INTRODUCTION

1
 CHAPTER 1
INTRODUCTION

A flywheel is a mechanical device with a significant moment of inertia

used as a storage device for rotational energy. Flywheels resist changes in their
rotational speed, which helps steady the rotation of the shaft when a fluctuating
torque is exerted on it by its power source. flywheels have become the subject
of extensive research as power storage devices for uses in vehicles. flywheel
energy storage systems are considered to be an attractive alternative to
electrochemical batteries due to higher stored energy density, higher life term,
deterministic state of charge and ecologically clean nature. Flywheel is basically
a rechargeable battery. It is used to absorb electric energy from a source, store it
as kinetic energy of rotation, and then deliver it to a load at the appropriate time,
in the form that meets the load needs. As shown in Fig1, a typical system
consists of a flywheel, a motor/generator, and controlled electronics for
connection to a larger electric power system.

The input power may differ from the output power in its temporal profile,
frequency, or other attributes. It is converted by the input electronics into a form
appropriate for efficiently driving a variable-speed motor. The motor spins the
flywheel, which stores energy mechanically, slowing down as it delivers energy
to a load. That decrease in mechanical energy is converted into electrical form
by the generator. A challenge facing the motor and the generator designer is to
size the system for the amount of storage (energy) and delivery rate (power)
required and also to minimize losses. The output electronics convert the
variable-frequency output from the generator into the electric power required by
the load. Since the input and output are typically separated in a timely manner,

2
many approaches combine the motor and generator into a single machine, and
place the input and output electronics into a single module, to reduce weight and
cost. Modern high-speed flywheels differ from their forebears in being lighter
and spinning much faster. Since the energy stored in a flywheel increases only
linearly with its moment of inertia but goes up as the square of its rotational
speed, the tradeoff is a good one. But it do raise two issues: flywheel strength
and losses caused due to air friction. To keep from flying apart, modern
flywheels are complex structures based on extremely strong materials like
carbon fibers.

1.2 Flywheel Origins:

The origins and use of flywheel technology for mechanical energy
storage began several hundred years ago and developed throughout the
Industrial Revolution. One of the first modern dissertations on the theoretical
stress limitations of rotational disks is the work by Dr.A.Stodola, whose first
translation to English was made in 1917. Development of advanced flywheel
begins in the 1970s.
1.3 Comparison among Alternative Forms of Energy Storage
Chemical batteries are widely used in many applications currently. But
there are a number of drawbacks of chemical batteries.

1. Narrow operational temperature range. The performance of the chemical

battery will be deteriorated sharply at high or low temperature.
2. Capacity decreases over life. The capacity of the chemical battery cannot be
maintained in a high level all through its life, the capacity will decrease with
time goes on.
3. Difficulty in obtaining charge status. It is not so easy to know the degree of
the charge of the chemical battery because the chemical reaction in the battery is
very hard to measure and control.

3
4. Overcharge and over-discharge. Chemical battery can neither be over-
discharged nor be over-charged, or its life will be shorted sharply.
5. Environmental concerns. Many elements of the chemical battery are
poisonous, they will do harm to the environment and the people. Obviously, the
presence of the shortcomings of the chemical batteries makes them notxiii so-
appealing to the users nowadays. Instead, flywheel energy storage system
become potential alternative form of energy storage.

This is a mechanical device which uses the flywheel to store energy in the
form of inertia. Let us explain all the system. In this system we apply extra
energy source to start the main motor like electricity or by applying the
mechanical energy. In this system a main motor is used to drive a series of
pulley and belt arrangement which forms a chain sprocket train arrangement
which produce a twice/ thrice speed at the shaft of generator. The intriguing
thing about this system is that grater electrical can be drawn from the output
generator than appears to be drawn from the input drive to the motor. The
inertia of flywheel can be increase by increasing the radius of flywheel, weight
of flywheel. It also increase if the flywheel weight is concentrated as far out
toward the rim of the flywheel as is possible. Firstly the requirement for an
effective system needs to be a suitable flywheel with as large a diameter as is
practical, and vast majority of the weight needs to be close to rim. The
construction needs to be robust and secure as ideally, the rate of rotation will be
high as possible, and of course, the wheel needs to be exactly at right angles to
the axle on which it rotates and exactly centred on the axle. The main motor is
low speed and low voltage input motor
and the generator is high speed and high voltage output generator. So when we
apply an extra energy to the main motor it start running, which causes to rotate
the flywheel. When the motor is reaches the highest speed (constant speed) we
switch the power by applying the electrical energy generated by the generator.

