A PROJECT REPORT

ON

“POWER GENERATOR FOREARMS MACHINE”

In Partial Fulfillment of the Requirement for the Degree of

Bachelor of Technology

In

MECHANICAL ENGINEERING

Submitted By

AMIT KUMAR (1552140005) ZISHAN (1552140063)

SARAL KUMAR(1552140040) AVDHESH KUMAR (1552140009)

WASEEM (1552140060)

Project Guide Project Incharge

Mr. Deepak Chauhan Mr. J.K. Sagar

1
DEPARTMENT OF MECHANICAL ENGINEERING

KOTHIWAL INSTITUTE OF TECHNOLOGY &

PROFESSIONAL STUDIES

Pachokara, Moradabad - 244001 (U.P.)

2
 KOTHIWAL INSTITUTE OF TECHNOLOGY &

PROFESSIONAL STUDIES

CERTIFICATE

This is to certify that the Project Report entitled “POWER GENERATOR

FOREARMS MACHINE” is a bonafied report of the work carried out by AMIT
KUMAR (1552140005), SARAL KUMAR (1552140040), WASEEM
(1552140060), ZISHAN (1552140063), AVDHESH KUMAR (1552140009) under
the guidance & supervision of Mr. Deepak Chauhan Sir for the award of the degree
of BACHELOR OF TECHNOLOGY in MECHANICAL ENGINEERING at
Kothiwal Institute of Technology & Professional Studies, Moradabad, Utter Pradesh.

To the best of my knowledge & belief, this work embodies the work of candidate
themselves, has duly been completed. Fulfill the requirement of the ordinance relating
to the Bachelor Degree of the university & is up to date the standard in respect of
content, presentation & language for being reffered to the examinar.

Project Guide

Mr. Deepak Chauhan

3
 DECLARATION

We hereby declare that this submission is my own work and that, to the best of
my knowledge and belief, it contains no material previously published or written by
another person nor material which to a substantial extent has been accepted for the
award of any other degree or diploma of the university or other institute of higher
learning, except where due acknowledgement has been made in the text.

AMIT KUMAR (1552140005)

SARAL KUMAR (1552140040)

WASEEM (1552140060)

ZISHAN (1552140063)

AVDHESH KUMAR (1552140009)

4
 ACKNOWLEDGEMENT

We would like to thank respected sir Mr. Deepak Chauhan and Mr. Jyoti
Sagar sir HOD of MECHANICAL DEPARTMENT for giving us such a wonderful
opportunity to expand our knowledge for our own branch and giving us guidelines to
present a project report. It helped us a lot to relize of what we studyfor.

Secondly, We would thank Microsoft for developing such a wonderful tool like
MS Word . It helped our work a lot to remain error free.

Last but clearly not the least, We would thank The Almightly for giving us
strength to complete our project report on time.

AMITKUMAR (1552140005)

SARAL KUMAR (1552140040)

WASEEM (1552140060)

ZISHAN (1552140063)

AVDHESH KUMAR (1552140009)

5
 ABSTRACT

Man has needed and used energy at an increasing rate for his sustenance and well
being ever since he came on earth for few million year ago. Due to this lot of energy
resources have been exhausted and wasted. Proposal for the utilization of waste
energy of power generation by gym pulley is very much relevant and important for
highly populated countries like India and china the people are crazy about gym. In
this project we are generating electrical power as non conventional method by simply
pull up and pull down. Non conventional energy system is very essential at this time
to our nation. Non conventional energy using pull up pull down is converting
mechanical energy into electrical energy. In this project the conversion of force
energy into electrical energy. The use of human-power in more efficient manner for
generation has been possible due to modern technology. Pull up pull down power is
an excellent source of energy, 95 percentage of the exertion put into pull up pull down
power converted into energy. A human-powered electricity generation has been
unveiled by company. In this apparatus, the user has to pull up pull down the gym
equipments for generating power. Another one is a foot- powered device that allows
individuals to pump out power at a 40-watt clip to charge its own internal battery.
Then this battery can be used for powering ac and dc devices, car batteries etc.

