DEVELOPMENT AND FABRICATION OF

ELECTROMAGNETIC ENGINE

Submitted by
Avin Ganapathi
Rithin R
Srinivas Rangan L
Vinay M
1
 A PROJECT WORK PROPOSAL ON

DEVELOPMENT AND
FABRICATION OF
ELECTROMAGNETIC ENGINE
Submitted By Under the Guidance of
AVIN GANAPATHI(4MH09ME010) Prof. B HARISH
RITHIN R(4MH11ME094) Assistant Professor
SREENIVAS RANGAN L(4MH11ME104) Department of Mechanical
VINAY M(4MH11ME118) Engineering
MIT Mysore
DEPARTMENT OF MECHANICAL ENGINEERING
MAHARAJA INSTITUTE OF TECHNOLOGY
MYSORE - 571438
2
 Index

1. Introduction
2. Literature survey
3. Overview
4. Components and description
5. Design Calculations
6. Fabrication and Assembly
7. Cost estimation
8. Testing
3
9. Result
10. Conclusion and Scope for future
development
References.
Fabricated model photographs

4
Introduction
• Conventional Engine Concept
An Internal Combustion is an engine where
combustion of fuel occurs with an oxidizer in
combustion chamber that is an integral part of
working fluid flow circuit.

5
Drawbacks of IC engine
• Air pollution.
• Because of high demand and decreasing
supply, the price of fuel is increasing.
• Running cost Maintenance cost is high.
• Manufacturing cost is high.

6
Windings on core
The force that sets up the magnetic field depends
on the number of turns on the coil and the magnitude of the current
flowing. This force is called the Magneto Motive Force and is measured
in Ampere-turn.
MMF=I*n Amp-turn

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Current carrying conductor

8
9
Literature survey

10
 OVERVIEW

Objective
• To Develop and fabricate an Electromagnetic
engine

• Testing of Engine for its power output and

efficiency

• To Evaluate the Performance of Electromagnetic

Engine
11
Methodology

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 COMPONENTS AND DESCRIPTION
• Cylinder

13
• Piston

14
• Connecting rod

15
• Flywheel

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• Electromagnet

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 Diameter 0.065 m

Height 0.080 m

An electromagnetic coil is formed when an insulated solid

copper wire is wound around a core or form to create an
inductor or electromagnet. When electricity is passed through a
coil, it generates a magnetic field. One loop of wire is usually
referred to as a turn or a winding. we have wound 350 turns.

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RELAY
A relay is an electrically operated switch.
Current flowing through the coil of the relay
creates a magnetic field which attracts a lever
and changes the switch contacts.

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• Battery

• The batteries we are using is lead acid battery which

has a nominal supply voltage 12 volts and 7Ah
current. By series combination we get supply voltage
of 36 volts. 20
TIMER 555 IC

TIMER 555 IC is used to control accurate time delays

for Relays to switch ON and OFF.

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 DESIGN CALCULATION
Input voltage = 36 V
Input current = 10A
Input Power = Voltage × Current= 36 × 10 = 360W

Force exerted by electromagnet on piston:

I K A
2 2

F1= N
2 G
2

22 22
Where, N = number of turns = 350
I = Current flowing through coil = 10 A
K = Permeability of free space = 4π×10-7
A = Cross-sectional area of electromagnet (radius
r = 0.0325m)
G = Least distance between electromagnet and
permanent magnet = 0.01m
d = diameter of electromagnet = 0.065 m

On substitution we get
Max Force F1 = 255.40 N

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Force exerted by permanent magnet:
F2 = B  A
2

2  0

 
Br  D  Z Z 

B= 2 [
 R  ( D  Z )
2 0.5 2

( R  Z 
2 ) 0.5


On substituting the value of flux density we get

F2 = 11.1 N

F = F1 + F2
= 266.48N
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Torque

T = F× r
Where F = total force on piston = 266.50 N
r = crank radius = 0.01m
T = 266.50 × 0.01
Torque T = 2.665 N-m

25 25
 Mass of Flywheel

Energy stored on Flywheel

E=T × Ѳ
Where T= torque
θ = Angle of rotation = 180̊   radians
on substitution we get
E = 6.372 Joules
Also,
E= 0.5×I×ω2
I = 0.0189 kg-m2 26
 I= 0.5 × m × r2
Where , m = mass of fly wheel
r = radius of fly wheel = 0.085 m
m = 2.12 kg.

