BGMEA University of Fashion and Technology

Faculty of Textile Engineering

Thesis No.

“Sustainable Power Generation for Textile Industry”

Submitted by:

Name: Kazi Nishat Mahmud

ID: 181-216-801
Name: Tanmoy Choudhury
ID: 181-240-801
Name: Mir Ishtiakul Haider
ID: 181-248-801

Supervisor:
Name: Ms. Taslima Ahmed Tamanna
Lecturer
Department of Textile Engineering (TE)
BGMEA University of Fashion & Technology

This Project Report submitted in partial fulfillment of the requirements for the degree of B.Sc. in
Textile Engineering in the Faculty of Textile Engineering of BGMEA University of Fashion and
Technology (BUFT).

21/04/2022
 Bachelor of Science Thesis (Thesis No……..)

“Sustainable Power Generation for Textile Industry”

By
Name: Kazi Nishat Mahmud
ID: 181-216-801
Name: Tanmoy Choudhury
ID: 181-240-801
Name: Mir Ishtiakul Haider
ID: 181-248-801
Bachelor of Science in Textile Engineering

Duration
30/09/2021 To 28/03/2022

Examination Committee:

Examiner 1(Supervisor): Ms. Taslima Ahmed Tamanna Signature:

Examiner 2: ……………………………………………. Signature:

Examiner 3: ……………………………………………. Signature:

Department of Textile Engineering (TE).

Date: 21/04/2022

ii
 DECLARATION OF ORIGINALITY

We hereby confirm that “Sustainable Power Generation for Textile Industry” submitted by us
and it is our own research work. We are the authors of the written work here enclosed and
that We have compiled it in my own words. Parts excepted are corrections of form and
content by the Supervisor. With our signature We confirm that

- We have committed none of the forms of plagiarism described in the “Citation etiquette”
information sheet.
- We have documented all methods, data, and processes truthfully.
- We have not manipulated any data.
- We have mentioned all persons who were significant facilitators of the work.
- We are aware that the work may be screened electronically for plagiarism.

Name: Kazi Nishat Mahmud

ID: 181-216-801
Signature:
Date:

Name: Tanmoy Choudhury

ID: 181-240-801
Signature:
Date:

Name: Mir Ishtiakul Haider

ID: 181-248-801
Signature:
Date:

iii
 CERTIFICATE

This is to certify that this thesis work entitled “Sustainable Power Generation for Textile
Industry” submitted by Mr. Kazi Nishat Mahmud (181-216-801), Mr. Tanmoy Choudhury
(181-240-801), Mr. Mir Ishtiakul Haider (181-248-801) is an authentic thesis work carried
out under my supervision and guidance and for the purpose of fulfilling the standard
requirement for the partial fulfilment of the degree of Bachelor of Science in Textile
Engineering. The work embodied in this thesis has not been submitted elsewhere for a
degree.

Ms. Taslima Ahmed Tamanna

Lecturer Department of Textile Engineering

BGMEA University of Fashion & Technology (BUFT)

iv
 ABSTRACT
The goal of this research is to look into and design a sustainable free energy generator that
uses a dynamo and a flywheel configuration. This paper suggests a method for producing
energy that is referred to as "free" since it requires us to pay nothing if certain conditions are
met. The wasted energy in a dynamo is used to generate free energy due to friction. This
power will be used to power other electrical devices. It comprises a single-phase motor that
drives the pulley drive and belt mechanical setup. As a result, the wheel is mounted on a shaft
that rotates. This design has a unique mechanism that allows for more significant electrical
power to be generated. A flywheel is used to do this. In this research work we have worked
on a prototype model of the project and generated 4500watt successfully. With this versatile
output we have tested some heavy load like DN8112 grinding motor. But faced some barriers
about power recycling and looping. The system will run without any fuel and serves as both a
motor and an alternator. As a result of the advantages, it will be an energy-efficient system.
The results of design testing suggest that this vitality option is quite expensive and need more
experiments with proper instruments.

Key Words: Sustainable Energy, Energy Efficient System, Generator, Free Energy, Eco-
friendly Power Generation System etc

v
 ACKNOWLEDGEMENTS

We would like to extend thanks to Honorable Founder Chairman, Board of Trustees Mr.
Muzaffar U. Siddique, BUFT, for not only his tremendous academic support, but also for
giving us so many wonderful opportunities and logistic support to do this project.

Special thank goes to our enthusiastic Prof. Dr. S.M. Mahfuzur Rahman, Vice Chancellor,
BUFT and Prof. Dr. Engr. Ayub Nabi Khan, Pro-Vice Chancellor, BUFT, who so generously
inspired & contributed to do this type of project work.

Special thanks go to our enthusiastic supervisor, Ms. Taslima Ahmed Tamanna, Lecturer of
TE, has been an amazing experience and we thank her wholeheartedly, not only for her
tremendous academic support, but also for giving us so many wonderful opportunities.

Finally, profound gratitude goes to Ms. Farhana Afroz, Asst. Professor & Head, Dept. of
TE, BUFT, who has been a truly dedicated mentor.

vi
 Contents
Chapter 01.............................................................................................................................................1

Introduction...........................................................................................................................................1

1.1 Introduction.....................................................................................................................................1

1.2 Objectives of the project:.................................................................................................................4

CHAPTER 2..........................................................................................................................................5

Theoretical Background........................................................................................................................5

2.1 Literature review.............................................................................................................................5

Chapter 3...............................................................................................................................................6

Methodology.........................................................................................................................................6

3.1 Working principle............................................................................................................................6

Chapter 3...............................................................................................................................................8

Materials and Machinery used...............................................................................................................8

3.1 Central circuit diagram....................................................................................................................8

3.2 Alternator.........................................................................................................................................8

3.2.1 working principle of alternator.................................................................................................8

3.2.2 Specification of the used alternator for this project...................................................................9
3.3 Motor:............................................................................................................................................10

3.3.1 Specification of the used alternator for this project.................................................................10

3.4 Flywheel........................................................................................................................................11

3.4.1 Types of the flywheel.............................................................................................................12

3.5 Bearing..........................................................................................................................................13

3.5.1 Types of bearing.....................................................................................................................13