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 CONTENTS

Table of content………………………………………………………..07

List of figures………………..…………………...……………………08

1. Introduction…………………….…………………………………..09

2. Gear type………...…………………………………………………11

3. Cast iron gear……………………………………………...……….25

4. Dynamo……………………………………………………...……..26

5. Capacitors……………………………..……………………………32

6. Resistance……………………………………………….………….33

7. Gear ratio work…………………………………………….……….35

8. Dc motor drive……………………………………………….……..37

9. Advantages…………………………………………………………38

10. Application……………………………………………….……….38

11. Conclution……………………………………………….………..38

12. References…………………………………………….…………..39

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 TABLE OF CONTENTS

1. Gear type……………………………………………………….11

2. Colour rings of resistance value………………………………..33

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 LIST OF FIGURE
1. Fig.1………………………………………..….13

2. Fig. 2……………………………………….….14

3. Fig. 3 to 4………………………………..…….15

4. Fig. 5…………………………………………..16

5. Fig. 6 to 7………………………………..…….18

6. Fig. 8 to 9……………………………….……..19

7. Fig. 10…………………………………...…….21

8. Fig. 11…………………………………………22

9. Fig. 12…………………………………...…….23

10. Fig. 13……………………………………..…25

11. Fig. 14………………………………..………26

12. Fig. 15………………………………..………28

13. Fig. 16………………………………..………29

14. Fig. 17……………………………….……….30

15. Fig. 18……………………………….……….32

16. Fig. 19………………………………..………34

17. Fig. 20………………………………………..35

18. Fig. 21………………………………………..36

19. Fig. 22………………………………………..37

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 INTRODUCTION

Pull up pull down power is the transfer of energy from a human source through
the use of rack an pinion system. This technology is most commonly used for gym
centre or house .less commonly gym power is used to power agricultural and hand
tools and even to generate electricity. Some application include battery charge home
appliance. Whenever the person is allowed to pass over the gym pull up pull down.
As the spring are attached to gym equipments, they get compressed and the rack,
which is attached to, the bottom of the rod moves down reciprocating motion of rack
in to rotary with certain RPM these shafts are connected through a chain drive to the
dynamos, which converts the mechanical energy into electrical energy. Now we made
a rotation of the wheel in one direction by supplying power to shaft, while other made
to rotate freely on the shaft, as the free wheel is inserted in the gears.

RACK

Material- Mild steel Function- To change the translator motion in to rotary

motion Properties- strength, Rigidity, Resistance to shock loads, less wear tear

MANUFACTURING PROCESS

Required square rod is cut from the bar fit in the vice of milling machine id to cut
on teeth according to dimensions of the drawing. Gears at infinite no.of. Teeth are
called RACK. With the help of rack and pinion, we can convert reciprocating motion
inn to rotary motion and vice versa.

SPUR GEAR

In precision machine, in which a definite velocity ratio is of importance, the only

positive drive is by gears or toothed wheels. A gear drive is also provided, when the
distance between the driver and follower is very small.

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CLASSIFICATION OF GEARS

1. According to the position of axis of shaft.

a) Parallel

b) Intersecting

c) Non-intersecting

2. According to peripheral velocity of gears.

a) Low velocity

b) Medium velocity

c) High velocity

3. According to type of gearing.

a) External gearing

b) Internal gearing

c) Rack and Pinion

4. According to position of teeth.

a) Straight

b) Inclined

c) curved

SPRINGS

A spring is defined as an elastic body whose function is to distort when loaded and to
recover its original shape when the load is removed.

ELECTRIC DYNAMO

It is well known that whenever electric current flow through the conductor a magnetic
flux is immediately brought to existence in the space surrounding the conductor. We
say that when the electrons are under motion they produce magnetic field. The

11
converse is also true, i.e., when magnetic field embracing a conductor moves relative
to the conductor, it produces a flow of electrons.