2   N  T
Output Power: P
60
Where,
N = speed= 200rpm
T = Torque= 2.665 N-m
On substitution,we get

P = 55.71 W
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 EFFICIENCY

55.81
Efficiency = Ƞ = 360
 100

Ƞ = 15.51 %

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Factor of Safety of Cast Iron Frame

3WL
Working stress, F 
2bd 2
3  40  9.81  610

2  30  202

F =29.9 N/mm2

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Where L = Length of the frame in mm,
W = Weight acting on the frame in Kg
b = Breadth in mm
d = Depth in mm

Factor of Safety, FOS =

130
= 29.9
FOS = 4.3
When Factor of Safety is greater than or equal to 1,
then the Design is safe.
i.e., FOS ≥ 1
4.3 > 1, hence Design is Safe.
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 FABRICATION AND ASSEMBLY
• CYLINDER
width 0.075 m

length 0.075 m

height 0.1 m

Bore diameter 0.038 m

• The cylinder developed is made of aluminum, a non-

magnetic material which limits the magnetic field
within the boundaries of cylinder periphery. Usage of
aluminum material makes the engine lighter unlike
the cast-iron cylinder used in internal combustion
engine.
31 31
 PISTON

Diameter 0.038 m
height 0.034m

• The hollow piston casing is made up of non-magnetic

stainless steel.
• One end of the hollow case is fitted with a powerful
permanent magnet made of neodymiumiron-boron
(NdFeB)

32 32
 CONNECTING ROD

Length 0.086m
Big end diameter 0.012m
Small end diameter 0.010m

In a reciprocating engine, the connecting rod is used to

connect the piston to the flywheel. It converts the
linear motion or reciprocating motion of the piston to
the circular motion of the flywheel. The material of
the connecting rod is cast iron. The connecting rod
used is same as that of an Internal Combustion engine
without any modification
33 33
 FLYWHEEL

• Flywheel is made up of mild steel and it is used to convert

reciprocating energy into rotational energy. It regulates the
engine’s rotation, making it operate at a steady speed. The
diameter of the outer circle is 170mm and of the through hole
at the center is 30mm

34 34
 ELECTROMAGNET

Diameter 0.065 m
Height 0.080 m

An electromagnetic coil is formed when an

insulated solid copper wire is wound around a core or
form to create an electromagnet. When electricity is
passed through a coil, it generates a magnetic field.
One loop of wire is usually referred to as a turn or a
winding. we have wound 350 turns.

35 35
 SUPPORT FRAME

Length 0.61 m
Width 0.26 m
Height 0.28 m

The support frame is made up of cast iron. It

holds the piston and cylinder assembly with
electromagnetic coil arrangement. The length, breadth
and height of the stand are 600 mm. 260mm and
280mm respectively. The manufacturing process
involved are cutting and welding
36 36
 ASSEMBLY
The setup is as follows:

• The electromagnetic coil is held

between two fixed supports on the
frame.
• Similarly the cylinder block is
mounted on the fixed electromagnetic
coil
• NdFeB permanent magnet is attached
to the piston head by means of a
strong adhesive.
• Piston is mounted inside the cylinder.
• The small end diameter of the
connecting rod is fixed to a piston and
the big end diameter to the flywheel.
• And the flywheel converts
reciprocatory motion of piston into
rotary motion.

