If we use a sprocket of 70mm diameter, circumference will be 220mm and it should rotate 6 times, the distance will be 1320mm

630mm
500mm
1320mm

35mm 76mm
681.6 mm
887.4mm
70mm

23kg
1100mm

80kg
800mm

Flywheel and
Generator shaft

326mm
600mm

1645mm

250mm

50 mm 60mm

500mm
3000mm

700mm 700mm 1600mm

Flange can be made by a sheet of 5mm thickness

If the flange is flat then spacer (steel sleeve) can be used, but if is the same as this one then no need for spacer
The distance marked with red which is the distance between the two shafts is not important, it depends on the builder
and the v-belts length will also depends on the builder.

Belt calculations

DL =630mm
DS =100mm
L = 887.4mm
Belt length = ((DL + DS) x π/2) + (2L) + (DL-DS) 2/4L
= ((630+100) x 3.14/2) + (2 x 887.4) + (630-100)2 /4 x 887.4
= (730 x 1.57) + (1774.8) + (530)2 /3549.6
= 1146.1 + 1774.8 + 280900 /3549.6
= 2920.9+ 79.13
= 3000.04

Belt will be SPB3000 which A=17mm and B=14mm

DL =500mm
DS =106mm
L = 1183mm
Belt length = ((DL + DS) x π/2) + (2L) + (DL-DS) 2/4L
= ((500+106) x 3.14/2) + (2 x 1183) + (500-106)2 /4 x 1183
= (606 x 1.57) + (2366) + (394)2 /4732
= 951.42 + 2366+ 155236 /4732
= 3317.42+ 32.80558
= 3350.226

Belt is SPA3350 which A=13mm and B=10mm

POWER TRANSMITION CALCULATIONS

PNUEMATIC CYLINDER
Double Acting DSBC-50-250-PPSA-N3

PUSHING STROKE

Calculate the first power transmitted by cylinder rod

EQUATION
Force (N) =Pressure (Nm²) x Area (m²)
What we know
Pressure=8 bar
We want to convert bar to Nm²
Note:
1bar = 100 000Pa
1Pa= 1Nm²
8bar =800 000Pa= 800 000Nm²
What we know
Diameter = 50mm

Area calculation
Area (m²) = π x (d) ²)/4

We want to convert mm to m
Note:
1mm = 0.001m
50mm = 0.050mm

Area calculation
Area (m²) = (22/7 x (0.050m) ²)/4
Area = 0.00196m²

Force (N) = Pressure (Nm²) x Area (m²)

Force (N) = 800 000 (Nm²) x 0.00196(m²)
Force = 1568N

PULLING STROKE
Calculate the first power transmitted by cylinder rod
EQUATION
Force (N) =Pressure (Nm²) x Area (m²)

What we know
Pressure=8 bar
We want to convert bar to Nm²
Note:
1bar = 100 000Pa
1Pa= 1Nm²
8bar =800 000Pa= 800 000Nm²

What we know
Diameter = 50mm – 15.97mm = 34.03mm

Area calculation
Area (m²) = π x (d) ²)/4

We want to convert mm to m
Note:
1mm = 0.001m
34.03mm = 0.034m

Area calculation
Area (m²) = (22/7 x (0.034m) ²)/4
Area = 0.0009074m²

Force (N) = Pressure (Nm²) x Area (m²)

Force (N) = 800 000 (Nm²) x 0.0009074(m²)
Force = 725.968N

Average = 725.968/1568
= 0.463 x 100
= 46.3%
Total torque
Pull back cylinder force Weight (store energy) + cylinder force pushing
= 23kg + 23kg (46.3%)
= 230N + 230N (46.3%)
= 230N + 336.49N
= 566.49N on the last shaft connected to the 500mm pulley

Torque = F x d
= 566.49N x 0.25m
=141.62Nm

CALCULATE THE GENERATOR NEEDED AND THE OUTPUT POWER

DATA
Torque = 141.62Nm
Speed = 1800rpm

FORMULA
Power = Torque x speed / 9.548
P = 141.62Nm x 1800 rpm / 9.548
P = 26.698.36 Watts
P = 26.70 Kw output power excluding the system loss

However we still have the first shaft power to add

PRECAUTION WHEN STARTING MACHINE

1. Excitation of generator must be made after reaching a full speed 1800rpm

2. Cylinder one, two and three can start simultaneously until the speed is increased and then changed to sequence
or
3. Cylinder one and two can start simultaneously until the speed is increased and then changed to sequence or
4. Cylinder one can be used to start the system alone

SLOW SPEED

If the speed of the stroke is longer than a second the speed will not be 1800rpm therefore we need to increase the speed

1. Increase the air flow rate will increase the speed (increase the size of the air pipe, connectors and cylinder bore
hole)
2. Decrease the force on the cylinder will increase the speed (changing the sizes of the weights)
3. Increasing pressure (but not recommended)
 4. Getting the same constant pressure continuously (8bar)

INPROVEMENTS

1. Increase the pressure size in the tank +/- 25bar, so that we can provide the constant pressure
2. Cylinders should face downwards (vertically)
3. Cylinders should be made by rings
4. The first pulley size can be increased (any bigger size)
5. Freewheel can be used on the second shaft (on the small pulley) connection of the first pulley