12
 Gears Types

Gears are categorized into several types. They are used in a

wide era of industries including automotive, milling, paper
industry etc. According to different applications in industries
and different materials used they are categorized separately.
Different types of gears are also custom design and are
fabricated by gear manufacturing services as par the
specifications.

Gears Types

 Spiral Bevel
 Angular Bevel Gears
Gears
 Bevel Gears
 Spur Gears
 Crown Wheel
 Straight
 Crown Wheel and
Bevel Gears
Pinion
 Support
 Differential Gears
Rollers
 Fine Pitch Gears
 Tacho
 Girth Gears
Drives
 Hardened and Ground
 Thrust
Gears
Rollers
 Helical Bevel Gears
 Idler Gear
 Helical Gears
 Gear Trains
 Herringbone Gears
 Planetary
 Master Gear
Gear
 Mill Headers
 Ground
 Miter Gears
Gear
 Non-Involute Gears
 Face Gear
 Pinion Gears
 Internal
 Rack Gears
Gears

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  Ring Gear and Pinion  Cycloidal
Gears
 External
Gear
 Winch
Gears
 Sprockets
 Worm
Gears
 Involute
Gears

Non-Intersecting
Intersectin Rotary to
Parallel Axes (Non-parallel)
g Axes Translation
Axes

Rack and
Spur Gears Bevel gears Hypoid gears
Pinion

Straight Crossed helical

Helical Gears -
bevel gears

Herring bone
or double Zerol bevel Worm gears -
helical gears

- Spiral bevel - -

Table 1 - Gear type

Angular Bevel Gears

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 These are bevel gears whose shafts are set at an angle other than 90 degrees. They
are useful when the direction of a shaft's rotation needs to be changed. Using gears of
differing numbers of teeth can change the speed of rotation.

Fig 1 : Angular Bevel Gear

These gears permit minor adjustment of gears during assembly and allow for
some displacement due to deflection under operating loads without concentrating the
load on the end of the tooth. For reliable performance, Gears must be pinned to shaft
with a dowel or taper pin.

The bevel gears find its application in locomotives, marine applications,

automobiles, printing presses, cooling towers, power plants, steel plants, defence and
also in railway track inspection machine. They are important components on all
current rotorcraft drive system.

Bevel Gears

They connect intersecting axes and come in several types. The pitch surface of
bevel gears is a cone. They are useful when the direction of a shaft's rotation needs to
be changed. Using gears of differing numbers of teeth can change the speed of

15
rotation. They are usually mounted on shafts that are 90 degrees apart, but can be
designed to work at other angles as well.

Fig 2 : Bevel Gear

These gears permit minor adjustment during assembly and allow for some
displacement due to deflection under operating loads without concentrating the load
on the end of the tooth. For reliable performance, Gears must be pinned to shaft with a
dowel or taper pin. Bevel gear sets consist of two gears of different pitch diameter that
yield ratios greater than 1:1.

Applications
A good example of bevel gears is seen as the main mechanism for a hand drill. As
the handle of the drill is turned in a vertical direction, the bevel gears change the
rotation of the chuck to a horizontal rotation. The bevel gears in a hand drill have the
added advantage of increasing the speed of rotation of the chuck and this makes it
possible to drill a range of materials.

The bevel gears find its application in locomotives, marine applications,

16
automobiles, printing presses, cooling towers, power plants, steel plants, defence and
also in railway track inspection machine. They are important components on all
current rotorcraft drive system.

Spiral bevel gears are important components on all current rotorcraft drive
systems. These components are required to operate at high speeds, high loads, and for
an extremely large number of load cycles. In this application, spiral bevel gears are
used to redirect the shaft from the horizontal gas turbine engine to the vertical rotor.

