POWER GENERATION FROM EXERCISE EQUIPMENT

Amrit.S#1, Ajith.R*2, Ganesh.J#3, Raj Kumar.T*4

Mechanical Department, Vel Tech Multi Tech Dr. RR and Dr. SR Engineering College Anna University Chennai
Abstract The main objective of this project is power

generation using exercise equipment which can produce rotational energy to run power generating devices such as the dynamo or an alternator and use it to charge batteries and supply the electricity for lighting. Equipments include elliptical, treadmills etc.
Secondary objective is to design a constant speed drive which is a system used to get constant output speed at varied input speeds and is being designed using hydraulic components to have optimum running of the power generating devices i.e., without fluctuations in power supply as well as prevent damage of the alternator.This document gives formatting instructions for authors preparing papers for publication in the Proceedings of an IEEE conference. The authors must follow the instructions given in the document for the papers to be published. You can use this document as both an instruction set and as a template into which you can type your own text. Keywords Constant Speed Drive, Accumulator, Pressure Regulation, Electricity Generation using Dynamo

USING A HYDRAULIC DRIVE AND INTERCONNECTING VARIOUS GYM EQUIPMENTS AND PUMP FLUID TO A SINGLE HYDRAULIC MOTOR IT IS POSSIBLE TO MAKE A SINGLE GENERATOR SUPPLY ENOUGH ELECTRICITY TO KEEP THE GYM LIGHTS AND EVEN AN AIR CONDITIONING UNIT RUNNING. BUT THE PROBLEM COMES WHEN TOO MANY PEOPLE USE THE GYM EQUIPMENTS AND LOT OF ENERGY IS PRODUCED THAT THE GENERATOR MIGHT BE GIVEN AN INPUT HIGHER THAN REQUIRED AND IN ORDER TO CONTROL THAT A SYSTEM CALLED CONSTANT SPEED DRIVE MAKING USE OF AN ACCUMULATOR HAS BEEN DESIGNED TO MAKE THE HYDRAULIC CIRCUIT SIMPLE. CONSTANT SPEED DRIVE IS A SYSTEM WHERE AT ALL INPUT CONDITIONS ONE GETS A CONSTANT SPEED OUTPUT. THE TRADITIONAL CONSTANT SPEED DRIVES USE REDUCTION GEARS. NOWADAYS THESE REDUCTION GEARS ARE HYDRAULICALLY CONTROLLED AND OTHER MODELS HAVE ROTATABLE ANNULUS, FRUSTO CONICAL EDGE ETC. CSD ARE ESSENTIALLY REQUIRED IN DRIVES OF ALTERNATORS FROM GAS TURBINES, IN AIRCRAFTS ETC. OUR MODEL OF THE CONSTANT SPEED DRIVE USES SIMPLE HYDRAULIC COMPONENTS THAT ARE AVAILABLE COMMERCIALLY. THEY INCLUDE A MOTOR, A PUMP, AN ACCUMULATOR, FITTINGS ETC. IN ORDER TO DEMONSTRATE THE WORKING OF THIS DRIVE IT HAS BEEN MOUNTED ON A SIMPLE EXERCISE EQUIPMENT HERE WHICH IS AN ELLIPTICAL TO DEMONSTRATE THE WORKING CONDITION TO WHICH THE EQUIPMENT WILL BE PUT THROUGH. THE PUMP IS CONNECTED TO THE ELLIPTICAL BY MEANS OF GEARS AND SO IS THE MOTOR MESHED TO A DYNAMO FOR THE DEMONSTRATIVE PURPOSE. BASIC DESCRIPTIONS OF COMPONENTS THAT ARE PUT INTO HYDRAULIC APPLICATIONS HAVE BEEN GIVEN AN OVERVIEW ON. IN THE FIRST PHASE OF THE PROJECT WE HAVE DEVELOPED A SYSTEM TO OBTAIN CONSTANT SPEED TO RUN A DYNAMO WHICH CAN BE USED TO CHARGE PROBABLY A PHONE BATTERY USING AN ELLIPTICAL WHICH IS A CARDIO EXERCISE EQUIPMENT. II. DESIGN CONSIDERATIONS MADE AND MATERIALS USED

I. INTRODUCTION IT HAS BEEN FOUND OUT THAT MOST PEOPLE TRY TO HIT THE GYM TO STAY FIT AND GET IN SHAPE. ONE THING THEY HAVE MISSED OUT IS THAT OPTIMUM WAY TO STAY FIT IS TO DO SIMPLE THINGS LIKE WALKING AND USING THE STAIRS INSTEAD OF THE ELEVATORS OR LIFTS. BUT SINCE IT HAS BECOME DIFFICULT THEY TEND TO HIT THE GYM AND IT IS SEEN THAT PEOPLE BURN THE EXTRA CALORIES WITHOUT PUTTING THEM TO ACTUAL PRODUCTIVE USE. MOST CARDIO GYMS HAVE EQUIPMENTS SUCH AS TREADMILLS, ELLIPTICAL, CYCLES ETC WHICH HAVE ROTATIONAL COMPONENTS FROM WHICH ELECTRICITY CAN BE GENERATED BY SUITABLE ATTACHMENTS. INDIVIDUAL COMPONENTS BEING FITTED WITH INDIVIDUAL ATTACHMENTS TO GENERATE ELECTRICITY MIGHT TURN OUT TO BE COSTLY AND IN EFFICIENT.
THE USE OF AN EXERCISE EQUIPMENT CAN ALSO BE WIDENED TO USING THEM TO POWER SCREW CONVEYORS OR BELT CONVEYORS TO TRANSPORT MANURE (OR) GRAINS (OR) EVEN WATER FROM A CANAL TO A FIELD.