4
We add the extra thing in the system like transformers, inverter, any extra
needed circuits etc. to run the system and take the efficienciable output.
ENGINE COMPONENTS:

CONNECTING ROD

The connecting rods are forged steel rods that connect the piston to the
crankshaft. They transfer the force from the piston to the crankshaft. Each
connecting rod is connected to a piston by a piston pin. The rod is attached to
the crank shaft by a bearing cap and bearing inserts that surround the crankshaft
journal. The piston pin and crankshaft bearings allow the rod to move in relation
to both the piston and crankshaft.

4.5 PISTON

It is made of a very strong Neodymium magnet or other magnet. Pistons

transfer the force of expanding combustion gases to the connecting rods. They
are made of aluminium to reduce weight. Most automotive pistons have two
compression rings and one oil ring, Compression rings seal in the pressure
created during the compression and power strokes.

5
LITERATURE REVIEW

6
 CHAPTER 2
LITERATURE SURVEY

K. Ghedamsi- “The flywheel energy storage systems (FESSs) are suitable for
improving the quality of the electric power delivered by electric motor.
Jamie Patterson, 2004, “The broad goal of this project was the development and
demonstration of a complete prototype Flywheel Power System (FPS) and
successful proof of the feasibility of this energy storage technology. The next
step in development will be final system modifications for the transition from
laboratory to field testing, and interface engineering for a field experiment.”
Michael Mathew, 2009, “Flywheels serve as kinetic energy storage and retrieval
devices with the ability to deliver high output power at high rotational speeds as
being one of the emerging energy storage technologies available today in
various stages of development, especially in advanced technological areas, i.e.,
spacecraft’s. Today, most of the research efforts are being spent on improving
energy storage capability of flywheels to deliver high power at transfer times,
lasting longer than conventional battery powered technologies. Mainly, the
performance of a flywheel can be attributed to three factors, i.e., material
Strength, geometry (cross-section) and rotational speed. While material Strength
directly determines kinetic energy level that could be produced safely
Combined (coupled) with rotor speed, this study solely focuses on exploring the
effects of flywheel geometry on its energy storage/deliver capability per unit
mass, further defined as Specific Energy”. Federal energy management
program, “Flywheels have been around for thousands of years. The earliest
application is likely the potter’s wheel. Perhaps the most common application in
more recent times has been in internal combustion engines. A flywheel
is a simple form of mechanical (kinetic) energy storage. Energy is stored by
causing a disk or rotor to spin on its axis. Stored energy is proportional to the

7
flywheel’s mass and the square of its rotational speed. Advances in power
electronics, magnetic bearings, and flywheel materials coupled with innovative
integration of components have resulted in direct current (DC) flywheel energy
storage systems that can be used as a substitute or supplement to batteries in
uninterruptible power supply (UPS) systems. Although generally more
expensive than batteries in terms of first cost, the longer life, simpler
maintenance, and smaller footprint of the flywheel systems makes them
attractive battery alternatives”. Rickard Östergård, “The main conclusion of the
literature review was that FESS is a promising energy storage solution; up to
multiple megawatt scale. However, few large-scale installations have so far
been built and FESS is not a mature technology. Therefore further research and
development is needed in multiple areas, including high strength composite
materials, magnetic bearings and electrical machines. The model was
implemented with the necessary control system and tested in a simulation case
showing the operational characteristics”. R. Hebner, 2014,” A FESS stores
energy in the form of kinetic energy of a spinning mass. Energy transformations
from electrical into mechanical and back are carried out by an electrical
motor/generator. Potentially, a FESS can offer an Essentially unlimited number
of charge/discharge cycles. Furthermore, if magnetic bearings and a brushless
motors/generator are used, the rotor can be suspended without any mechanical
contact. This allows very high rotational speeds and energy densities without
affecting the system life.” Seong-yeol Yoo,2009,” Flywheel energy storage
systems (FESS) store electric energy in terms of the kinetic energy of a rotating
flywheel, and convert this kinetic energy into electric energy when necessary. A
FESS is a viable technology for energy storage because it is environmentally
safe, can sustain infinite charge/discharge cycles, and has higher power-to-
weight ratio than chemical batteries”