Crown Wheel

A crown wheel is a wheel with cogs or teeth set at right angles to its plane. The
internal diameter of a crown wheel is ground by holding the component in pitch like
chucks to ensure accuracy of the finished gear

Fig 3 : Crown Wheel

As a result of the development of "flat" crown wheels it has become possible to

construct a special gearbox. IHC has used these new gearwheels to produce a
prototype of a continuously variable speed gearbox.
Applications
Crown wheels are used in motorcycle automotive gearboxes. It is also used in
mechanical clocks. The clock consists of a crown wheel, rotated by a falling weight,
whose teeth drive the pallets of a verge backward and forward. This verge is
connected to an arm with a hammer on the end that struck the bell.

Crown Wheel and Pinion

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 A crown wheel is a wheel with cogs or teeth set at right angles to its plane and the
pinion is a small cogwheel that meshes with the crown wheel. Crown wheel and
pinion have excellent heat distortion control, high strength, wear resistance property
and noiseless and vibration free operation. They are made of fine-grained steel billet.

Fig 4 : Crown Wheel and Pinion

The pinion thread is specially made on the thread grinder to ensure proper fitting.
Tooth contact of a crown pinion is inspected on a Gleason machine at regular
intervals of time for uniform hardness and adequate case depth. They are checked
thoroughly for high spots because this ensures premature failure and noise-free
operation. The crown wheel & pinion are paired and checked for centralized tooth
bearing and desired proximity. An elliptoid contact pattern is ensured between the
crown wheel and pinion.

In a machine, when any torque is applied to the drive unit, the tendency is for the
crown wheel and pinion to be forced into or out of mesh by the sliding contact. The
amount of pre-load on the bearings determines how much torque can be transmitted
without allowing end float, which cause the meshing of the gears to become incorrect.

Application
Crown wheel & pinion are used widely in automotive industries. They are one of
the most stress prone parts of a vehicle. They are used in automobiles to maintain
forward motion. To maintain forward motion both output drive shaft sides covers are
removed and the pinion and crown wheel are swapped completely with differential.

18
Helical Gears

Helical gears connect parallel shifts but the involute teeth are cut at an angle to
the axis of rotation. Two mating helical gears must have equal helix angle but
opposite hand. They run smoother and more quietly. They have higher load capacity,
are more expensive to manufacture and create axial thrust.

Fig 5 : Helical Gear

Helical gears can be used to mesh two shafts that are not parallel and can also be
used in a crossed gear mesh connecting two perpendicular shafts. They have longer
and strong teeth. They can carry heavy load because of the greater surface contact
with the teeth. The efficiency is also reduced because of longer surface contact. The
gearing is quieter with less vibration.

Gear Configuration
They can be manufactured in both right-handed and left-handed configurations
with a helix angle to transmit motion and power between non-intersecting shafts that
are parallel or at 90 degrees to each other. For shaft at 90 degrees, the same helix
angles are used and the tooth contact area of the gear is very small. If the angle of
gear teeth is correct, they can be mounted on perpendicular shaft by adjusting the
rotating angle by 90 degrees. The inclination of the teeth generates an axial force. As
the angle of inclination increases the axial force also increases. Thrust bearings can
counter these forces.

Applications
These are highly used in transmission because they are quieter even at higher

19
speed and are durable. The other possible applications of helical gears are in textile
industry, blowers, feeders, rubber and plastic industry, sand mullers, screen, sugar
industry, rolling mills, food industry, elevators, conveyors, cutters, clay working
machinery, compressors, cane knives and in oil industry.

Disadvantage
A disadvantage of helical gear is the resultant thrust along the axis of the gear,
which needs to be accomodated by appropriate thrust bearings. This can be overcome
by the use of double helical gears by having teeth with a 'v' shape.

Master Gear

They offer high precision, low volume productions. They are used for composite
testing of production components. They have high speed, quiet operation, longer life
and greater efficiency.

Fig 6 : Master Gear

The most common applications are as setting masters and rolling masters for
inspection and production applications. They are used to determine the accuracy of
work gears. When master gears and work gears are rolled together on rolling fixtures
dimensional variations are determined by various indicators, charts or other indicating
devices. Master Gears are also used in aerospace and automotive industry.

