RIZAL TECHNOLOGICAL UNIVERSITY

Eusebio, Pasig, Metro Manila

“DESIGN AND FABRICATION OF ENERGY SELF-SUFFICIENT BATTERY-

OPERATED GENERATOR SYSTEM”

A Student – Faculty Collaborative Research

Presented to the Faculty of Mechanical Engineering

Rizal Technological University

Pasig City

In Partial Fulfillment of the Requirements

for the Degree of Bachelor of Science in Mechanical Engineering

By:
Cantera, Cris Bryan E.
Fernandez, Arjayar B.
Estanislao, Marwin Jedzter O.
Labrador, James Gilbert L.
Magtibay, John Carlo E.
Martillano, Oliver C.
Osaan, Jonard H.
Quiao, Stephen Kurl D.

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 RIZAL TECHNOLOGICAL UNIVERSITY
Eusebio, Pasig, Metro Manila

DECEMBER 2022

CHAPTER I

THE PROBLEM AND ITS BACKGROUD

INTRODUCTION

Free energy machines do not operate effectively. No machine can

generate energy from nothing, as this would violate the fundamental and

universal law of mass-energy conservation. According to the law of mass-energy

conservation or also known as 2nd law of thermodynamics, mass-energy can

never be created or destroyed. It can only be redistributed across space and

transformed into different states.

There is no such thing as free and open energy. As it is only produced

with the assistance of a basic type of source. A self-sufficient battery operated

generator is a perpetual electrical device that is designed to run indefinitely and

produce a continuous electrical output that is typically greater in magnitude than

the input supply through which it is powered. There are numerous successful

methods for accomplishing this, which span many countries and many years.

The amount of power that can be collected is quite large, and the few kilowatts

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required to power a household are well within the capabilities of the majority of

the devices mentioned. Other energies derived from wind power, waterpower,

and solar power

are mechanical energy that drives windmills or solar energy in solar cells

that is converted into DC current. 

According to research, nearly 30% of Filipinos do not have access to

electricity or experience brownouts, particularly in rural or remote areas, which

are frequently at a disadvantage in terms of access to electricity. Due to the

overall high cost of providing this service in thinly populated, remote areas with

difficult terrain and low consumption, rural electricity schemes are typically more

expensive to implement than urban schemes.

In conclusion, building self-sufficient battery-operated generators will be

the primary source of energy in areas that cannot be reached by power lines

capable of distributing energy or electricity. It allows us to address the issue of

electricity scarcity while also lowering the cost of supplying electricity to a small

population.

BACKGROUND OF THE STUDY

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The Energy self-sufficient battery operated generator system is a system

designed to generate electricity from a main source or a battery, allowing the DC

motor to operate and provide the rotation that connects to the flywheel. The

flywheel serves as the main component in circulating the lead rotation towards

the

alternator, which converts mechanical energy into electrical energy, and

the electrical energy generated by the alternator is then connected back to the

battery.

The energy cycle continues to circulate within the system, increasing

efficiency and effectiveness. Self-sufficient battery-operated generators are an

important component in enabling remote areas to generate electricity as they

have the greatest disadvantage in terms of access to electricity. Self-sufficient

battery-operated generators play a key role in lowering the cost of providing

power in such places.

Some remote locations have a limited form of solar power that can only

create a limited quantity of energy; it is more expensive to develop solar power

with the same level of power output as a self-sufficient battery-operated

generator. According to previous research on self-sufficient battery-operated

generators, it can only create a little quantity of electricity inside a largely similar

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component. This research tends to give more efficient electrical energy, and like

previous studies, it can generate without the use of additional equipment, and it

is non-hazardous and environmentally friendly.

  In contrast to the Self-Sufficient battery-operated generator, which

combines a battery with a DC motor for a more powerful and efficient output than

conventional generators that only employ AC motors and can only produce a

certain amount of energy. The researchers consult the localities and the persons

concerned when performing this sort of study.