8
COMPONENT USED

9
 CHAPTER 3
COMPONENT USED

 FLY WHEEL

 GENERATOR

 CHAIN

 SPROCKET

 LED

10
 CHAPTER 4
COMPONENTS USED

4.1 Fly Wheel:

A flywheel is a rotating mechanical device that is used to store rotational

energy. Flywheels have an inertia called the moment of inertia and thus resist
changes in rotational speed. The amount of energy stored in a flywheel is
proportional to the square of its rotational speed. Energy is transferred to a
flywheel by the application of a torque to it, thereby increasing its rotational
speed, and hence its stored energy. Conversely, a flywheel releases stored
energy by applying torque to a mechanical load, thereby decreasing the
flywheel's rotational speed.
Common uses of a flywheel include:
 Providing continuous energy when the energy source is discontinuous.
For example, flywheels are used in reciprocating engines because the
energy source, torque from the engine, is intermittent.
 Delivering energy at rates beyond the ability of a continuous energy
source. This is achieved by collecting energy in the flywheel over time
and then releasing the energy quickly, at rates that exceed the abilities of
the energy source.
 Controlling the orientation of a mechanical system. In such applications,
the angular momentum of a flywheel is purposely transferred as a torque
to the attaching mechanical system when energy is transferred to or from
the flywheel, thereby causing the attaching system to rotate into some
desired position.
Flywheels are typically made of steel and rotate on conventional bearings; these
are generally limited to a revolution rate of a few thousand RPM. Some modern

11
flywheels are made of carbon fiber materials and employ magnetic bearings,
enabling them to revolve at speeds up to 60,000 RPM (1 kHz).
Carbon-composite flywheel batteries have recently been manufactured
and are proving to be viable in real-world tests on mainstream cars.
Additionally, their disposal is more eco-friendly.

Fig: 4.1 Flywheels

4.2 CHAIN AND SPROCKETS

4.2.1 CHAIN DRIVES

Three major types of chain are used for power transmission: roller,
engineering steel, and silent. Roller chains are probably the most common and
are used in a wide variety of low-speed to high-speed drives. Engineering steel
chains are used in many low-speeds, high-load drives. Silent chains are mostly
used in high-speed drives. Other types of standard chains, and many types of
special chains for unique applications, may be found in manufacturers’ catalogs.
Chains can span long center distances like belts, and positively transmit speed
and torque like chain sprockets. For a given ratio and power capacity, chain
drives are more compact than belt drives, but less compact than chain sprocket
drives. Mounting and alignment of chain drives does not need to be as precise
12
as for chain sprocket drives. Chain drives can operate at 98 to 99 percent
efficiency under ideal conditions. Chain drives are usually less expensive than
chain sprocket drives and quite competitive with belt drives. Chain drives can
be dangerous. Provide proper guarding to prevent personnel from coming in
contact with, or being caught in, a running drive. Any chain can break from
unexpected operating conditions. If a chain breaks at speed, it can be thrown off
the drive with great force and cause personal injury and property damage.
Provide adequate guarding to contain a broken chain or to prevent personnel
from entering an area where they might be struck by a broken chain. A broken
chain can sometimes release a load and cause personal injury and property
damage. Provide an adequate brake or restraint to stop and hold the load in case
of a chain breakage.

4.2.2 ROLLER CHAINS STANDARD ROLLER CHAINS

A portion of a typical roller-chain drive is shown in Fig. 15.1. The

American National Standards Institute (ANSI) has standardized limiting
dimensions, tolerances, and minimum ultimate tensile strength for chains and
sprockets of 0.25 to 3.0 in pitch [15.1]. The chain pitch is the distance between
successive roller, or bushing, centers, and is the basic dimension for designating
roller chains. The standard includes both standard and heavy series chains.
Multiple-Strand Roller Chains. Multiple-strand roller chains consist of two or
more parallel strands of chain assembled on common pins. They also are
standardized. Double-Pitch Roller Chains. Double-pitch roller chains are
standardized in Ref. Double-pitch chains have the same pin, bushing, and roller
dimensions as cor- responding chains but the pitch of the link plates is twice as
long. The standard covers chains of 1.0 to 4.0 in pitch.

