CHAPTER 1

INTRODUCTION
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 many
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 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

1
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 transmit 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 pedaled or cranked by hand/foot to charge 12
volt batteries and run small appliances.

Pedal powered Hacksaw cutting machine is a manually pedal operated system

which is mainly used for cutting metals, wood and plastics.

The pedal powered hacksaw setup has a simple mechanism operated with chain
and sprocket gear arrangement. During pedaling, the wheel rotary motion is
converted into the “To and Fro” motion of the cutting tool (Hacksaw). That is the
principle of slider crank mechanism. The size and shape is similar to a bicycle, it
can be operated by very low power since it requires a very low pedaling power.
The means of transmission is through a simplex chain mechanism and thus it
transmits power without much loss.

The lubrication of the chain and crank arrangement is made by applying SAC 20 or
SAE 30, a very high viscous lubricant. The system also uses the flywheel which
reduces the fluctuations speed caused by the fluctuations of pedaling and also
uniform cutting. The flywheel also serves as energy reservoirs that stores energy
when it is excess and release it when there is shortage of energy within the system.
2
Pedal power is the transfer of energy from a human source through the use of a
foot pedal and crank system. This technology is most commonly used for
transportation and has been used to propel bicycles for over a hundred years. 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 into pedal powered tools for sustainable
development. This project concentrates on pedal powered hacksaw machining. An
individual can generate four times more power (1/4 HP) by pedaling than by hand-
cranking. At the rate of ¼ HP, continuous pedaling can be served for only short

Periods, approximately 10 minutes However, pedaling at half this power (1/8 HP)
can be sustained for close to 60 minutes but power capability can depend upon age.
As a consequence of the brainstorming exercise, it was apparent that the primary
function of pedal power one specific product was particularly useful: the bicycle.
Many devices can be run right away with mechanical energy. A saw is a tool that
uses a hard blade or wire with an abrasive edge to cut through softer materials. The
cutting edge of a saw is either a serrated blade or an abrasive. A saw may be
worked by hand, or powered by steam, water, electric or other power. An abrasive
saw uses an abrasive disc or band for cutting, rather than a serrated blade.

3
 CHAPTER 2
LITERATURE SURVEY
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. From 1880 to 1900, there was a period of
rapid development in electrical machines.

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.

According to Jamie and Aaron (2012), Wind stream, Convergence Tech and
Magnificent Revolution have manufactured stationary pedal powered generators.
Typical design included a back-wheel stand that elevates the bicycle and causes the
back wheel to come in contact with a smaller wheel that is hooked up to a “bicycle
dynamo” and a battery

Stephen, Tambari, Dan Orawari Gloria., Oruene W. Diabi, Ayejah Victor

The aim of this work is to design and construct a pedal driven hacksaw machine
that will use a less effort pedaling power to produce uniform cutting of PVC pipes,
metals, wood and as the same time serve as an exercising machine for fitness. it is

4
also done to show the performance difference between hand driven and pedal
driven hacksaw This work is design to overcome the stress attached to hand cutting
of engineering materials by turning it into an exercise for body fitness.

2.1 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.
Mc.Cullagh, (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).

5
 CHAPTER 3
ANALYSIS
3.1 ENERGY ANALYSIS

 Heslin and Annette (2005) provided an insight into the average daily
consumption of an average male as 2440kcal; this is about 119W of power
in, 10.299MJ or 2861Wh of energy every single day. This is approximately
the same amount of energy stored in the typical car battery (2400Wh).

 The primary fuel used in the production of human power is consumed food.
The human body utilizes energy stored in the chemical bonds of consumed
compounds such as carbohydrate, proteins, fats and fiber to fuel metabolic
processes. These processes include basal metabolic function that sustain life,
and advance metabolic function used during physical activities.

 Food energy is commonly measured in the empirical units of Kilocalories

(Kcal) or food calories (C), 1Kcal is equivalent to 1C. In the metric system,
is measured in Joules, where 1C is equivalent to 4184J. 3

3.2 MESUREMENT OF ENERGY EXPENDITURE (Human Power Input)

The Different methods of energy measurement are available: Direct

Calorimetric based on the heat production, Indirect Calorimetric based on the
volume of oxygen consumed, Open circuit Spirometer based on the
measurement of ventilator volumes, Open-flow system etc. for the purpose of
this report, the indirect calorimetric method is adopted. This method includes:

6
  Measurement of oxygen consumption
 One liter of consumed = 21KJ used (varies slightly with metabolic
fuel consumption – carbons/fats)
3.3 DESIGN ANALLYSIS

3.3.1 SIZING AND ECONOMIC CONSIDERATION

This system is design to compact in consideration of the power
requirement as well as reduction in the cost of fabrication. For affordability,
the device is relatively small.