CONCEPTUAL FRAMEWORK

PROCESS
INPUT OUTPUT
Hydropower to
Construction of Power Usage
Electrical power
Power Generating
Hydro-Gear system → Hydropower extracts → The accumulated
kinetic energy from the energy produced by
Materials:
flowing water. the system will charge
→Double helical batteries.
plastic gears, PVC → The energy
pipes, Single Phase transforms into
→The stored power in
Synchronous mechanical energy as
Generator, Water filter 5 rotates
flowing water
the batteries will
double helical gears. become main source
→Software: SketchUp to power the whole
Pro → The gears will then operation.
 RIZAL TECHNOLOGICAL UNIVERSITY
Eusebio, Pasig, Metro Manila

 The first step is INPUT, during this stage, the main plan for the prototype is

established. Constructed in accordance with their specifications in order to

supply the materials needed to carry out the design plan. Hydro-gear, PVC

Pipes, a Single-Phase Synchronous Generator, and water filters are some of the

most important materials required. The use of SketchUp pro software is notably

necessary for the design and construction.

The second stage is the PROCESS; at this point, the design plan or prototype is

already planned and under construction, showing that all materials for this

prototype have been finalized and it is now ready for construction.

Finally, the OUTPUT of this prototype construction has been accomplished at

this stage. This has been tried and evaluated in order to determine the product's

importance, cost, and durability, as well as the accuracy of its output.

STATEMENT OF THE PROBLEM

This study will investigate and analyze how efficient a self-sufficient

battery-operated generator is in remote areas of Barangay Calawis, Antipolo

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City. The researchers tend to build a self-sufficient battery-operated generator

that can help to answer the following questions:

1. How much power can the self-sufficient battery-operated generator

generate?

2. How is this self-sufficient battery-operated generator more efficient

compared to past studies with the same useful output?

3. How many appliances this self-sufficient battery-operated generator can

supply?

4. Do the communities obtain long-term energy access and most

significantly, sustainable energy that can benefit their socioeconomic

needs?

HYPOTHESIS:

1. The self-sufficient battery-powered generator can provide enough power

for remote household areas.

2. The self-sufficient battery-operated generator is more efficient and

effective compared to the past studies with the same useful output.

3. This self-sufficient battery can power appliances simultaneously.

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The system did not encounter major difficulties or malfunctions while

performing its maximum capacity.

OBJECTIVES OF THE STUDY

General Objective:

The study’s general objective is to design and fabricate a battery powered

generator that will generate electricity.

Specific Objectives:

1. To allow isolated places to have access to electricity. 

2. To improve the performance of remote areas electricity distribution. 

SIGNIFICANCE OF THE STUDY

The application of this technology on a broad scale can effectively remove the

use of fuel and end pollution; yet appliances and tiny tools can run successfully in this

small scale design. The researchers tend to develop a system that can provide electricity

single or multi-phase for isolated communities using Self power generators. This study is

therefore beneficial to the following:

For Communities, since they are the ones who would directly use the

machine to gain access to electricity to power devices in remote locations

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For Local Government units, this will serve as their project for them to

improve the lives of their residents living in their vicinity who are having

adversities connecting to the power line.

For Environment, through this study another contribution to sustainability of

the environment since the study focuses on making self-power generators without the

use of fuel that will contribute to lessen the pollution.

For researchers, as they will learn more about the field of mechanical

engineering and will provide them an opportunity to gain knowledge about the

significance of new designs and the study's variables.

For future researchers, the outcome of the research and the novel

prototype will provide important data that might serve as a source of inspiration

for their future research efforts in this field.

SCOPE AND DELIMITATIONS OF THE STUDY:

This study will focus only on Brgy. Calawis Antipolo City which will help to

assess the adversity of electricity in remote areas in the community. Also, this

study intends to make a significant contribution to electricity distribution. 

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Eusebio, Pasig, Metro Manila

The

private consumers that are interested in the self-powered generator have been

excluded from this study.  This study will also exclude any interested companies.

every aspect of unforeseen scenarios that might occur when carrying out this

research.

DEFINITION OF TERMS:

Direct current (DC) motor - is a type of rotary electrical motor that converts

direct current electrical energy into mechanical energy.

Alternating current (AC) motor - is a motor that converts alternating current

into mechanical power through the use of electromagnetic induction.

Shaft - is a rotating machine element, usually circular in cross section, that is

used to transmit power from one part to another, or from a power-producing

machine to a power-absorbing machine.

Pulley - is a wheel on an axle or shaft that is designed to support movement and

direction change of a taut cable or belt, as well as power transfer between the

shaft and the cable or belt.