13
 Fig 4.2: Typical Roller Chain on Sprocket

4.2.3 NONSTANDARD ROLLER CHAINS

Many manufacturers offer high-strength, extra clearance, sintered metal
bushing, sealed-joint, and corrosion-resistant chains for special applications or
adverse environments. These chains are not covered by any standard, but most
are designed to run on standard sprockets.

4.2.4 SPROCKETS

Roller-chain sprockets have precisely designed, radiuses pockets which

smoothly engage the rollers on the chain and positively transmit torque and
motion. Driver sprockets receive power from the prime mover and transfer it to
the chain. Driven sprockets take power from the chain and transfer it to the
selected machinery. Idler sprockets transmit no power; they are used to take up
slack chain, increase the amount of chain wrap on another sprocket, guide the
chain around other machine members, and reverse the normal direction of
rotation of another sprocket.

14
Engineering Steel Chains Standard Engineering Steel Chains.

The engineering steel chains designated for power transmission are

heavy-duty offset sidebar chains. Limiting dimensions, tolerances, and
minimum ultimate tensile strength for chains and sprockets of 2.5 to 7.0 in pitch
are standardized in Nonstandard Chains. Some manufacturers offer engineering
steel chains in straight-sidebar and multiple-strand versions, and in pitches that
are not included. Although these chains are not standardized, they are listed in
manufacturers’ catalogs because they are used extensively in special
applications.

Machine-cut engineering-steel-chain sprockets look much like roller chain

sprockets, but they have pitch line clearance and undercut bottom diameters to
accommodate the dirt and debris in which engineering-class chain drives often
operate.

4.3 FRAME

15
 Fig 4.3: Frame

Steel framing is a practical, code approved solution to many of the

limitations that builders face today when using traditional building
materials. The strength and ductility of structural cold-formed steel (CFS)
framing, along with the holding power of CFS connections, make it the ideal
material for construction in high wind speed and seismic zones such as the
U. S. eastern seaboard, the Gulf Coast states, California and Hawaii.
Characteristics such as non-combustibility, termite resistance, and
dimensional stability can lower construction and home ownership costs.

CFS can provide the framework for a solid sustainable building

program. Each piece of CFS shipped to the jobsite contains a minimum of
25% recycled content and is 100% recyclable at the end of its lifespan. And
a recent study, conducted by the NAHB Research Center, showed that the
zinc coating on steel framing materials can protect against corrosion for
hundreds of years. For these reasons, and many others, the use of steel
framing continues to grow every year with more than 40% of commercial
structures now using steel framing and with nearly 500,000 homes built
with steel framing over the past decade. This Builder’s Guide answers the
most commonly asked questions regarding CFS and describes the
fundamental process for converting to steel framing. In addition, this
document provides a guide to where more detailed knowledge or resources
are available

16
 Fig 4.4: Structure

Cold-formed steel framing is sheet steel that is formed into shapes

and sizes that are similar to what builders are accustomed to seeing in
dimensional lumber (2x4, 2x6, 2x8, 2x10, 2x12, and so forth). Steel framing
members are formed in a process called roll forming by passing sheet steel
through a series of rollers to form the bends that make the shape, e.g. the
web, flanges, and lips of a stud or C-shape. Because this process is done
without heat (also called “cold forming”) the studs and joists are made
stronger than the original sheet steel.

4.4 LED (Light Emitting Diode)

17
 “LED” redirects here. For other uses, see LED (disambiguation). A
light-emitting diode (LED) is a two-lead semiconductor light source. It is a p–n
junction diode, which emits light when activated. When a suitable voltage is
applied to the leads, electrons are able to recombine with electron holes within
the device, releasing energy in the form of photons.