PinionGears

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 It is a small cogwheel. The teeth fit into a larger gear wheel. Rotational motion is
converted into linear motion when the pinion turns and moves the rack. Pinion gears
are engineered to be the best gears.

Fig 7 : Pinion Gear

Pinion gear system involves the use of a small round gear called pinion and a
large flat gear called rack, more the number of teeth in the pinion gear, more is the
speed of rotation. Pinion with smaller number of teeth produces more torque. Pinion
is attached to the motor shaft with glue. Rotation of pinion is done by rotation of
pinion about a fixed center that helps the rack to move in the straight line. If the rack
is moved and the pinion rotates then the center of the pinion moves taking along the
pinion with it.

Rack Gears

Rack gear is a toothed bar into which a pinion meshes. Racks are gears of infinite
pitch radius. They are used to translate rotary motion to linear motion or vice versa.
They will mesh with pinions of the same pitch.

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 Fig 8 : Rack Gear

Racks are made of various materials. The commonly used materials for racks are
stainless steel, brass, and plastic.
They are widely used in automobiles. The steering wheel of a car rotates the gear
that engages the rack. The rack slides right or left, when the gear turns, depending on
the way we turn the wheel. Windshield wipers in cars are powered by a rack and
pinion mechanism. They are also used in some scales to turn the dial that displays
weight.

Spur Gears

They connect parallel shafts, have involute teeth that are parallel to the shaft and
can have internal or external teeth. They cause no external thrust between gears. They
are inexpensive to manufacture. They give lower but satisfactory performance. They
are used when shaft rotates in the same plane.

Fig 9 : Spur Gear

The main features of spur gears are dedendum, addendum, flank, and fillet.
Dedendum cylinder is a root from where teeth extend, it extends to the tip called the
addendum circle. Flank or the face contacts the meshing gear, the most useful feature
if the spur gears. The fillet in the root region is kinetically irrelevant.

Characteristics

The speed and change of the force depends on the gear ratio, the ratio of number
of teeth on the gears that are to be meshed. One gear among the two is on the input

22
axle, the axle of the motor and the other gear of the pair is on the output axle, the axle
of the wheel.

They have higher contact ratio that makes them smooth and quiet in operation.
They are available for corrosion resistant operation. They are among the most cost-
effective type of gearing. They are also used to create large gear reductions.

Materials
They are available in plastic, non-metallic, brass, steel and cast iron and are
manufactured in a variety of styles. They are made with many different properties.
Factors like design life, power transmission requirements, noise and heat generation,
and presence of corrosive elements contribute to the optimization of the gear material.

Applications
Generally used in simple machines like washing machines, clothes dryer or
power winches. They are not used in automobiles because they produce sound when
the teeth of both the gears collide with each other. It also increases stress on the gear
teeth. They are also used in construction equipment, machine tools, indexing
equipment, multi spindle drives, roller feeds, and conveyors.

Internal Gears

Internal gears have cylindrical pith surface with teeth parallel to the axis. Gears
make an internal contact with these gears. They have the teeth cut on the inside of the
rim rather than the outside. When they are used with the pinion more teeth carry the
load and are evenly distributed. This even distribution decreases the pressure intensity
and increases the life of the gear. The center distance of a given velocity is shorter.

23
 Fig 10 : Internal Gear

Internal gears are hollow. The properties and teeth shape is similar as of external
gears except that the internal gear had different addendum and dedendum values
modified to prevent interference in internal meshes. They are designed to
accommodate a wide range of equipment. These are ideal and cost effective. The teeth
are cut into the inside diameter while the outside diameter is smooth. These gears are
available only in brass. Internal gear offers low sliding and high stress loading. They
are used in planetary gears to produce large reduction ratios.

When choosing a mating gear the difference between the number of teeth of girth
gear and the pinion should not be less than 15. Their non-binding tooth design ensures
smooth, quiet operation. They are used to transmit rotary motion between parallel
shafts, the shaft rotating in the same direction as the arrangement.

The main applications of internal gears are in rollers, indexing, timing and other
light duty applications. They are used as tools for creating solid models of drive
components.