3.3.2 SAFETY CONSIDERATIONS

This system is design in such a way that women and children can use it
for sustained period of time. It preserves the safety of our immediate
environment from noise and air pollution because it’s noiseless and smokeless.
Stability of the unit was also considered to ensure that the equipment remains
upright at all time, i.e. it should not drift or bend to one direction and it should
remain stationary.

3.3.3 ERGONOMICS
The ergonomics aspect has to do with optimizing the physical contact
between human and the equipment. Four important areas of bike ergonomics
are usually considered:

 The strain of the arm and shoulder

 The muscle support and the position of the lower back
 The work of proper pedaling
3.3.4 TECHNOLOGICAL CONSIDERATION
The design of this system is well considered in such a manner that it
can be produced within the technology of our immediate environment.

7
 CHAPTER 4
MAJOR COMPOMENT AND DESCRIPTION
4.1 BICYCLE FRAME

Old Bicycle frames are recycled to make the basic frame of the machine.
Seating arrangement and rear wheel fork is kept as is, so are the pedals, rest is cut
away and a basic smithy shop is used to make the machine.

4.2 SPROCKET

A sprocket or sprocket-wheel is a profiled wheel with teeth, cogs, or even

sprockets that mesh with a chain, track or other perforated or indented material.
The name 'sprocket' applies generally to any wheel upon which are radial
projections that engage a chain passing over it. It is distinguished from a gear in
that sprockets are never meshed together directly, and differs from a pulley in that
sprockets have teeth and pulleys are smooth. Sprockets are used in bicycles,
motorcycles, cars, tracked vehicles, and other machinery either to transmit rotary
motion between two shafts where gears are unsuitable or to impart linear motion to
a track, tape etc.

Fig.4.2.1 SPROCKET

8
4.3 CHAIN DRIVE

A chain is made up of a series of links with the links held together with steel
pins. These arrange makes a chain a strong, long lasting way of transmitting rotary
motion from one gear wheel to another.

Chain drive has one main advantage over a traditional gear train. Only two gear
wheels and a chain are needed to transmit rotary motion over a distance. With a
traditional gear train, many gears must be arranged meshing with each other in
order to transmit motion. Two distinct chains can be connected using a quick link
which resembles a carabineer with a screw close rather than a latch. A chain is a
series of connected links which are typically made of metal. A chain may consist
of two or more links.

Fig.4.3.1. CHAIN DRIVE

9
4.4 DC MOTOR

A DC motor is a mechanically commutated electric motor powered from

direct current (DC). The stator is stationary in space by definition and therefore the
current in the rotor is switched by the commutated to also be stationary in space.
This is how the relative angle between the stator and rotor magnetic flux is
maintained near 90 degrees, which generates the maximum torque.

DC motors have a rotating armature winding (winding in which a voltage is

induced) but non-rotating armature magnetic field and a static field winding
(winding that produce the main magnetic flux) or permanent magnet. Different
connections of the field and armature winding provide different inherent
speed/torque regulation characteristics. The speed of a DC motor can be controlled
by changing the voltage applied to the armature or by changing the field current.
The introduction of variable resistance in the armature circuit or field circuit
allowed speed control. Modern DC motors are often controlled by power
electronics systems called DC drives. The introduction of DC motors to run
machinery eliminated the need for local steam or internal combustion engines, and
line shaft drive systems.

Fig.4.4.1 DC MOTOR

10
4.5 HACKSAW

A hacksaw is a fine tooth hand saw with a blade held under tension in a
frame, used for cutting materials such as metal or plastics. Hand held hacksaw
consist of a metal arch with a handle, usually a piston grip, with pins for attaching
a narrow disposable blade.

Fig: Hacksaw frames a screw or other mechanism is used to the thin blade under
tension. The blade can be mounted with the teeth facing toward or away from the
handle, resulting in cutting action on either push or pull stroke. On the push stroke,
the arch will flex slightly decreasing the tension on the blade, often resulting in an
increased density of the blade to buckle and crack. Cutting on the pull stroke
increases the blade tension and will result in greater control of the cut and longer
blade life.