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Belt - is a flexible material loop used to mechanically connect two or more

rotating shafts, most often parallel. Belts can be used as a source of motion, to

efficiently transmit power, or to track relative movement.

Alternator - is a type of electrical generator that converts mechanical energy to

electrical energy in the form of alternating current.

Switch - is an electrical component that can disconnect or connect the

conducting path in an electrical circuit, interrupting or diverting the electric current

from one conductor to another.

Flywheel - is a mechanical device that uses angular momentum conservation to

store rotational energy, which is proportional to the product of its moment of

inertia and the square of its rotational speed.

Power lines - a power transmission cable, especially one supported by pylons or

poles

Dry-cell battery - is a battery composed of one or more electrochemical cells

that convert stored chemical energy into electrical energy.

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CHAPTER II

REVIEW OF RELATED LITERATURE AND STUDIES

     This chapter provides an overview of the existing literature and studies related

to the topic of this thesis. It reviews the relevant literature and studies that have

been conducted in the past, as well as any current research or studies related to

the topic. Additionally, this chapter offers a critical assessment of the strengths

and weaknesses of the literature and studies reviewed and identifies potential

gaps in the existing literature.

Comparison between DC motor and AC Motors

Definition of Dc motor

            According to Thomas (2009), basically a DC motor transforms electrical

energy from DC sources into mechanical energy. A DC motor generates torque

directly from the DC power source through internal communication, stationary

permanent magnets, and rotating electrical magnets. A direct current (DC) motor

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electric motor that uses DC power to operate. In addition to many other industrial

and consumer devices, DC motors are frequently employed in applications such

as electric vehicles, elevators, and conveyor belts. DC motors come in a variety

of sizes and types, are reasonably cheap and simple, and are available. DC

motors can transform DC power directly into mechanical motion in contrast to AC

motors, which need a complicated system of gears and other parts to do so. As a

result, they are excellent choices for applications where accurate motor speed

and torque control is crucial.

Types of DC Motor

The properties of brushless direct current (BLDC) motors make them widely

employed. According to Oscar-David C. and Felipe R. (2020) These qualities

include a high dynamic responsiveness and a high power density. These types of

motors are typically managed by a three-phase electronic inverter of

commutation. Sreeram used fuzzy logic and a four-switch three-phase inverter to

construct a sensor less BLDC motor's speed regulation control. Usually, a six-

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step commutation and a three-phase voltage source inverter are used to drive

these types of motors, and the condition of the Hall effect sensors governs how

the inverter's components commute. https://www.mdpi.com/2297-8747/25/3/57

How DC Motor works

              According to new research, when it comes to variable-speed

applications, DC electric motors are difficult to surpass because of their special

performance characteristics and ease of control. Even though AC motors and

controls have lately advanced to the point where they can compete with many of

its advantages, DC electric motors continue to be widely used in many industries,

especially when a small, efficient, and highly responsive motor is needed.

https://www.emotorsdirect.ca/knowledge-center/article/how-does-a-dc-motor-

work

 Definition of Ac motor

        Alternating Current is defined by James (2020), as an electric current that

periodically reverses its direction, in contrast to direct current (DC) which only

flows in a single direction which cannot change sporadically.

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    A

ccording to IQS Directory (2022), an AC motor or alternating current motor is an

electric motor that consists of a stator with a coil that is supplied with alternating

current to convert electric current into mechanical power. The stator is the

stationary part of the motor while the rotor is the rotating part. AC motors can be

single or three phase with three phase motors mainly used for bulk power

conversion. Single phase AC motors are used for small power conversions. 

 Types of AC Motor

          According to Shepard (2020), the two main types of AC motors are

induction motors and synchronous motors. The induction motor (or asynchronous

motor) always relies on a small difference in speed between the stator rotating

magnetic field. The rotor shaft speed is called slip to induce rotor current in the

rotor AC winding. As a result, the induction motor cannot produce torque at

nearly synchronous speed where induction (or slip) is not available. In contrast,

the synchronous motor does not rely on slip-induction for operation. It uses

permanent magnets, projecting magnetic poles (usually made with steel

laminations and called salient poles), or an independently excited rotor winding.

The synchronous motor produces its rated torque at exactly synchronous speed.