Cycloidal Gears

Cycloidal gears are used in pairs and are set at an angle of 180 degrees used to
balance the load and are driven by multiple crank shafts to share the load and increase
torsion rigidity. The cycloidal gear mesh with a large quantity of precisely ground
steel pins. The combined tooth contact area of the two cycloidal gears and pins
ensures that the load is distributed almost entirely around the pitch circle.

24
 Fig 11 : Cycloidal Gear

With cycloidal gearing the input and output remains in constant mesh. Cycloidal
gearing provides considerable latitude in selection of operating characteristics-
deceleration, dwell periods, ratio of input to output motions etc. In cycloidal gear if
the output crank is to stop then the drive pin must be on the pitch circle of the planet
gear to avoid reversing of the motion.

Gearing Mechanism
Cycloidal gearing requires two different curves to obtain conjugate action. Two
gears are placed on either side of a roller. The roller is rolled along the outer edge of
one of the gear wheels. The curve traced out from this initial point of contact is called
epicycloid. The same roller is then rolled on the inside edge of the other gear wheel
generating another curve called hypocycloid. These two curves will be conjugate to
each other. The smaller roller disk is called the generating circle for the gear set.

For cycloidal gear to be interchangeable, circles of the same size must generate
them. The teeth of a cycloidal rack are cycloid generated by the rolling generating
circle. They are not straight and their shape depends on the radius of the generating
circle.

Worm Gears

A worm gear is an inclined plane wrapped around a central axle. It is a gear with
one or more teeth in the form of screwed threads.

25
 Fig 12 : Worm Gear

Worm gears are made of two parts: the pinion and the worm gear. The pinion has
small number of teeth and they wrap around the pitch cylinder. The worm gear has
concave faces to fit the curvature of the worm in order to provide line of contact
instead of point of contact. They are cut helically for better mating Worm gears can
provide a high angular velocity between non-intersecting shafts at right angles. They
are capable of transmitting high tooth loads, the only disadvantage is the high sliding
velocities across the teeth. They provide ultimate power ratio.

Features
The efficiency of worm gear depends on the lead angle, sliding speed, and
lubricant, surface quality and installation conditions. They offer smoothest, quietest
form of gearing. They provide high-ratio speed reduction in minimal spaces.

Worm gears are used when large gear reductions are required. Worm gear has a
unique property of easily turning the gear. The gear cannot turn the worm because the
angle on the worm is shallow and when the gear tries to spin the worm, the friction
between the two holds the worm in place.

Worm gears work under difficult conditions, presenting unique lubrication

demands. The types of oils most commonly used to lubricate worm gears are
compounded mineral oils, EP mineral gear oils and synthetics. Operation of the Gear
Worm gear is always used as the input gear. For the operation of worm gear, torque is
applied to the input end of the worm shaft by a driven sprocket or electric motor. The
worm and the worm shaft are supported by anti-friction roller bearings. Because of
high friction worm gears are very inefficient. There is lot of friction between a worm

26
gear and the gear being driven by the worm gear. When used in high torque
applications, the friction causes the wear on the gear teeth and erosion of restraining
surface.
Types
There are three types of worm gears:
Non throated- a helical gear with a straight worm. Tooth contact is a single
moving point on the worm drive.
Single throated- has concave helical teeth wrap around the worm. This leads to
line contact.
Double throated- called a cone or hourglass. It has concave teeth both on the
worm and helical gear.
Applications
Worm gears are widely used in packaging machinery, material handling, machine
tools, indexing and food processing. They are used widely in conveyor systems. They
are also used in torsen differential, used on some high-performance cars and trucks.
They serve as speed reducers in many different industries.