3.5.2 Specification of the used Bearing for this project...................................................................14
3.6 Belt drive.......................................................................................................................................14

3.7 U- Channel bar..............................................................................................................................15

3.8 Relay:............................................................................................................................................16

3.9 Post Processing Unit:.....................................................................................................................16

Chapter 4.............................................................................................................................................18

vii
Experimental Result............................................................................................................................18

4.1 Power Generation..........................................................................................................................18

4.2 Power Distribution.........................................................................................................................18

4.3 Power Re-Use................................................................................................................................19

Chapter 5.............................................................................................................................................19

Findings & Innovative ideas................................................................................................................19

5.1 Barriers..........................................................................................................................................19

5.2 Future Initiates...............................................................................................................................19

Chapter 6.............................................................................................................................................22

Calculation..........................................................................................................................................22

References...........................................................................................................................................22

viii
 List of Tables

Table Number Page

Table 3.2.2: Specifications of the dynamo 10

Table 3.3.1: Specifications of the dynamo 11

Table 4.1: Output of Dynamo 18

List of Figures

Figure Number Page

Figure 2.1: Basic principle of the project 7

Figure 3.1: Central circuit diagram 8

Figure 3.2.2: 3KW dynamo used in the project 10

Figure 3.3.1: 2 HP motor used in the project 11

Figure 3.4.1 Flywheel / Gravity Wheel 13

Figure 3.5.2: UC209 ball bearing 14

Figure 3.6: Belt drive model 15

Figure 3.7: U-Channel bar 15

Figure 3.9a: Circuit diagram of the post-processing unit 17

Figure3.9b: Circuit diagram of the safety fuse 17

Figure 4.2: DN8112 Grinder motor 18

Figure 5.2.1: Thermal Sensor 20
Figure 5.2.2: Cooling fan 20
Figure 5.2.3: Arduino UNO programmer 21

ix
 ABBREVIATIONS

RMG - Ready-made garment

GDP - Gross Domestic Product

BGMEA -Bangladesh Garment Manufacturers and Exporters Association

VSD- Variable Speed Drive

HEM- High-Efficiency Motors

CNG- Compressed Natural Gas

LPG- Liquefied Petroleum Gas

PSMP- Power Sector Master Plan

INDC- Intended Nationally Determined Contribution

LED- Light Emitting Diode

AC- Alternating Current

DC- Direct Current

GND- Ground

VCC- Voltage Common Collector

EMF- Electromotive Force

VR- Voltage Regulator

RPM- Revolutions Per Minute

HVAC- Heating, Ventilation, and Air Conditioning

x
 Chapter 01

Introduction

1.1 Introduction

The textile and clothing industry

undoubtedly is
playing a significant role in the
development of the
economic growth of Bangladesh
by exporting textiles
and garments products to a
different region of the
world
The textile and clothing industry
undoubtedly is
playing a significant role in the
development of the
economic growth of Bangladesh
by exporting textiles
and garments products to a
different region of the
1
world
The textile and clothing industry
undoubtedly is
playing a significant role in the
development of the
economic growth of Bangladesh
by exporting textiles
and garments products to a
different region of the
world
Bangladesh's ready-made garments (RMG) sector has got a greater facet than any other sector
in terms of growth and foreign exchange earnings. It makes a significant contribution to the
national economy by creating generous employment opportunities and reducing poverty
through socio-economic development. Textiles, garments, and readymade garments (RMG)
exports accounted for 77% of Bangladesh's total exports in 2002. In 1972, the World Bank
estimated Bangladesh's gross domestic product (GDP) at US$6.29 billion and increased to
$368 billion by 2021, of which $46 billion came from exports, of which 82% were
readymade garments. Readymade garment (RMG) exports from Bangladesh increased by
28.02 percent to $19.900 billion in the first six months of fiscal 2021-22 compared to exports
of $15.545 billion in the same period of the previous fiscal, according to the provisional data
released by the Export Promotion Bureau. [1]

The textile sector is considered one of the highest energy users in the industrial sector of
Bangladesh. To generate this huge amount of energy we generally use fossil fuels, coal, gas,
etc. A little quantity comes from natural sources like the solar system, air turbine, etc. A
walk-through energy audit has been conducted at Garments in Bangladesh to identify the
energy-using equipment and energy consumption breakdown. Different energy-saving

2
strategies and emissions reduction has been estimated for the garment. It is also found that
about 137,003 kWh, 319,673 kWh and 502,343 kWh of energy and BDT 1,312,484, BDT
3,062,463 and BDT 4,812,442 of bill savings for 20%, 40% and 60% speed reduction by
using variable speed drive (VSD) respectively. By using high-efficiency motors (HEM),
about 28,311 kWh, 41,713 kWh, and 57,080 kWh of energy and BDT 271,242, BDT
399,574, and BDT 546,852 of the bill can be saved for motor loadings of 50%, 75%, and
100% respectively. [2]
Electricity is the major source of power for most of the country's economic activities.
Bangladesh's total installed electricity generation capacity (including captive power) was
15,351 megawatts (MW) as of January 2017 and 20,000 megawatts in 2018. The largest
energy consumers in Bangladesh are industries and the residential sector, followed by the
commercial and agricultural sectors. Problems in Bangladesh's electric power sector include
high system losses, delays in the completion of new plants, low plant efficiency, erratic
power supply, electricity theft, blackouts, and shortages of funds for power plant
maintenance. Overall, the country's generation plants have been unable to meet system
demand over the past decade. [3]
As of 2011, 79 natural gas wells were present in the 23 operational gas fields which produce
over 2,000 million cubic feet (57 million cubic meters) per day of gas. It is well short of over
2,500 million cu ft (71 million m3) per day that is demanded, a number which is growing by
around 7% each year. More than three-quarters of the nation's commercial energy demand is
being met by natural gas. This influential sector caters for around 40% of the power plant
feed-stock, 17% of industries, 15% captive power, 11% for domestic and household usage,
another 11% for fertilizers, 5% in Compressed natural gas (CNG) activities, and 1% for
commercial and agricultural uses.