How AC Motor works

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   I n

an AC motor, there's a ring of electromagnets arranged around the outside

(making up the stator), which are designed to produce a rotating magnetic field.

Inside the stator, there's a solid metal axle, a loop of wire, a coil, a squirrel cage

made of metal bars and interconnections (like the rotating cages people

sometimes get to amuse pet mice), or some other freely rotating metal part that

can conduct electricity. Unlike in a DC motor, where you send power to the inner

rotor, in an AC motor you send power to the outer coils that make up the stator.

The coils are energized in pairs, in sequence, producing a magnetic field that

rotates around the outside of the motor. (Woodford, 2021).

https://www.power-and-beyond.com/what-is-alternating-current-a-907931/

https://www.iqsdirectory.com/articles/electric-motor/ac-motor.html

https://www.powerelectronictips.com/basics-ac-motors-and-their-applications-faq/

https://www.explainthatstuff.com/induction-motors.html

Comparison of DC motors and AC motors

Flywheel mechanism     

             Flywheel mechanism is defined by  The Editors of Encyclopedia

Britannica (2022), as a heavy wheel attached to a rotating shaft so as to smooth

out delivery of power from a motor to a machine. The inertia of the flywheel

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opposes and moderates fluctuations in the speed of the engine and stores the

excess energy for intermittent use.

          According to Thomas (2019), The Flywheel Energy Storage is made up of

a heavy rotating part, the flywheel, with an electric motor/generator. The inbuilt

motor uses electrical power to turn at high speeds to set the flywheel turning at

its operating speed. This results in the storage of kinetic energy. When energy is

required, the motor functions as a generator, because the flywheel transfers

rotational energy to it. This is converted back into electrical energy, thus

completing the cycle. As the flywheel spins faster, it experiences greater force

and thus stores more energy. Flywheels are thus showing immense promise in

the field of energy storage systems designed to replace the typical lead-acid

batteries.

           Flywheel Energy Storage uses kinetic energy as a form of storage. This

technology has many advantages such as its high efficiencies ranging from 90%

to 95%, its long-life cycles and long lifetime (15–20 years). Issues associated

with this storage technology include the high capital cost of $1000–$5000/kWh

and the high self-discharge rates that can go from 50% up to 100%. Therefore,

flywheel storage can be used especially for large storage capacities. In addition,

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because of its high self-discharge rates, this technology can be seen as effective

only when storing energy for short periods of time. It is also used to regulate

current fluctuations in power output from RE sources. (Berrada PhD et. al 2019).

           A disk, an electrical device, a large capacitor, source converters, and

control mechanisms make up the flywheel. Over time, the flywheel—the primary

technological component—has supported the efficient operation of machinery.

Flywheels are typically made of steel but using composite materials has recently

been promoted. Their rotational stress restrictions are the major difference

between steel and composite materials. Compared to those made of steel,

composite flywheels are built to support higher speeds and rotational stress

thresholds. As a result, it is advised that steel be used for low-speed flywheels

and composite materials for high-speed flywheels. The biggest issue with

composite materials, however, is their high price. (Abdul Ghani (A.G.) Olabi.

2021)

https://www.britannica.com/technology/flywheel

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https://www.azom.com/article.aspx?ArticleID=17336

https://www.sciencedirect.com/topics/engineering/flywheel-energy-storage

12v Dry cell rechargeable battery

The battery stores electrical energy through a reversible chemical

process. It is rated based on how much storage it has. each amp-hour. One amp

is the same as taking one amp nonstop for an hour. The system may use a

standard 12V battery with a capacity of 800 amp-hours. It makes reference to the

100 amp rating of the battery. if completely drained after being fully charged for 8

hours. However, a battery's life is significantly reduced when it is drained. The

majority of batteries only drain to 50% or more of their full capacity before being

recharged due to their 50% drain depth. 

According to Egwaile, J.O. and Oyedoh, M. O(2019) Deep Cycle Batteries are

used in renewable energy systems that require the storage of electricity. Many

challenges remain unsolved to characterize and manage the battery

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For its energy needs, the modern world is heavily dependent on fossil fuels

including coal, gas, and oil. The society is plagued by environmental issues and

its finite resources, yet the only realistic solution to these issues is the

sustainable use of energy. Thus, Energy conversion and storage are essential

steps for improving overall energy efficiency.  process of generation and use.