27
GEAR-3

METAL: CAST IRO Fig 13 : Cast Iron Gear

TEETH: 73

DIAMETER: 113 MM

TOOTH THICKNESS: 4 MM

GEAR PITCH: 4 MM

WIDTH: 9 MM

28
Dynamo

A dynamo, originally another name for an electrical generator, now means a

generator that produces direct current with the use of a commutator. Dynamos were
the first electrical generators capable of delivering power for industry, and the
foundation upon which many other later electric-power conversion devices were
based, including the electric motor, the alternating-current alternator, and the rotary
converter. They are rarely used for power generation now because of the dominance
of alternating current, the disadvantages of the commutator, and the ease of
converting alternating to direct current using solid state methods.

The word still has some regional usage as a replacement for the word generator. A
small electrical generator built into the hub of a bicycle wheel to power lights is called
a Hub dynamo.

Fig 14 : Dynamo

29
Description

The dynamo uses rotating coils of wire and magnetic fields to convert mechanical
rotation into a pulsing direct electric current through Faraday's law. A dynamo
machine consists of a stationary structure, called the stator, which provides a constant
magnetic field, and a set of rotating windings called the armature which turn within
that field. On small machines the constant magnetic field may be provided by one or
more permanent magnets; larger machines have the constant magnetic field provided
by one or more electromagnets, which are usually called field coils.

The commutator was needed to produce direct current. When a loop of wire
rotates in a magnetic field, the potential induced in it reverses with each half turn,
generating an alternating current. However, in the early days of electric
experimentation, alternating current generally had no known use. The few uses for
electricity, such as electroplating, used direct current provided by messy liquid
batteries. Dynamos were invented as a replacement for batteries. The commutator is a
set of contacts mounted on the machine's shaft, which reverses the connection of the
windings to the external circuit when the potential reverses, so instead of alternating
current, a pulsing direct current is produced.

Jedlik's dynamo

In 1827, Hungarian Anyos Jedlik started experimenting with electromagnetic

rotating devices which he called electromagnetic self-rotors. In the prototype of the
single-pole electric starter, both the stationary and the revolving parts were
electromagnetic. He formulated the concept of the dynamo about six years before
Siemens and Wheatstone but did not patent it as he thought he was not
the first to realize this. His dynamo used, instead of permanent magnets, two
electromagnets opposite to each other to induce the magnetic field around the rotor.

30
 Fig 15 : Jedlik’s Dynamo

Pixii's dynamo

The first dynamo based on Faraday's principles was built in 1832 by Hippolyte
Pixii, a French instrument maker. It used a permanent magnet which was rotated by a
crank. The spinning magnet was positioned so that its north and south poles passed by
a piece of iron wrapped with wire. Pixii found that the spinning magnet produced a
pulse of current in the wire each time a pole passed the coil. However, the north and
south poles of the magnet induced currents in opposite directions. To convert the
alternating current to DC, Pixii invented a commutator, a split metal cylinder on the
shaft, with two springy metal contacts that pressed against it.

31
Pacinotti dynamo

These early designs had a problem: the electric current they produced consisted
of a series of "spikes" or pulses of current separated by none at all, resulting in a low
average power output. Antonio Pacinotti, an Italian physics professor, solved this
problem around 1860 by replacing the spinning two-pole axial coil with a multi-pole
toroidal one, which he created by wrapping an iron ring with a continuous winding,
connected to the commutator at many equally spaced points around the ring; the
commutator being divided into many segments. This meant that some part of the coil
was continually passing by the magnets, smoothing out the current.

Fig 16 : Pacinotti Dynamo

Gramme ring dynamo

Zénobe Gramme reinvented Pacinotti's design in 1871 when designing the first
commercial power plants, which operated in Paris in the 1870s. Another advantage of
Gramme's design was a better path for the magnetic flux, by filling the space occupied
by the magnetic field with heavy iron cores and minimizing the air gaps between the
stationary and rotating parts. The Gramme dynamo was the first machine to generate
commercial quantities of power for industry. Further improvements were made on the
Gramme ring, but the basic concept of a spinning endless loop of wire remains at the
heart of all modern dynamos.