CNG is substituting more than US$0.8 billion worth of foreign exchange annually and is also
used in most vehicles on the road. In addition to CNG, Liquefied Petroleum Gas (LPG) is
also demanded at around 0.1 million tons. The nation furthermore demands 3.5 million tons
of oil imports in addition to almost 2 million tons of diesel to feed oil-based power plants
being planned and built all around the country. The additional petroleum and coal imports are
disrupting the GDP by as much as 2% annually. The new purchases are affecting
improvement initiatives in other sectors causing reduced export earnings and curtailing
employment opportunities. This massive failure in the energy sector is mostly attributed to

3
prolonged negligence, inappropriate implementation, inefficiency, and lack of planning. To
make matters worse, natural gas reserves are expected to expire by 2020. The only coal mine
in the country is in the development stage, the reserve of which is also expected to dry up
anywhere from 75 to 80 years after the start of its operations. [3]

According to Bangladesh's Power Sector Master Plan 2016 (PSMP–2016), the country has
the potential to generate a combined 3.6 GW of electricity from renewable
energy sources. Another research has estimated that the potential from wind power alone
stands at 20 GW. [4]

Bangladesh has a 15 MW solar energy capacity through rural households and 1.9 MW wind
power in Kutubdia and Feni. [5]  The government of Bangladesh has approved the
construction by private developers of 19 on-grid solar parks, with would have a cumulative
generation capacity of 1070 MW. A solar power plant having a power generation capacity of
28 MW has recently started its operation in Teknaf of Cox's Bazar. Accounting for this, the
power generation capacity from renewable energy sources exceeds five percent of the
country's total demand. Technical Solartech Energy Ltd (TSEL) has installed this power plant
in Teknaf utilizing a total of 116 acres of land. Currently, the power plant is feeding 20MW
to the national grid. [6]

Bangladesh has planned to produce 10% of total power generation by 2020 from renewable
energy sources like wind, waste, and solar energy. The country plans to increase its
renewable energy share to 17% by 2041 under its Intended Nationally Determined
Contribution (INDC) commitment to reduce greenhouse gas emissions by 5% until 2030. [7]

BGMEA, the apparel exporters’ forum, has submitted a plan to the prime minister to set up
several small-scale area-based power plants in a bid to add 1000-megawatt (MW) more
electricity to the national grid for ensuring uninterrupted power supply to garments factories,
insiders in the industry have said.

Some 406MW of electricity is supplied by the government to the sector but the RMG
manufacturers have demanded 720MW. Still, there will be a 35 percent shortage of electricity
in the sector. However, as the electricity shortage is a national problem, the RMG units have
been dependent on ‘captive-power’, incurring BDT 20 billion additional costs. Worried about
the increased price of oil, “This situation has led to a 35 percent hike in production cost”. A
total of 20,010 million liters of diesel are needed in the industry per year. [8]

4
We also use gas generators to generate power but the natural reserve of gas is decreasing day
by day. In recent times, production of the textile sector shut down for some days due to the
shutdown of the Bibiana gas field. That causes a huge amount of loss to the industry. To get
rid of this problem we ran a project, with a target is to discover a new sustainable power
generation process.
The main worries of the world in recent decades have been energy and the environment.
Considering the absence of industry-friendly regulations, Bangladesh, a developing country,
has witnessed steady fiscal growth in recent years as a result of rising industrialization.
Despite limited energy output, the industrial index has been rising in recent years. The need
for energy is increasing every day as a result of rapid economic growth.
Demands for alternative energy sources as a response to depleting energy supplies have risen
as our top priority. As a result, interest in Free Energy/Electricity has grown in popularity.
The concept of "free energy" or "electricity" is a popular misconception. There isn't any such
thing as free energy. However, it is only free after the initial capital cost if we create it using
readily available resources such as the Sun, Wind, Tidal, and hydroelectric. [9]
The word "free-energy" refers to a way of obtaining energy from the surrounding
environment without the use of a fuel source. There are numerous successful strategies for
accomplishing this, which span many countries and decades. The amount of power that may
be collected is enormous, and the few kilowatts required to power a home are well within the
capabilities of most of the devices discussed.
The idea of free energy suppression is that corporate energy interests deliberately block
technology that could deliver energy at a low cost. All other untapped natural forces, such as
earth batteries, atmospheric electricity, tellurium current, and pressure system variations, are
widely documented in scientific literature.
Nikola Tesla once stated that everyone should have access to free energy sources. Electricity
exists in infinite numbers everywhere and can power the world's machinery without the use
of gas, coal, or oil.
The objective of this work is to use the principle of an energy recovery system to recover
energy from a flywheel and produce enough energy to run the project setup as well as enough
extra energy to run an external power supply.

1.2 Objectives of the project:

 To discover a new sustainable power generation system for the textile sector.

5
 To solve the electricity problem in the textile sector.
 To reduce the cost of power production in the textile sector.
 To reduce the use of fossil fuel and natural gas to produce power.
 To reduce CO2 emissions to the environment due to fossil fuel burning.

6
CHAPTER 2

Theoretical Background

2.1 Literature review

Renewable and non-renewable energy sources, as well as various types of magnets and
radioactive materials, have all been employed to generate energy. As a result, we'll go over
each category one by one. First and foremost, we will discuss efforts on renewable energy
sources.

The European Commission's proposal for a modified sustainable power source order, which
was released on 2 November 2016, includes updated maintainability models for bio-powers
used in transportation and biofluids, as well as strong and vaporous biomass, energizes used
for warmth and force, as well as updated ozone-depleting substance outflow bookkeeping
rules and default values, which were used in free energy production.

Saiful Islam and Md. Ziaur Rahman Khan has worked on A review of energy sector of
Bangladesh. A brief overview of current electricity generation status and energy scenarios in
Bangladesh has been presented in this paper. New policies have been drafted to cope with the
challenges in the energy sector. These policies are also briefly discussed in this paper. The
energy pricing issues are also touched. These policies will play a major role in ensuring
energy security and in turn sustainable development of the country. The paper contains very
valuable contents like Power Generation, Installed Capacity in Bangladesh, Maximum
Demand in Bangladesh, Power plants and types of power plants available in Bangladesh also
Energy policies and pricing subsidies information are represented in a very interesting
manner in this article. Previous and current pictures of power generation, electricity demand
and fuel mix has been highlighted. Energy polices and subsidies are briefly presented
highlighting the future plans of the Government of Bangladesh. Bangladesh has attained
development with a relatively low per capita energy consumption compared to many other
countries. Further Energy availability will be very important for attaining Millennium
Development Goals (MDGs). [10]

A S M Monjurul Hasan, Mohammad Rokonuzzaman, Rashedul Amin Tuhin, Shah Md.