In modern era we are highly familiar with the term LED. It stands
for light emitting diode. These are mainly used for making indicators and
various other types of lightning. In 1962 first this type of light appeared to the
market. Which are the low intensity red light, now the modern versions of this
type of lights are visible, ultraviolet, inferred etc. In LED electrical energy is
converter in to optical energy. These are example of electro-luminescence, the
process in which emission of photos takes place by the recombination of excess
electrons and holes in a direct band gap semiconductor. The main advantages of
using these are the low energy consumption, longer lifetime, strong build,
smaller size etc. Fig 3.3 and 3.4 shows the basic diagram of a Light Emitting
Diode and its symbol.

Fig 4.5: Different Parts of a Light Emitting Diode

18
 Fig 4.6: Light Emitting Diode and its Circuit Symbol

4.4.1 Working of LED or Light Emitting Diode

Fig 4.7: Schematic Diagram of Working of Light Emitting Diode

19
 The schematic diagram of Working of Light Emitting Diode. In
LED’s the electrical energy is converted in to optical energy. The main
mechanism of working is injection electro luminescence. In injection electro
luminescence, the carriers are injected across a p-n junction. Now the
recombination of excess electrons and the holes can result photon emission if
the semiconductor used, is a direct band gap semiconductor. In direct band gap
semiconductor, transition between the two allowed bands can take place with no
change in crystal momentum.

When across the p-n junction, a voltage is applied then electrons and
the holes are injected across the depletion region and they become excess
minority carriers. These recombine with majority carriers when these minority
carriers diffuse this in to neutral semiconductor region. This recombination
process in direct band gap material results the emission of photons. The output
photon intensity is directly proportional to the ideal diode diffusion current
which is proportional to the recombination rate.

4.5 Generator:

D.C GENERATOR:

An electric generator is a device used to convert mechanical energy into

electrical energy. The generator is based on the principle of electromagnetic
induction discovered in 1831 by Michael Faraday. Faraday discovered that if an
electric conductor, like a copper wire, is moved through a magnetic field,
electric current will flow in the conductor.

So the mechanical energy of the moving wire is converted into the

electric energy of the current that flows in the wire. To change the Simple
Generator into a direct-current generator, the following work should be done,

1. The current must be made to move in only one direction.

20
 2. The current must be conducted from the rotating loop of wire

4.5.1 Generator Components

A DC generator consist of the following components

Rotor:

In its simplest form, the rotor consists of a single loop of wire made to
rotate within a magnetic field. In practice, the rotor usually consists of several
coils of wire wound on an armature.

Armature:

The armature is a cylinder of laminated iron mounted on an axle. The

axle is carried in bearings mounted in the external structure of the generator.
Torque is applied to the axle to make the rotor spin.

Coil:

Each coil usually consists of many turns of copper wire wound on the
armature. The two ends of each coil are connected either to two slip rings (AC)
or two opposite bars of a split-ring commutator (DC).

Stator:

The stator is the fixed part of the generator that supplies the magnetic
field in which the coils rotate. It may consist of two permanent magnets with
opposite poles facing and shaped to fit around the rotor. Alternatively, the
magnetic field may be provided by two electromagnets.

4.2.2 Dc Generators Working:

The commutator rotates with the loop of wire just as the slip rings do with
the rotor of an AC generator. Each half of the commutator ring is called a
commutator segment and is insulated from the other half. Each end of the

21
rotating loop of wire is connected to a commutator segment. Two carbon
brushes connected to the outside circuit rest against the rotating commutator.

One brush conducts the current out of the generator, and the other brush
feeds it in. The commutator is designed so that, no matter how the current in the
loop alternates, the commutator segment containing the outward-going current
is always against the "out" brush at the proper time. The armature in a large DC
generator has many coils of wire and commutator segments.

Because of the commutator, engineers have found it necessary to have the

armature serve as the rotor (the rotating part of an apparatus) and the field
structure as the stator (a stationary portion enclosing rotating parts), which is the
inverse of an AC Generator.

Fig: No: 4.8 Dc Generators

4.5.3 Types of Dc Generators:

In some DC generators, the direct current needed for the electromagnets

that make up the field structure comes from an outside source, just as it does in
most AC generators. These DC generators are called separately excited
generators. Many other DC generators use part of the direct current they
produce to operate their own electromagnets. These generators are called self-
excited generators.