More than design the major requirement here was in selection of pump, motor, working fluid and type of power transmission from the exercise equipment (here the elliptical) to the pump. A. Design Consideration The following considerations were made while designing: Gear ratios required between equipment shaft and pump shaft Gear ratios between the motor shaft and the dynamo shaft Gear material required Pump speed required to get optimum output speed at the motor Operating pressures of the hydraulic fluid at minimum cycling speed B. Materials and Components The following components and materials are made use of An elliptical Gears made of cast iron Hydraulic Pump and motor of lowest specification available Dynamo Accumulator Frame to hold the components at required position The pump and motor made use of is HPI Series 0 Model 050(VI Sign) which is most common pump available at the least specification that is develops pressures up to 100 bar at 800 rpm and is light in weight and small in size to attach to an exercise equipment with the use of SAE 40 oils. The motor used is also of the same specification as the pump can develop enough working pressures to run the motor. The accumulator made use of is a gas loaded diaphragm accumulator with permitted operating pressures up to 210 bar and a nominal volume of 0.32 litres. Other components include the regular hydraulic hoses made of nitrile rubber which can withstand pressures up to 200 bar and suitable fittings as required. The frame houses the accumulator, dynamo and the motor as a separate unit from the pump. III. WORKING, OBSERVATION AND EXPLANATIONS The use of hydraulic fluid for power transmission and the need has been explained in the following paragraphs. A. Working When the elliptical is pedalled hydraulic fluid from the reservoir is pumped through the accumulator to the hydraulic motor via an FCV if required. The accumulator is set at 100 bar pressure the minimum working pressure of the pump and motor and the gear ratios are so designed that at the lowest speed of the elliptical pedalling the minimum rpm of the pump is reached so as to get the minimum line pressure.

At higher pedalling speeds the accumulator absorbs the excess fluid and reduces the pressure to the set hundred bar and hence the motor runs at the constant speed at varying pedalling speeds. For very high speed pedalling a FCV is essential to maintain the speed of the motor constant so that the dynamo runs at constant speed hence power fluctuations are avoided and also the dynamo is not damaged. B. Observation and Explanation The running of the motor at test was slightly lower due to frictional losses. Hence had to increase working pressure so that the motor runs at the required optimum speed. The developed power at that rate was quite enough to even drive a 24V dynamo and hence could be used directly to power an inverter battery. Conclusions The first phase of the project to derive power using a hydraulic transmission was a success and can also be implemented in high power and high speed applications which involve constant speed drives. The gears, pumps, motors, hoses and fittings have to be selected appropriately. Power generation using exercise equipments if implemented in all places we could reduce usage of electricity to an extent and also stay fit and healthy. With the success of the first phase of the project we can continue with the second phase of the project of combining hydraulic power from more exercise equipments to generate enough electricity to power up the entire gym with air conditioners, two or three lights and also charge batteries of electronic devices. ACKNOWLEDGMENT We take this opportunity to express our sincere gratitude to our chairman Col. Prof. Dr.Vel. R. Rangarajan, B.E (Mechanical), B.E (Electrical), MS (Automobile), D.Sc for his kind words and enthusiastic motivation which has inspired us a lot in completing this project. We are deeply indebted to our Principal Prof. Dr. V. PARTHASARATHY, M.E., PhD for being a source of inspiration throughout my study in this college. We thank our Head of the Department Mr. N. RAM PRAKASH, M.E., & our project coordinator Mr. S. LAKSHMANAN, M..E., (PhD), for their guidance and encouragement at each and every stage of our project work and also guiding us properly throughout the reviews. We would like to express our heartfelt gratitude to all the faculty and supporting staff of Department of Mechanical Engineering for the help they extended for completion of project. This project is dedicated to our parents and friends who sacrificed a lot and extended their full support to us. REFERENCES
[1] [2] R.S. Khurmi and J.K. Gupta (2005) 'Machine Design', Eurasia Publishing House (PVT.) LTD. Dr. R.K. Bansal (2005) 'Fluid Mechanics and Hydraulic Machines'.

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Patent on 'Generating Power from Exercise Equipment' with Patent no. US 2012/0238406 A1, dated Sep 20, 2012. Patent on 'Constant Speed Hydraulic Drive' with Patent no. 4644748, dated Feb 24,1987.

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General Catalogue for Hydraulic Fittings. Basic Catalogue for Hydraulic Pumps by JTEKT-HPI HYDAC Product Catalogue for Accumulators N.R.P. Product Catalogue for Hydraulic Hose