Salimullah, Mahfuz Ullah, Taiyeb Hasan Sakib and Patrik Thollander has worked on energy
situation and barriers named Drivers and Barriers to Industrial Energy Efficiency in Textile

7
Industries of Bangladesh. A pertinent contribution in the energy management at the industrial
sector ensures the proper utilization of energy. Energy management and its efficiency in the
textile industries of Bangladesh are studied in this paper. The outcomes demonstrate several
barriers to energy management practices which are inadequate technical cost-effective
measures, inadequate capital expenditure, and poor research and development. However, this
study also demonstrates that the risk of high energy prices in the future, assistance from
energy professionals, and an energy management scheme constitute the important drivers for
the implementation of energy efficiency measures in the studied textile mills. The studied
textile industries seem unaccustomed to the dedicated energy service company concept, and
insufficient information regarding energy service companies (ESCOs) and the shortage of
trained professionals in energy management seem to be the reasons behind this. This paper
likewise finds that 3–4% energy efficiency improvements can be gained with the help of
energy management practices in these industries. [11]

Prof. Rudolf Bergermann has worked on Sustainable Electricity Generation with Solar
Updraft Towers or solar chimneys where he used thermal power to drive turbines to generate
electricity. By using a very basic thermodynamic principle, he produces power by using
direct and diffuse solar radiation. [12]

Mayank Grover, B. Lohith Kumar, and Isaac Ramallaa have worked on The Free Energy
Generator using electromagnets according to faraday's law of electro-magnetism induction.
They have used a 5-volt cooler fan, Neodymium magnets to set on the propellor of a cooler
fan, and a 9-volt dry cell battery. They primarily had succeeded to produce some tiny
electricity which has a small amount of voltage only but the current flow is too low. Although
they used a boost converter to step up the voltage to make the voltage useable. This free
generator system is only useable for small applications like running LED or other tiny pieces
of stuff. As the produced power contains Resistive Load current only resistive loads can be
used by this free generator. [13]

Mohammed Asif Kattimani and Mohammed Ashafaque Inayath have worked on Free Energy
Generation Using Flywheel which consists of motors, pulleys, gear train, alternator, and
gravity wheel. They have completed this project using gravitational energy. Energy is stored
in the gravity wheel which is utilized to run the alternator. The gear train is linked with the
gravity wheel or flywheel to produce extra excess energy or free energy. The interesting thing

8
about this system is that it can get more electrical output power from the alternator's output
than appears to be drawn from the input motor. To get the free energy out of the system, a
detailed examination of various flywheel parameters is carried out. [14]

Albert Patrick J. David has worked on Electro-Magnetic Induction to produce Free Electricity
Generator. The author try to make a kind of wind turbine generator to produce energy by
implementing the device on bicycle. He used a 12V DC cooler fan of CPU by a minor
modification, connect the shaft with propellor. A voltage booster circuit module is used here
which contains ferrite toroid coil, 1K resistor, 2N2222 transistor and a load. The Free
Electricity Generator was designed in consideration with the materials that are readily
available locally and at less cost. To achieve this, a type of motor that is cheaper and can be
found anywhere must be considered. The researcher decided to use a brushless DC motor that
is found in computers such as from the power supply and ventilations. These types of
fans/motors can be found in nearly every electronics store locally. This study focuses on the
construction of the generator and evaluating the device to identify its possible applications
and future enhancements. The researcher sees greater opportunity and applications for this
study. The sought for renewable and green energy are main trends in the field of research
nowadays. The prototype (Free Electricity Generator) can be enhanced further for more
efficiency and better results. But the report contains some unnecessary logics and
components like Bridge rectifier diodes connection which is absolutely irrelevant and
unnecessary. Because the induction motor doesn't produce alternating current so it doesn’t
requires and rectifier to convert it into DC. [15]

Chapter 3

Methodology & Principle

3.1 Methodology
The idea of this project explores the possibility to generate free electricity power by
combining three units i.e. Torsional vibrations, Flywheel and Mechanical drive into a single
unit, such that the device generates energy.
3.1.1 Flywheel:
Flywheels are around for about thousands of years. The initial application is the potter’s
wheel. Perhaps the most commonly used application in recent years is in internal combustion

9
engines. A flywheel is a simple form of mechanical energy storing device. Energy is stored
by rotating disc to spin about its axis. This energy is proportional to its mass and the square
of its rotational speed.
• Advances in magnetic bearings, power electronics, and flywheel materials coupled with
integration of mechanisms have resulted in DC supply flywheel energy storage systems that
can be used as a supplement or auxiliary to batteries in UPS systems.
• Introduction to Flywheel Energy Storage (Kinetic storages), also known as FES, are used in
many technical fields. The flywheel rotors are coupled with an integral motor–generator that
is contained in the housing. The motor generator is used to store and then harness energy
from the rotating flywheel. The use of flywheel power system can improve the overall life,
replace batteries, regulate power frequency and provide a sustainable energy conversion.
• Flywheel energy storage systems (FES) are designed for regenerative braking applications,
to supplement DC power in UPS (uninterruptible power system). Flywheel braking systems
utilize a regenerative brake or KERS (Kinetic Energy Recovery System). Flywheel braking
systems reduce power consumption in mobile cranes, rail transport, automobiles and in other
significant load bearing rotary motors. Inertial mass is increase speed to a very high revolving
speed and maintaining the energy in the system as rotational energy. The energy is
transformed back by slowing down the flywheel. The available performance comes from
Inertia effect and rotational speed.
• Flywheels are the primary load-bearing device inside flywheel power systems. The flywheel
is commonly fabricated from steel or carbon fiber. Carbon fiber flywheels have a higher
energy density due to the light weight and high strength. Steel, aluminum and composite
rotors are an economical alternative to the carbon fiber rotor.
• The flywheel consists of a heavy circular disc fitted with a strong axle projecting on either
side. The axle is mounted on ball bearings onto fixed supports. There is a small peg on the
axle. One end of a cord is loosely looped around the peg and its other end carries the weight –
hanger.
The FESS 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.
Things moving in a straight line have momentum (a kind of "power" of motion) and kinetic
energy (energy of motion) because they have mass (how much "stuff" they contain) and
velocity (how fast they're going). In the same way, rotating objects have kinetic energy
because they have what's called a moment of inertia (how much "stuff" they're made from
and how it's distributed) and an angular velocity (how fast they're rotating). Moment of
inertia is the equivalent of mass for spinning objects, while angular velocity is like ordinary
velocity only going round in a circle.
Just as the kinetic energy of an object moving in a straight line is given by this equation:
E = ½mv2