22
 A self-excited DC generator depends on residual magnetism--that is, a
small amount of magnetism remains in the electromagnets after the generator is
shut off. Without this residual magnetism, it would be impossible to start a self-
excited generator once it had stopped.

The direct current needed for a self-excited generator's electromagnets

can be drawn from its armature by means of three different connections: Shunt,
Series and Compound, a combination of shunt and series connections.

The type of generator used for a certain task depends on the amount of
voltage control required. For example, a DC generator used to charge a battery
needs only simple voltage control. It might be a shunt generator.

A DC generator that supplies electricity for a passenger elevator needs

more complicated voltage control. It would be a separately excited generator.

4.5.4 Uses of DC Generators:

Many DC generators are driven by AC motors in combinations called

motor-generator sets. This is one way of changing alternating current to direct
current. Factories that do electroplating and those that produce aluminum,
chlorine, and some other industrial materials need large amounts of direct
current and use DC generators. So do locomotives and ships driven by diesel-
electric motors.

Because commutators are complex and costly, many DC generators are

being replaced by AC generators combined with electronic rectifiers. Rectifiers
are devices that let current flow in one direction only. They permit use of
simpler, more rugged AC generators, even when DC is required.

23
4.5.5 The Loop Stitch

The loop stitch approach is very different from ordinary hand-

sewing. In the simplest hand stitch, a length of thread is tied to a small eye at
the end of a needle. The sewer passes the needle and the attached thread all the
way through two pieces of fabric, from one side to the other and back again. In
this way, the needle runs the thread in and out of the fabric pieces, binding them
together.

While this is easy enough to do by hand, it is extremely difficult to

pull off with a machine. The machine would have to release the needle on one
side of the fabric just as it grabbed it again on the other side. Then it would have
to pull the entire length of loose thread through the fabric, turn the needle
around and do the whole thing in reverse. This process is way too complicated
and unwieldy for a simple machine, and even by hand it only works well with
short lengths of thread. Instead, sewing machines pass the needle only part-way
through the fabric. On a machine needle, the eye is right behind the sharp
point, rather than at the end.

The needle is fastened to the needle bar, which is driven up and

down by the motor via a series of chain sprockets and cams (more on this
later).When the point passes through the fabric, it pulls a small loop of thread
from one side to the other. A mechanism underneath the fabric grabs this loop
and wraps it around either another piece of thread or another loop in the same
piece of thread.

24
WORKING PRINCIPLE

25
 CHAPTER 5
WORKING PRINCIPLE

Fig 5.1: Construction of Flywheel Power Generation

WORKING PRINCIPLE

 This project use to create the power generated in fly wheel rotation.
 Here fly wheel attached in chain sprocket so fly wheel rotational force
transfer to the chain sprocket.
 Chain sprocket and fly wheel connecting with shaft and bearing, it can
easy to transmitted the power.
 Fly wheel have some wait part attached in the head and bottom side
because it can get a extra rotation of gravity force.
 We are rotating the handle, its case chain sprocket rotated, here chain
sprocket and fly wheel inter connected so fly wheel also rotate.
 Fly wheel rotation transfer to the chain sprocket, chain sprocket attached
in another chain sprocket with chain drive.
 This chain sprocket attached to the generator its use to convert the
mechanical energy to electrical energy, finally electrical energy stored in
the battery.
26
ADVANTAGES & APPLICATIONS

27
 CHAPTER 6
ADVANTAGES & APPLICATIONS

ADVANTAGES

 Easy method
 Maintain easy
 Less cost
 High efficiency

APPLICATIONS

 Transportation

28
CONCLUSION

29
 CHAPTER 7
CONCLUSION

Therefore, the result obtain from the project is use to create the
electricity and efficiency over the other system. The necessary requirements
and fulfilment of the project details which we have given is factual.

This report details with design of fly wheel power generation method
with suitable drawing. The project carried out by us made an impressing task.
The operation is Simple in construction where as additional accessories are not
needed. It is comparatively cheaper in cost than the other systems. The system
becomes as a Quick response and then Continuous power production use fly
wheel operation is possible without stopping.

30
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