Fig.4.5.1 HACKSAW

11
4.6 BEARING

Bearing is a machine element that constrains relative motion and reduces

friction between moving parts to only the desired motion. The design of the
bearing may, for example, provide for free linear movement of the moving part or
for free rotation around a fixed axis or, it may prevent a motion by controlling the
vectors of normal forces that bear on the moving parts. Many bearings also
facilitate the desired motion as much as possible, such as by minimizing friction.
Bearings are classified broadly according to the type of operation, the motions
allowed, or to the directions of the loads (forces) applied to the parts. The term
"bearing" is derived from the verb "to bear"; a bearing being a machine element
that allows one part to bear (i.e., to support) another. The simplest bearings are
bearing surfaces, cut or formed into a part, with varying degrees of control over the
form, size, roughness and location of the surface. Other bearings are separate
devices installed into a machine or machine part. The most sophisticated bearings
for the most demanding applications are very precise devices; their manufacture
requires some of the highest standards of current technology

Fig.4.6.1 BEARING

12
4.7 BLADES

Blades are available in standardized lengths, usually 10 or 12 inches for a

standard hand hacksaw. "Junior" hacksaws are typically 150mm long. Powered
hacksaws may use large blades in a range of sizes, or small machines may use the
same hand blades. The pitch of the teeth can be anywhere from fourteen to thirty-
two teeth per inch (tips) for a hand blade, with as few as three tips for a large
power hacksaw blade. The blade chosen is based on the thickness of the material
being cut, with a minimum of three teeth in the material. As hacksaw teeth are so
small, they are set in a "wave" set. As for other saws they are set from side to side
to provide a kerf or clearance when sawing, but the set of a hacksaw changes
gradually from tooth to tooth in a smooth curve, rather than alternate teeth set left
and right. Hacksaw blades are normally quite brittle, so care needs to be taken to
prevent brittle fracture of the blade. Early blades were of carbon steel, now termed
'low alloy' blades, and were relatively soft and flexible. They avoided breakage,
but also wore out rapidly. Except where cost is a particular concern, this type is
now obsolete. 'Low alloy' blades are still the only type available for the junior
hacksaw, which limits the usefulness of this otherwise popular saw.

Fig.4.7.1 BLADE

13
 CHAPTER 5
PEDAL ARRANGEMENT
A pair of pedals is attached to the stand setup in which the power will be
generated manually. A typical Bicycle arrangement is used.

5.1 PEDAL

A bicycle pedal is of a bicycle that the rider pushes with their foot to propel
the bicycle. It provides the connection between the cyclists’ foot or shoe and the
crank allowing the leg to turn the bottom bracket spindle and propel the bicycle's
wheels.

Pedal Pedals were initially attached to cranks connecting directly to the

driven (usually front) wheel. The safety bicycle, as it is known today, came into
being when the pedals were attached to a crank driving a sprocket that transmitted
power to the driven wheel by means of a roller chain.

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

Fig.5.1.1 PEDAL

14
 CHAPTER 6
WORKING
6.1 PEDAL POWER HACKSAW

It consists of the pedal arrangement which rotates the crank and through it
slider consists of oscillating mechanism. The power is transmitted to the crank and
slider mechanism. This mechanism is used to rotate the crank disc; the disc which
is having an extended rod is connected to the sliding portion of the hacksaw
directly by means of a linkage. The hacksaw is passed through the guide ways by
means of maintaining the cutting axis. As the user operated the pedal, the hack saw
cuts the various materials automatically with less power. The dead weight is for
compressive force while the user operated the foot pedal.

Fig.6.1.1 PEDAL POWER HACKSAW MACHINE

15
6.2 PEDAL OPERATED POWER GENERATOR

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 and torque. Usually, a sort
of mechanical transmission system is needed to adapt these variables into the
generator’s required ones. Then, this mechanical power is turned into electric
power by the generator (Pout gen). Eventually, 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.

Fig.6.2.1 PEDAL OPERATED POWER GENERATOR

16
 CHAPTER 7
CRANK AND SLIDER MECHANISM
This mechanism is used to convert the rotary motion of the crank into the
reciprocating motion of hacksaw. The lengths of the crank and connecting rods are
made using trial and error method.

The hack saw is guided by an aluminum plate. The vertical movement of the
hacksaw will be guided by to iron rods. The vertical movement will act as a
feeding unit.

Fig.7.1 SLIDER CRANK MECHANISM

17
 CHAPTER 8
POWER LEVELS
The power levels that a human being can produce through pedaling depend
on how strong the peddler is and on how long he or she to pedal. If the task to be
powered will continue for hours at a time, 75 watts mechanical power is generally
considered the limit for large, healthy no-athlete. A healthy athletic person of the
same build might produce up to twice this amount. A person who is smaller and
less well nourished, but not till, would produce less; the estimate for such a person
should probably be 50 watt for the same kind of power production over an
extended period. The graph in figure 3 showed various record limits for pedaling
under optimum condition. The meaning of these curves is that any point on a curve
indicated the maximum time that the appropriate class of person could maintain the
given average power level.