10
 (where m is mass and v is velocity), so the equivalent, kinetic energy of a spinning object is
given by this one:
E = ½Iω2
(where I is the moment of inertia and ω is the angular velocity).
"Moment of inertia" sounds horribly abstract and confusing, but it's much easier to
understand than you might think. What it really means is that, from the viewpoint of kinetic
energy and momentum, the effective mass of a spinning object depends not just on how much
actual mass it has but on where that mass is located in relation to the point it's spinning
around. The further from the center the mass is, the more effect it has on the object's
momentum and kinetic energy—and we quantify that by saying the mass has a higher
moment of inertia. So a large diameter, lightweight, spoked flywheel with a very heavy steel
rim might have a higher moment of inertia than a much smaller, solid flywheel, because more
of its mass is further from the point of rotation.
Thus the best flywheel in terms of moment of inertia could be one which is larger, spoked
and lightweight, but with a heavy rim of metal. If the rim is twice as heavy as the original,
this would store double the energy that a lighter rim would, but the mechanical limitations
increase correspondingly. On the other hand, doubling the rate of spinning yields twice the
angular velocity, which means the energy stored is quadrupled!

Flywheels turn on bearings which require proper lubrication to minimize frictional forces. Air
resistance must also be reduced to as little as possible. For this reason, the latest development
in flywheels is mounting them on low-friction bearings inside sealed metal cylinders, or even
better, floating them on superconducting magnets which avoids friction almost completely
and placing them inside vacuum chambers to avoid air drag as well.
The FESS is capable of generating several mW of power for brief periods. Flywheels are best
suited to produce high power outputs of 100 kW to 2 mW over a short period of 12-60
seconds. The peak output, at 125 kW for 16 seconds, is sufficient to provide 2 mW for one
second.
There are two basic flywheel configurations. In one type the flywheel is attached to the shaft
and both rotate together. This is termed a conventional rotor. The other type consists of a
flywheel spinning around a shaft which does not move, also called an inside-out rotor.

3.1.2 Dynamo: Dynamo is an older term used to describe a generator that makes direct
current power. DC power sends electrons in only one direction. The problem with a simple
generator is that when the rotor rotates it eventually turns completely around, reversing the
current. Early inventors didn't know what to do with this alternating current, alternating
current is more complex to control and design motors and lights for. Early inventors had to
figure a way to only capture the positive energy of the generator, so they invented a
commutator. The commutator is a switch that allows current to only flow in one direction.
The Dynamo consists of 3 major components: the stator, the armature, and the commutator.

11
The stator is a fixed structure that makes magnetic field, you can do this in a small dynamo
using a permanent magnet. Large dynamos require an electromagnet.
The armature is made of coiled copper windings which rotate inside the magnetic field made
by the stator. When the windings move, they cut through the lines of magnetic field. This
creates pulses of electric power.
The commutator is needed to produce direct current. In direct current power flows in only
one direction through a wire, the problem is that the rotating armature in a dynamo reverses
current each half turn, so the commutator is a rotary switch that disconnects the power during
the reversed current part of the cycle.
Brushes are part of the commutator; the brushes must conduct electricity as the keep contact
with the rotating armature. The first brushes were actual wire "brushes" made of small wires.
These wore out easily and they developed graphic blocks to do the same job.
Dynamos and generators work using the wild complex phenomena of electromagnetism.
Understanding the behavior of electromagnetism, its fields and its effects is a large subject of
study. There is a reason why it took 60 years AFTER Volta's first battery to get a good
powerful dynamo working. We will keep things simple to help introduce you to the
interesting subject of power generation.
In the most basic sense a generator/dynamo is one magnet rotating while inside the influence
of another magnet's magnetic field. You cannot see a magnetic field, but it is often illustrated
using lines of flux. In the illustration above lines of magnetic flux would follow the lines
created by the iron filings.
The generator/dynamo is made up of stationary magnets (stator) which create a powerful
magnetic field, and a rotating magnet (rotor) which distorts and cuts through the magnetic
lines of flux of the stator. When the rotor cuts through lines of magnetic flux it makes
electricity.

Due to Faraday's Law of Induction if you take a wire and move it back and forth in a
magnetic field, the field pushes on electrons in the metal. Copper has 27 electrons, the last
two in the orbit are easily pushed on to the next atom. This movement of electrons is
electrical flow.

12
 Figure 3.1.2: Diode Connection in dynamo
To rectify the produced current in the output of dynamo it requires rectifier diode system
(Figure 3.1.2).

3.2 Working principle

The project consists of three different steps, the first one is power generation, the second one
is the distribution of produced power and the last one is making the power production free.
The project's methodology is based on CHAS CAMPBELL's Generator. The AC supply is
used to start an AC motor. With the use of pulleys of various diameters, the shaft speed can
be varied. The initial AC input supply is replaced by the generator's output supply once the
generator shaft has reached maximum speed.

The shaft on which the two pulleys are mounted with the help of a belt is driven by a motor
with a 4-inch pulley in this free energy generation technique. The motor with a 4-inch pulley
drives the shaft on which the two pulleys are connected by a belt in this free energy
generation procedure.