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38
 COST ESTIMATION

Name of the
Sl. No. Material Used Qty. Amount (Rs)
Parts
1 Battery - 3 2100
Permanent Neo Dymium –
2 1 1000
magnet Boron
3 Stand (Frame) Cast iron 1 1000
4 Electromagnet - 1 2000
Relay and Ic
5 - 1 500
timer
6 Piston Stainless steel 1 1500
7 Connecting rod Cast iron 1 600
8 Flywheel Mild steel 1 900
9 Nut and bolts Mild steel 2 20
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• Material Cost =Piston+ connecting rod +
flywheel + Nuts and Bolts
= 1500 + 600 + 900+20
= Rs. 3020/-
• Fabrication Cost =Rs. 2000/-

• Total cost = Component cost + Material

cost + Fabrication cost = Rs.11620/ -
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 TESTING
• Variation of Current with Force
Current, amp Force, N

2 21.48

4 52.07

6 103.07

8 174.47

10 266.27

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Variation of input Power with Efficiency
Power input Efficiency

72 6.09

144 7.56

216 9.98

288 12.68

360 15.48

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 RESULT
The prototype of an electromagnetic engine which works on
the principle of magnetism was successfully developed, fabricated
and tested. Result analysis was done on the prototype. The results
obtained are as follows.
• Prototype of an engine which works on the principle of magnetism
was tested successfully.
• It uses electricity as its input without fuel.
• The prototype creates no pollution and is eco-friendly.
• Only the repulsive force between the magnet and electromagnet is
used for power generation.
• Acceleration is done by controlling the timer which controls the relay.
• Maximum efficiency obtained was 15.81 %.
• Maximum output power obtained was 55.81 W .
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CONCLUSION AND SCOPE FOR FUTURE
DEVELOPMENT
The prototype is an idea which uses the property of an
electromagnet by virtue of which it changes the polarity of its poles
whenever the direction of current is changed. This variation in polarity is
utilized to attract or repel the permanent magnet attached to the piston. The
usage of relay and timer will limit the output of the engine. By using an ECU
in the engine instead, power can be obtained on each stroke which will
result in an increased output. Also, by inserting more permanent magnets in
series on the piston will enhance the output of the engine. By slight
modification in design and by the use of better hands the engine can be
modified to generate more power, thereby increasing its efficiency, so that it
can be used in commercial vehicles and other applications.

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Jeff Baird-
A inventor whose creation was recently featured in Popular
Science magazine unveiled his latest invention Saturday.
Ada area resident Jeff Baird’s newest invention is an
engine that uses a technology that really isn’t new at all.
Large batteries fire the magnets and the motor acts as
an alternator that keeps the batteries charged
continuously.
The technology works like windmills except it uses
magnets instead of wind.

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46
Peter van Blarigan-

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 References
• [1]Atulkumarsingh, PrabhatRanjanTripathi, Microcontrolled Electromagnetic Engine, 2011, International
Conference on Advances in Electrical and Electronics Engineering (ICAEE'2011)

• [2]J.Rithula,J.Jeyashruthi and Y Anandhi,Electric Vehicle with Zero-fuel ElectromagneticAutomobile

Engine,2013,1,2&3Department of Electrical & Electronics Engineering, Sri Sairam Engineering College, West
Tambaram, Chennai, India. Volume 6, Number 4 (2013), pp. 483-486

• [3]Shirsendu Das,An ELECTROMAGNETIC MECHANISM WHICH WORKS LIKE AN ENGINE, IJETT- Volume 4
Issue 6-June 2013

• [4]Abil Joseph Eapen, AbyEshowVarughese, Arun T.P,Athul T.N, 2014,

ELECTROMAGNETIC ENGINE, International Journal of Research in Engineering and Technology.

• [5]AmarnathJayaprakash, Balaji, G., Bala Subramanian, S. and Naveen, N.,STUDIES ON ELECTROMAGNETIC

ENGINE International Journal of Development Research Vol. 4, Issue, 3, pp. 519-524, March, 2014

• [6]C. Sudhakar, K. Premkumar, K.Vijith, S.Balaji,“EMISSIONLESS ENGINE BY USING ELECTRO MAGNET”,

2014
• [7]K.Mahadevan and L.Balaveera Reddy “DESIGN DATA HAND BOOK” for Mechanical Engineers, Third
Edition.

• [8]Peter van Blarigan, “ADVANCED INTERNAL COMBUSTION ENGINE RESEARCH ” Proceedings of the 2000
DOE Hydrogen Program Review.

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Fabricated model photographs

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Cylinder

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51
Piston with Connecting rod

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Flywheel

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Electromagnet

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Relay and timer

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Battery

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Assembly

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