Human Power Output Pedaling Power levels are also directly related to the
environment of the person doing the pedaling. To be able to continue pedaling over
an extended period, a person must be able to keep cool whether because the
ambient temperature is low enough or because there is adequate breeze.

18
8.1 RECIPROCATING POWER HACKSAW

It uses a blade that moves back and forth across the work. The blade cuts on
the backstroke. There are several types of feeds available.

Positive feed produces an exact depth of cut on each stroke. The pressure on
the blade varies with the number of teeth in contact with the work.

Definite pressure feed-yields a pressure on the blade that is uniform

regardless of the number of teeth in contact with the work. The depth of the cut
varies with the number of teeth contacting the work. This condition prevails with
gravity feed.

Feed can be adjusted to meet varying conditions. For best performance, the
blade and feed must be selected to permit high-speed cutting and heavy feed
pressure with minimum blade bending and breakage.

Standard reciprocating metal cutting saws are available in sizes from 6~ ~

6~ (150 mm ~ 150 mm) to 24~ ~ 24~ (900 mm ~ 900 mm). The saws can be fitted
with many accessories, including quick-acting vises, power stock feed, power
clamping of work, and automatic cycling of the cutting operation. The latter moves
the work out the required distance, clamps it, and makes the cut automatically. The
cycle is repeated upon completion of the cut. High-speed cutting requires use of a
coolant. Coolant reduces friction, increases blade life, and prevents chip-clogged
teeth. Cast iron and some brass alloys, unlike most materials, do not require
coolant.

19
 CHAPTER 9
DESIGN CONSIDERATIONS
When designing our attachment, the following considerations were taken
into account

1. The device should be suitable for local manufacturing capabilities.

2. The attachment should employ low-cost materials and manufacturing
methods.
3. It should be accessible and affordable by low-income groups, and should
fulfill their basic need for mechanical power
4. It should be simple to manufacture, operate, maintain and repair.
5. It should be as multi-purpose as possible, providing power for various
agricultural implements and for small machines used in rural industry.
6. It should employ locally available materials and skills. Standard steel pieces
such as steel plates, iron rods, angle iron, and flat stock that are locally
available should be used. Standard tools used in machine shop such as hack
saw, files, punches, taps & dies; medium duty welder; drill press; small lathe
and milling machine should be adequate to fabricate the parts needed for the
dual-purpose bicycle.
7. It should make use of standard bicycle parts wherever possible.
8. The device should adapt easily to as many different bicycles as possible. No
permanent structural modification should be made to the bicycle.
9. Though the device should be easy to take off the bicycle, it is assumed that it
would usually remain attached to facilitate readiness and ease of transport
from site to site. The device, therefore, should not interfere with the
bicycle's transportation mode.

20
10. The broad stand, which provides stability during power production mode,
can be flipped upward during the transport mode. This stand/carrier would
be a permanent fixture of the dual- purpose bicycle.
11. Care must be exercised to insure that the power take-off assembly is far
enough forward so as not to interfere with pedaling. Most standard adult
bicycle frames have plenty of room for the power take-off mechanism and
pulley. Power is supplied to the shaft by means of a chain from the bike's
chain wheel (crank) to a ratcheted sprocket on the shaft. During the prime-
mover mode, the bike's regular chain is slipped off of the chain-wheel, and
the specially sized chain to the power take-off mechanism is slipped on.
12. The device should be able to transmit power to a variety of machines, and
changing drive ratios should be as simple as possible. We decided that a V-
belt and pulley arrangement would be most appropriate for this. Belts do not
require the precise alignment that chains do. Belts can even accommodate
pulleys that are slightly skewed with respect to each other. Changing drive
ratios is as easy as changing pulleys. Also, belts are reasonably efficient.
13. The device should contain a ratcheting mechanism that would let the
operator "coast” periodically to rest and conserve energy. A free wheel from
any bicycle can be easily adapted for this purpose.
14. Excessive weight should be avoided, as durability is a prime consideration