With the help of a belt, the Motors pulley is connected to an 8- inch pulley that is fitted on
one end of the shaft. The shaft and the motor both revolve at the same rate with a flywheel or
gravity wheel attached to this shaft. The other end of the shaft, which is supplied with a 10-
inch pulley, drives a 5-inch dynamo pulley, dynamo pulley has a speed of double that of the
shaft 10- inch pulley. The flywheel, which is mounted on the shaft, rotates at a rapid rate and
stores the energy as a result. The flywheel's energy is used to power the alternator, which
produces the maximum amount of current required. When the alternator generates the
maximum amount of current, this current is transferred to the motor via an electrical
connection to run the motor. The electric source that was previously used to power the motor
is disconnected by an electromagnetic relay module and the alternator's current is utilized to
power the motor. The alternator now drives the motor and vice versa using a shaft, pulleys,
and belts. As a result, free energy is generated.

A 1500 watt (2 horsepower) main motor drives a set of belts and pulleys that form a gear
train that provides over twice the rotational speed at an electrical generator's shaft. The
strange thing about this system is that it can pull more electrical power from the output
generator than appears to be drawn from the motor's input drive. Mr. Tseung's gravity theory
states that if an energy pulse is applied to a flywheel, excess energy equal to 2mgr is fed into
the flywheel during the instant of the pulse, where "m" is the flywheel's mass, "g" is the

13
gravitational constant, and "r" is the radius of the flywheel's center of mass or the distance
from the axle to the point where the mass of the wheel shows to act. The "r" would be the
radius of the wheel itself if all of the flywheel mass is at the rim. This indicates that there is
no energy gain if the flywheel is driven at a constant speed in a sophisticated manner. If the
drive isn't smooth, though, the gravitational field is drained of extra energy. As the diameter
of the flywheel increases, so does disorderly storage in it. It also rises in tandem with the
flywheel's weight. It also increases if the flywheel's weight is concentrated as far out as
possible towards the rim. It also rises as the system's impulses are sent faster.

Figure 3.2: Basic principle of the project

14
Chapter 4

Materials and Machinery used

4.1 Central circuit diagram

Figure 4.1: Central circuit diagram

The above circuit is showing the required components and their connection to accomplish the
circuit (Figure 4.1). A detailed description of the components is given below

4.2 Alternator
An alternator is an electrical generator that converts mechanical energy to electrical energy in
the form of alternating current. For reasons of cost and simplicity, most alternators use a
rotating magnetic field with a stationary armature. Occasionally, a linear alternator or a
rotating armature with a stationary magnetic field is used. In principle, any AC electrical
generator can be called an alternator, but usually, the term refers to small rotating machines
driven by automotive and other internal combustion engines. An alternator that uses a
permanent magnet for its magnetic field is called a magneto. Alternators in power stations
driven by steam turbines are called turbo-alternators.

4.2.1 working principle of alternator

A conductor moving relative to a magnetic field develops an electromotive force (EMF) in it
(Faraday's Law). This EMF reverses its polarity when it moves under magnetic poles of
opposite polarity. Typically, a rotating magnet, called the rotor turns within a stationary set of

15
conductors wound in coils on an iron core, called the stator. The field cuts across the
conductors, generating an induced EMF (electromotive force), as the mechanical input causes
the rotor to turn.

The rotating magnetic field induces an AC voltage in the stator windings. Since the currents
in the stator windings vary in step with the position of the rotor, an alternator is a
synchronous generator.

The rotor's magnetic field may be produced by permanent magnets, or by a field coil
electromagnet. Automotive alternators use a rotor winding which allows control of the
alternator's generated voltage by varying the current in the rotor field winding. Permanent
magnet machines avoid the loss due to magnetizing current in the rotor but are restricted in
size, due to the cost of the magnet material. Since the permanent magnet field is constant, the
terminal voltage varies directly with the speed of the generator. Brushless AC generators are
usually larger than those used in automotive applications.

An automatic voltage control device controls the field current to keep output voltage
constant. If the output voltage from the stationary armature coils drops due to an increase in
demand, more current is fed into the rotating field coils through the voltage regulator (VR).
This increases the magnetic field around the field coils which induces a greater voltage in the
armature coils. Thus, the output voltage is brought back up to its original value.

Alternators used in central power stations also control the field current to regulate reactive
power and to help stabilize the power system against the effects of momentary faults. Often
there are three sets of stator windings, physically offset so that the rotating magnetic field
produces a three-phase current, displaced by one-third of a period concerning each other.

4.2.2 Specification of the used alternator for this project

Here we used a 3KW dynamo. As a result, it produces electricity at its rated revolutions per
minute (rpm) from an external source. The dynamo is shown in Figure 4.2.2

16
 Figure 4.2.2: 3KW dynamo used in the project

Table 4.2.2: Specifications of the dynamo

Criteria Amount
Power 5 KW
Phase 1 phase
Current 18 AMP
Volt 230 Volts

4.3 Motor:
An electric motor is an electrical machine that converts electrical energy into mechanical
energy. Most electric motors operate through the interaction between the motor's magnetic
field and electric current in a wire winding to generate force in the form of torque applied on
the motor's shaft. An electric generator is mechanically identical to an electric motor, but
operates with a reversed flow of power, converting mechanical energy into electrical energy.

Electric motors may be classified by considerations such as power source type, construction,
application, and type of motion output. They can be powered by AC or DC, be brushed or
brushless, single-phase, two-phase, or three-phase, axial or radial flux, and may be air-cooled
or liquid-cooled.

4.3.1 Specification of the used alternator for this project

The dynamo shaft needs to drive by an external source. Here we used a single-phase
induction motor of 2HP. It drives the flywheel and is used to get rpm. The motor is shown in
Figure 3.3.1

17
 Figure 4.3.1: 2 HP motor used in the project

Table 4.3.1: Specifications of the dynamo

Criteria Value
Power 1500
Horsepower 2 HP
Current 11.5 AMP
Volt 230 Volts
RPM 1450 RPM

4.4 Flywheel
A flywheel is a heavy wheel attached to a rotating shaft to smooth out the delivery of power
from a motor to a machine. The inertia of the flywheel opposes and moderates fluctuations in
the speed of the engine and stores the excess energy for intermittent use. To oppose speed
fluctuations effectively, a flywheel is given high rotational inertia; i.e., most of its weight is
well out from the axis. A wheel with a heavy rim connected to the central hub by spokes or a
web has high rotational inertia. Many flywheels used on reciprocating engines to smooth out
the flow of power are made in this way. The energy stored in a flywheel, however, depends
on both the weight distribution and the rotary speed; if the speed is doubled, the kinetic
energy is quadrupled. A rim-type flywheel will burst at a much lower rotary speed than a
disk-type wheel of the same weight and diameter. For minimum weight and high energy-
storing capacity, a flywheel may be made of high-strength steel and designed as a tapered
disk, thick at the center and thin at the rim.