The most popular kind of energy storage is the battery.

The fact that they may be recharged for a very low cost and used repeatedly

makes up for their higher initial cost in the long run. Both applications with high

drain and those with low drain use rechargeable batteries. Portable consumer

electronics, auto starters, light vehicles including motorized wheelchairs, golf

carts, electric bicycles, and electric forklifts, as well as tools and uninterruptible

power sources are all used for them. The sizes and shapes of rechargeable

batteries range from a button cell to megawatt systems. Nickel Cadmium (NiCd),

Lead Acid, Lithium Ion (Li-ion), Nickel Metal Hydride (NiMH), Silver Zinc (Ag-Zn),

and Lithium Polymer (Li-Pol) batteries are a few of the more popular chemistries. 

(https://nipesjournals.org.ng/wp-content/uploads/

2019/03/2019_2_002_NJETE.pdf)
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belt

Definition of V belt

            Based on the study conducted by Zülküf B, Mesut K. and Omer E. (2022)

that V-belts, a crucial component of the automobile industry, are utilized as a

safety measure to safeguard the machine and limit speed. Gears or (chain)

gears, which are likewise used to reduce speed, cannot be employed to give this

insurance condition. Consequently, it occupies a significant position in the

automobile industry. https://dergipark.org.tr/en/pub/ejosat/issue/68221/977740

How does Mechanical  V Belts work?

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an ic

al V-belts, also known as V-ribbed belts, are a type of drive belt used in a variety

of power transmission applications, according to Leiseca (2020). V-belts are

made of high-strength synthetic rubber compounds that are reinforced with one

or more layers of fiber reinforcement and have a trapezoidal cross-section. The

V-trapezoidal belt's shape concentrates the belt's force onto the sides of the

pulleys, allowing for efficient power transmission. The V-belt also keeps the belt

in place on the pulley, which helps to prevent slippage and reduces belt wear.

The tension of the V-belt can also be adjusted, giving you precise control over

power transmission and the speed of the driven pulley.

https://www.thomasnet.com/articles/mechanical-components/v-belts/

The Difference of self powered energy and solar power energy (parang ganon) 

       The article "Renewable Energy vs. Solar Power" compares the two (n.d.).

Self-powered energy sources, such as wind turbines, hydroelectric dams, and

geothermal plants, generate electricity directly from natural sources, according to

the article. These sources can be used to generate electricity on both a large and

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small, localized scale. Solar energy sources use photovoltaic cells to convert

sunlight into electricity. Solar power is a small-scale method of generating

electricity that can be used to power individual homes or businesses. The

primary distinction between the two is that self-powered energy sources produce

electricity directly from natural sources, whereas solar power is produced through

a conversion process.

https://www.renewableenergyworld.com/solar-energy/tech/renewable-energy-vs-

solar-power

SERIES  AND PARALLEL CONNECTION

    A series/parallel connection, according to Ahamed (2019), is an electrical

circuit in which components are connected in both series and parallel.

Components connected in series share the same current, while components

connected in parallel share the same voltage in this type of circuit. The

advantage of this type of circuit is that it allows you to change the configuration of

the components connected in series and/or parallel to adjust the total resistance

of the circuit. This type of connection is commonly used in amplifiers, LED

lighting, and other devices that require precise voltage and current control.

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Ahamed, Imran. “Series and Parallel Connections.” Electronics Post, 27 Dec.

2019

Synthesis 

     The comparison between DC motors and AC motors, flywheel mechanism,

12V dry cell rechargeable batteries, V-belts and the differences between self-

powered energy and solar power energy are all related to the use of energy

storage and conversion systems. DC motors and AC motors are two types of

electric motors that are used to convert electrical energy into mechanical energy.

DC motors are more efficient and accurate in terms of speed and torque control,

while AC motors are more reliable and require less maintenance. Flywheel

Energy Storage systems are used to store energy and regulate current

fluctuations in power output from renewable energy sources. Deep cycle

batteries are used in renewable energy systems to store electricity, while V-belts

are used as a safety measure to limit speed. Finally, self-powered energy

sources produce electricity without the use of natural sources, while solar power

is produced through a conversion process. All these sources and components

are necessary for the effective use of energy storage and conversion systems.