21
 CHAPTER 10
FRAME DESIGN
10.1 FRAME MATERIAL CHOOSING

One of the key elements of the design process of objects under cyclical
changing loading is the knowledge of service load history. It is especially
important in the case of the bike exerciser in which components are under threat of
fatigue damage formation because of the diversified influence of many factors of
deterministic and random nature. Bike frames encounter a complex set of stresses
which in most cases cannot be calculated by hand. Therefore, in designing a frame,
engineers usually makes use of an older design which has proven reliable as a
starting point. The frame of the POPG was designed to replicate a typical Schwinn
DX bike exerciser with little modifications on the materials used in order to
minimize cost and also considering availability of materials. The materials used for
exercise bike frames have a wide range of mechanical properties. For most bike
builders, steel is the material of choice; steel bikes impart a certain level of
confidence in the ability of the bike. It provides the ideal combination of
performance and purchase cost. They can be inexpensively repaired and have the
ability to reveal frame stress injuries before they become failures. When a steel
frame breaks, it tends to break slowly rather than suddenly and they have the
ability to store and release energy at different degrees of the pedal strokes. The
table below shows a breakdown of all the component part of the pedal system and
the materials used.

22
 CHAPTER 11
SPECIFICATION
 Driver sprocket teeth =44

 Driven gear teeth=18

 Bore diameter (d)=25mm

 Outer diameter (d)=52mm

 Frame length (L) =900 mm

 Max allowable working stress = 63Mpa

 Maximum shear stress = 42Mpa

 Voltage (V)=20V

 Current (A)=3A

 speed (N)= 875rpm

 Overall efficiency =66.6%

23
 CHAPTER 12
FORMULAS
 Power (W) = voltage × current
 Energy = current × time
 Power (P) = (T1-T2) V

T1  Tension on the tight side

T2  Tension on the slack side

V  Velocity of the belt

 Length of the belt (L) = (D+d)+2C+

 Belt center distance (C) = 2× √ 𝐷 − 𝑑 × 𝑑

L  length of the belt

D  diameter of big pulley

d  diameter of small pulley

C center to center distance

 System force torque and power input

Input force =

Input torque = force × 𝑑𝑖𝑠𝑡𝑎𝑛𝑐𝑒

Input power =

 Pedal mechanical efficiency

Power output =T × 2 𝜋𝑟 × N

Power output is equivalent to 2.1 Kcal/min

Expand power in the pedal system =P out –Pin

Efficiency = Pout/Pin
24
 CHAPER 13
ADVANTAGES

 Human energy source.

 Time saving as compared to simple hacksaw
 Power saving as it is manually operated
 Easy machinery used
 As it is pedal operated so good for health
 Comfortable then ordinary hacksaw
 It could be used wherever metal cutting is done in small scales, including at
 Construction sites and furniture units, or to cut metal for window panes.
 No dependency on sun or wind.
 Can generate electricity anytime and anywhere.
 Pollution free power generation.
 Simple construction and easy maintenance.
 No fuel transportation problem

25
 CHAPTER 14
COST ESTIMATION
1. MATERIAL COST

Material cost = 1500

2. LABOUR COST

Welding, Cutting, Wiring = 700

3. OVERGHEAD CHARGES

The overhead charges are arrived by “manufacturing cost”

Manufacturing cost = material cost + labor cost

= 1500+700

= 2200

Overhead charges = 25% of the manufacturing cost

= 550

4. TOTAL COST

Total cost = material cost + labor cost +overhead charges

= 1500+700+550

= 2750

Total cost for this project = 2750

26
 CHAPTER 15
RESULT
15.1 FOR PVC PIPES

Performance of Pedal powered hacksaw for light duty cutting operations on

pvc pipes

S.NO R.P.M TIME(min) DEPTH OF

1 30
2 40
3 50
Table no.15.1.1
CUT(mm)
2 14
2 18
2 22

15.2 FOR WOOD BLOCK

Performance of Pedal powered hacksaw for light duty cutting operations on

wood block

S.NO R.P.M TIME(min) DEPTH OF

1 30
2 40
3 50
Table no.15.2.1
CUT(mm)
2 17
2 22
2 28

27
15.3 FOR GENERATOR SPEED AND VOLTAGE PRODUCED

RPM OF MOTOR VOLTAGE (V) CURRENT (A)

1000 9.1 0.58
1500 14.2 0.8
2500 17 1.2
3200 23.4 1.8
5000 32 2.2
Table no.15.3.1

28
 CHAPTER 16
CONCULSION
Thus a low cost and simple design pedal operated hacksaw machine is
fabricated. This machine reduces the human effort and hence we don’t need two
persons to cut the wooden logs. This simple design of conventional design which
can enhance day today household needs and daily day to day purposes and it can
be also used in for industrial applications during power shut down scenarios. By
using this method we can do any operation as per our requirement without the use
of electricity. so we can save the electrical power.

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 any time.

29
 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.Kurmi

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