18
The electrical devices should function as both a motor and a generator, transferring electrical
energy to the flywheel and restoring the energy stored in the flywheel. The electric energy
supplied to the stator winding is turned into mechanical energy when working as a motor,
increasing the speed of the flywheel. In generator mode, the rotor's kinetic energy is
converted to electrical energy. The motor/generator component has a lot of upgrade
possibilities, and its design is getting better all the time. A flywheel is a mechanical
component that stores energy. To maintain inertia, it stores kinetic energy in the form of a
revolution delivered by an external source.

4.4.1 Types of the flywheel

 Solid Disc Flywheel: A solid disc flywheel is a kind of Flywheel. It is used in singles
flywheel thresher, which is made of cast iron. Solid disc flywheel, the flywheel is
equipped with a hub and disc. In the design calculations of a solid disc flywheel,
various parameters are used as inputs. This includes the dimensions of the Solid Disc
Flywheel. In addition, the resulting functional values are calculated.
 Rimmed Flywheel: A rim-type wheel will detonate at a much lower rotary speed
than a solid disc-type wheel of the same weight & diameter. For minimal weight and
high energy-storage capacity, flywheels can be made from high-strength steel and
produced as a tapered disc, which is thicker in the center.
 High-Velocity Flywheel: In this type of Flywheel, the high-velocity Flywheel has a
velocity between 30000 RPM to 80000 RPM. It can also be adjusted up to 100,000
RPM. They have magnetic levitation bearings & require little maintenance. In terms
of size/capacity, they are lighter in weight than low-velocity flywheels. They are more
expensive than low-velocity flywheels.
 Low-Velocity Flywheel: In this type of Flywheel, the low-velocity Flywheel has a
velocity of 10000 rpm. They are heavier and heavier than the high-velocity Flywheel.
They require periodic maintenance and do not use magnetic levitation bearings. Their
installation requires special concrete construction to bear its weight. They are more
economical than high-velocity flywheels.

19
Here we also used a 5KG flywheel. The flywheel is presented in Figure 4.4.1

Figure 4.4.1 Flywheel / Gravity Wheel

4.5 Bearing
A bearing is a machine element that constrains relative motion to only the desired motion and
reduces friction between moving parts. The design of the bearing may, for example, provide
for free linear movement of the moving part or 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.
Most bearings facilitate the desired motion by minimizing friction. Bearings are classified
broadly according to the type of operation, the motions allowed, or the directions of the loads
(forces) applied to the parts.

4.5.1 Types of bearing

There are 6 common types of bearing, each of which operates on different principles:

 Plain bearing: Consisting of a shaft rotating in a hole. There are several specific
styles: bushing, journal bearing, sleeve bearing, rifle bearing, composite bearing;
 Rolling-element bearing: In which rolling elements are placed between the turning
and stationary races to prevent sliding friction. There are two main types:
 Ball bearing: In which the rolling elements are spherical balls;
 Roller bearing: In which the rolling elements are cylindrical, taper, or spherical
rollers;
 Jewel bearing: It is a plain bearing in which one of the bearing surfaces is made of an
ultra-hard glassy jewel material such as sapphire to reduce friction and wear;
 Fluid bearing: A noncontact bearing in which the load is supported by a gas or liquid
(i.e. air bearing);

20
  Magnetic bearing: in which the load is supported by a magnetic field;
 Flexure bearing: In which the motion is supported by a load element that bends.

4.5.2 Specification of the used Bearing for this project

For this project, we choose the UC209 ball bearing.

Specification:

 Model: UC209 Bearing

 Type: Mounted Ball Bearing
 Bearing Size: 45mm x 85mm x 22mm/49.2mm

Figure 4.5.2: UC209 ball bearing

4.6 Belt drive

Belt drive, in machinery, is a pair of pulleys attached to usually parallel shafts and connected
by an encircling flexible belt (band) that can serve to transmit and modify rotary motion from
one shaft to the other.

We began by selecting a pulley that met the usual specifications. We already know that a belt
drive is beneficial for power transmission via pulleys. The diameter and speed of each pulley
vary. For power transmission, belt and wire (rope) drives are utilized. We'll be using a total of
four pulleys in the project, so we'll need two separate belt drives. A belt is a flexible material
loop that is used to mechanically connect two or more spinning shafts, usually in parallel.
Belts can be employed as a source of motion, a means of efficiently transmitting power, or a
means of tracking relative movement. Belts are wrapped around pulleys with a twist between
them, and the shafts do not have to be parallel. Two shafts, a motor, a flywheel, and a
generator are all connected by three V-type belts of varying lengths. The diameters of pulleys

21
are a way to create numerous drive ratios in a belt and pulley system that can deliver
mechanical advantage, just as the diameters define a gear ratio and hence the speed increases
or reductions and mechanical advantage that they can deliver. The belt drive model is shown
in figure 3.6

Figure 4.6: Belt drive model

4.7 U- Channel bar

U channel made of aluminum is utilized in practically every industry and is a suitable
material for a wide range of applications. The structure of this project is made from U-
channel bars. The bar is shown below in Figure 3.7

 Size: (3×1.5),
 Total Length: 40 feet,
 Total Weight: 80KG

22
Figure 4.7: U-Channel bar

23
4.8 Relay:
Relays are the switches that aim at closing and opening the circuits electronically as well as
electromechanically. It controls the opening and closing of the circuit contacts of an
electronic circuit. When the relay contact is open (NO), the relay isn’t energized with the
open contact. However, if it is closed (NC), the relay isn’t energized given the closed contact.
However, when energy (electricity or charge) is supplied, the states are prone to change.

Relays are normally used in the control panels, manufacturing, and building automation to
control the power along with switching the smaller current values in a control circuit.
However, the supply of amplifying effect can help control the large amperes and voltages
because if low voltage is applied to the relay coil, a large voltage can be switched by the
contacts.

