through tool
length 10

5.. StepTurning OD to Lathe Turning Vernier - 14 14

Ø 20mm through tool
length 15

6. Hex milling Milling End mill 40 100 140

 MATERIAL SPECIFICATION : EN9
PART NAME : MAIN SHAFT
RAW MATERIAL SIZE:  60 X 50

Sr. Description of Tools Time in minutes

Operation
No

Jigs & M/c Cutting Measuring Setting M/c Total

Fixture Instrument
Tools Tools Time Time Time

1 Clamp stock Three jaw Lathe - - 20 - 20

chuck

2 Facing Both side to Three jaw Lathe Facing Vernier - 5 5

total length 37mm chuck
tool

3 Turning OD Ø Turning 5 10 15
53mm through tool
length

4. Drilling Ø 15 Fixture --”-- Twist Vernier 15 10 25

through thickness drill

5.. Boring Ø 36hrough --”-- --”-- Boring Vernier 15 10 25

thickness tool

6. Counter boring Ø --”-- --”-- Boring Vernier 15 10 25

42hrough tool
thickness12mm

6. Hex milling Milling End mill 40 100 140

CONCLUSION:
 The Result of experimentation on the Inertia power wheel
generator:

1. Weight of Max. inertia tray : 4.8 kg

2. Weight of minimum inertia tray : 3.2 kg

3. Dynamo Specification : 3 watt ---12 Vdc

  BILL OF MATERIALS:-
SR PART CODE DESCRIPTION QTY MATERIAL
NO.

1. IPWG-1 BASE PLATE 01 EN9

2. IPWG -2 BOOM BASE PLATE 01 EN9

3. IPWG -3 BOOM HOLDER 01 EN9

4. IPWG -4 MAX INERTIA TRAY 01 MS

5. IPWG -5 MIN INERTIA TRAY 01 MS

6. IPWG -6 CEN. BRG HOUSING 01 EN24

7. IPWG -7 MAIN SHAFT 01 EN24

8. IPWG -8 BOOM 01 MS

9. IPWG -9 TENSION SPRINGS 03 STD

10. IPWG –10 COMPRESSION 03 STD

SPRINGS

11. IPWG-11 GEAR 01 EN24

12. IPWG-12 SPRING BRACKET 01 EN9

13. IPWG-13 PINION 01 EN24

14. IPWG-14 DYNAMO 01 STD

15. IPWG-15 BRG_6004 01 STD

16. IPWG-16 BASE FRAME 01 MS

17. IPWG-17 FLOATING BOOM 01 MS

MATERIAL PROCUREMENT

Material is procured as per raw material specification and part quantity. Part
process planning is done to decide the process of manufacture and appropriate
machine for the same.
GENERAL MATERIAL USED

EN24- ALLOY STEEL

EN9- PLAIN CARBON STEEL

MS-MILD STEEL

STD- STANDARD PARTS SELECTED FROM PSG DESIGN DATA/MANUFACTURER

CATALOGUE

RAW MATERIAL COST

 The total raw material cost as per the individual materials and their
corresponding rates per kg is as follows,

Total raw material cost = Rs 56 00/-

 MACHINING COST
OPERATION RATE TOTAL TIME TOTAL COST
Rs/-
Rs /HR HRS

LATHE 80 26 2080

MILLING 90 32 2880

DRILLING 60 4 240

TOTAL 5200

 MISCELLANEOUS COSTS
 OPERATION COST(Rs)

GAS CUTTER 100

SAWING 120

WELDING - 1360
FABRICATION

TOTAL 1580

 COST OF PURCHASED PARTS :-

SR NO. DESCRIPTION QTY COST

1. BEARINGS 01 400

2. BOLTS - 110

3. GRUB SCREW - 56

4. SPRINGS 06 1080

5. DYNAMO 01 1240

The cost of purchase parts = Rs 2886/-

TOTAL COST

TOTAL COST = Raw Material Cost +Machine Cost + Miscellaneous Cost

+ cost of Purchased Parts +Overheads

Hence the total cost of machine = Rs 16446/-

 BIBLIOGRAPHY

1. MACHINE DESIGN

:- R S KHURMI
2.DESIGN OF MACHINE ELEMENTS

:- V B BHANDARI

3.P S G DESIGN DATA

4.PRODUCTION TECHNOLOGY

:- P C SHARMA