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CHAPTER III

RESEARCH METHODOLOGY

This chapter explains the techniques that were used by the researchers to gather

the information and data necessary to support their findings. In this chapter, the

research design is also discussed, along with a step-by-step procedure for

improving the reliability of the research. The techniques for gathering data as well

as specific tools used to accomplish the goals mentioned in the previous

chapters are covered in this chapter.

RESEARCH METHOD

This process describes the methodology that the progressive study design

and observation technique were employed by the researchers as their research

approach. The organizational research methodology was utilized to assist

improve an already existing system that supplies power in remote areas. The

formative research design will make an effort to fulfill all of the objectives

established by the researchers in this study. The researchers will see if the

"Design and Fabrication of Energy Self-Sufficient Battery-Operated Generator

System" have the same efficiency as the ones that are presently on the market.

PLANNING 

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this chapter that must be properly followed in order to get the desired findings

when the studies objectives and method are accomplished. By doing this, the

researchers showed the project design. The first is to describe the variables and

measures required in familiarizing with and constructing the basis of the current

investigation. This design serves as the representative of the entire output of the

study. In order to obtain the correct input and provide the relevant results

required for the research study, the data to be collected must be familiarized with

and thoroughly studied. To ensure that there are no technical issues during the

testing of the trials, the construction of this design must comply with the proper

parameters.

GATHERING OF DATA 

Following testing of the prototype, the proponents gathered the relevant data with

the appropriate tools in order to produce the desired result.

DATA PREPARATION 

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The prototype's supporters carefully examined each component and put it to the

test in numerous scenarios to see whether it functioned or not. This stage

ensured the project's caliber and the contributors' skill. 

DATA ANALYSIS 

The proponents computed the output using a variety of formulas (including

theoretical ones) after gathering the requisite data. To demonstrate if the

prototype complied with the specification, the proponents used the output.

PROJECT DESIGN

           GENERAL DESCRIPTION – INCLUDE FIGURES The general

description of this project design is a useful system to power the household in

remote areas in Brgy. Calawis Antipolo Rizal

           DETAILED DESCRIPTION – INCLUDE FIGURES The detailed

description of the energy self-sufficient battery operated generator system is to

generate electricity with the use of the battery, DC motor, drive and driven pulley,

flywheel, AC generator and DC alternator.

           

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WORKING DESCRIPTION - 

The working description of the energy self-sufficient battery  operated generator

system is it will start on a two batteries that are connected to parallel to each

other and two batteries that are connected to series, a total of 4 batteries  to start

up the DC motor which have a built-in drive pulley that is link by a V-belt to a

driven pulley that is connected to a shaft with a flywheel that serves as a load to

prepare the double driven pulley that is also in the shaft to start up the generators

with the use of the built-in drive pulley of the generator and V-belt that links the

drive and driven pulleys, the DC alternator which is the one that charge the

battery and the AC alternator that converts rotary mechanical energy into

electrical energy in the form of alternating current. This electricity is used to

power households in remote areas. 

MATERIALS AND SPECIFICATION

The table below summarizes all the materials and specifications employed

throughout the project. Functions are also explained.

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Material Function Specifications Cost

4pcs 12V device consisting of one or 12v 7ah 4,480 PHP
Rechargeable Battery more electrochemical cells Rechargeable
that converts stored Sealed Lead
chemical energy into Acid Battery
electrical energy.

DC Motor A machine that transforms 2000 RPM 2,090 PHP

electrical energy to
mechanical energy.
Driving Pulley is linked to a mechanical
power source
Driven Pulley is linked to the shaft of a
spinning piece of
equipment, receiving
mechanical power from the
electric motor.
Shaft Spins and transfers power
from a driving device
Flywheels A mechanical device that
uses angular momentum
conservation to store
rotational energy..
V-Belts It transfers force from the
engine to the auxiliary
components such as the
alternator and the hydraulic
pump for power steering.

DC Alternator The alternator generates a 12V, 90 Amps PHP 1,045

direct current voltage to
charge the battery while it
revolves.

AC Generator A generator that transforms 10 kVa 10,080 php

rotating mechanical energy
into alternating current
electrical energy..

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