Based on types of current there are two types of the relay, one is AC Relay another one is DC
Relay. In our project, we use AC Relay.

4.9 Post Processing Unit:

A post-processing unit is used here to maintain a safe and continuous power supply as well as
to ensure input to the single-phase induction motor from the alternator without losing the
RPM and output rate.

The post-processing unit is consisting of two major sections. One is for Automatic switching
of input current to the motor. And the other is the safety feature for the output useable
current.

As we discussed before, the generator will be driven by a single-phase motor. And the motor
starts by any external temporary power source. So, when the dynamo produces power, we
need to switch the input of the motor to drive the dynamo by its power.

Here we used an electromagnetic relay module as a changeover function to switch the input
power of the motor. This operation can be accomplished within a millisecond by this module.
The circuit diagram is shown below in Figure 4.9.

24
 Figure 4.9a: Circuit diagram of the post-processing unit
Here Pole point is the phase line of the motor. The other end of this Pole point is N/C
(Normally Closed) point which is connected to the external energy source (PE) when the
relay is inactive. PD belongs to the Dynamo output power source which is the input to
activate the relay module. When the relay becomes active, the induction coil between points 1
& 2 starts to produce electromagnetism. This magnetic wave switches the pole from N/C to
N/O (Normally Opened). By this operation, the phase line of the motor connects with the
output power source of Dynamo (PD). By this method, the dynamo starts to be driven by its
power source.

When the alternator produces current, it fluctuates because of variation in rotation. It may
produce an extra voltage that causes damage to the load circuit. To prevent this, we have
attached a safety fuse in the post-processing unit. The circuit diagram of the safety Fuse is
shown below in Figure 3.9b

Figure 4.9b: Circuit diagram of the safety fuse

25
Chapter 5

Experimental Result

Our project is consisting of three basic levels:

1) Power Generation
2) Power Distribution
3) Free power making by recycling

5.1 Power Generation

Our first process, Power generation was tested by a 2HP 1500W single phase motor and a
5KVA dynamo alternator. The motor and dynamo were connected directly by a cross link
shaft. This experiment had a convincing success rate with an enrich output. The experiment
data is shown below:

Table 5.1: Output of Dynamo

SL Motor Speed Dynamo Output
(RPM) Speed (Watt)
(RPM)

1 1215 1260 2520

2 1530 1595 3190

3 2200 2250 4500

5.2 Power Distribution

The power distribution part was consisting of different loads like Lights, heavy duty grinder
motors, fans. The motor is shown in figure 4.2.

Figure 5.2: DN8112 Grinder motor

26
5.3 Power Re-Use
The experiments for Power re-use was not successful because of some technical barriers and
limitation, specially need financial support for proper experiments.

Chapter 6

Findings & Innovative ideas

6.1 Barriers
 For lack of flywheel
 For lack of gear pulley setup.
 Need Digital RPM Tachometer to take accurate reading
 Need digital Ammeter & Voltmeter
 Need financial support

6.2 Future Initiates

In the future, we will work on the safety parameter of this system by using different sensors
like the thermal sensor to monitor the temperature of the system and control them. A Arduino
Uno board will monitor the temperature and on/off the cooling fan to make the device stable
and trouble free. Otherwise the system can be damaged due to overheat. A brief description
of all parts is shown below:
6.2.1 Thermal Sensor:
This is a waterproofed version of the DS18B20 Temperature sensor. Handy for when need to
measure something far away, or in wet conditions. While the sensor is good up to 125°C the
cable is jacketed in PVC so we suggest keeping it under 100°C. Because they are digital,
don't get any signal degradation even over long distances! The DS18B20 provides 9 to 12-bit
(configurable) temperature readings over a 1-Wire interface, so that only one wire (and
ground) needs to be connected from a central microprocessor. Usable with 3.0-5.5V systems.
Because each DS18B20 contains a unique silicon serial number, multiple DS18B20s can
exist on the same 1-Wire bus. This allows for placing temperature sensors in many different
places. Applications where this feature is useful include HVAC environmental controls,
sensing temperatures inside buildings, equipment or machinery, and process monitoring and
control. The sensor is shown below (Figure 5.2.1).

27
 Figure 6.2.1: Thermal Sensor

6.2.2 Cooling Fan:

Specifications:

 Operating voltage: 5V
 Current: 0.2 A
 Brushless DC fan
 Fan dimensions: 30mm x 30mm x 8mm
 Wire length: 3.25" / 80mm
 Fan weight: 6.2g / 0.22oz

Figure 6.2.2: Cooling fan

6.2.3 Arduino Programmer:

Arduino Uno is a microcontroller board based on the ATmega328P (datasheet). It has 14
digital input/output pins (of which 6 can be used as PWM outputs), 6 analog inputs, a 16
MHz ceramic resonator (CSTCE16M0V53-R0), a USB connection, a power jack, an ICSP
header and a reset button. It contains everything needed to support the microcontroller.

28
 Figure 6.2.3: Arduino UNO programmer
Specification:
 Microcontroller : ATmega328P
 Operating Voltage : 5V
 Input Voltage : 7-12V
 Input Voltage (limit) : 6-20V
 Digital I/O Pins : 14 (of which 6 provide PWM output)
 PWM Digital I/O Pins :6
 Analog Input Pins :6
 DC Current per I/O Pin : 20 mA
 DC Current for 3.3V Pin : 50 mA
 Flash Memory : 32 KB (ATmega328P) of which 0.5 KB used by
bootloader
 SRAM : 2 KB (ATmega328P)
 EEPROM : 1 KB (ATmega328P)
 Clock Speed : 16 MHz
 LED_BUILTIN : 13
 Length : 68.6 mm
 Width : 53.4 mm
 Weight : 25 g

29
Chapter 7

Calculation
After performing this experiment, we concluded that it is possible to make such type of
generators in which we have to pay zero after certain conditions consisting of some energy
storing elements like a flywheel. But need to build fully functional prototype. Because one of
our understandings is that flywheel is behaving as a capacitor and a filter as well because it
helps the system to run smoothly. Flywheels are one of the most potential energy storage
technologies for a range of applications, including autos, cost-effective rural electrification
schemes, and stand-alone, remote power units often used in the telecommunications industry.

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