32
 Fig 17 : Gramme Ring Dynamo

Discovery of electric motor principles

While not originally designed for the purpose, it was discovered that a dynamo
can act as an electric motor when supplied with direct current from a battery or
another dynamo. At an industrial exhibition in Vienna in 1873, Gramme noticed that
the shaft of his dynamo began to spin when its terminals were accidentally connected
to another dynamo producing electricity. Although this wasn't the first demonstration
of an electric motor, it was the first practical one. It was found that the same design
features which make a dynamo efficient also make a motor efficient. The efficient
Gramme design, with small magnetic air gaps and many coils of wire attached to a
many-segmented commutator, also became the basis for the design of all practical DC
motors.

Large dynamos producing direct current were problematic in situations where

two or more dynamos are working together and one has an engine running at a lower
power than the other. The dynamo with the stronger engine will tend to drive the
weaker as if it were a motor, against the rotation of the weaker engine. Such reverse-
driving could feed back into the driving engine of a dynamo and cause a dangerous
out of control reverse-spinning condition in the lower-power dynamo. It was
eventually determined that when several dynamos all feed the same power source all
the dynamos must be locked into synchrony using a jackshaft interconnecting all
engines and rotors to counter these imbalances.

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Dynamo as Commutated DC Generator

After the discovery of the AC Generator and that alternating current can in fact be
useful for something, the word dynamo became associated exclusively with the
commutated DC electric generator, while an AC electrical generator using either slip
rings or rotor magnets would become known as an alternator.

An AC electric motor using either slip rings or rotor magnets was referred to as a
synchronous motor, and a commutated DC electric motor could be called either an
electric motor though with the understanding that it could in principle operate as a
generator.

Rotary Converter Development

After dynamos were found to allow easy conversion back and forth between
mechanical or electrical power, the new discovery was used to develop complex
multi-field single-rotor devices with two or more commutators. These were known as
a rotary converters. These devices were usually not burdened by mechanical loads,
but watched just spinning on their own.

The rotary converter can directly convert, internally, any power source into any
other. This includes direct current (DC) into alternating current (AC), 25 cycle AC
into 60 cycle AC, or many different output currents at the same time. The size and
mass of these was very large so that the rotor would act as a flywheel to help smooth
out any sudden surges or dropouts.

The technology of rotary converters ruled until the development of vacuum tubes
allowed for electronic oscillators. This eliminated the need for physically spinning
rotors and commutators.

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 CAPACITORS

It is an electronic component whose function is to accumulate charges and then

release it.

To understand the concept of capacitance, consider a pair of metal plates which all
are placed near to each other without touching. If a battery is connected to these plates
the positive pole to one and the negative pole to the other, electrons from the battery
will be attracted from the plate connected to the positive terminal of the battery. If the
battery is then disconnected, one plate will be left with an excess of electrons, the other
with a shortage, and a potential or voltage difference will exists between them. These
plates will be acting as capacitors. Capacitors are of two types: - (1) fixed type like
ceramic, polyester, electrolytic capacitors-these names refer to the material they are
made of aluminium foil. (2) Variable type like gang condenser in radio or trimmer. In
fixed type capacitors, it has two leads and its value is written over its body and variable
type has three leads. Unit of measurement of a capacitor is farad denoted by the symbol
F. It is a very big unit of capacitance. Small unit capacitor are pico-farad denoted by pf
(Ipf=1/1000,000,000,000 f) Above all, in case of electrolytic capacitors, it's two
terminal are marked as (-) and (+) so check it while using capacitors in the circuit in
right direction. Mistake can destroy the capacitor or entire circuit in operational.

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Fig 18 : Capacitors

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 RESISTANCE

Resistance is the opposition of a material to the current. It is measured in Ohms

( ). All conductors represent a certain amount of resistance, since no conductor is
100% efficient. To control the electron flow (current) in a predictable manner, we use
resistors. Electronic circuits use calibrated lumped resistance to control the flow of
current. Broadly speaking, resistor can be divided into two groups viz. fixed &
adjustable (variable) resistors. In fixed resistors, the value is fixed & cannot be varied.
In variable resistors, the resistance value can be varied by an adjuster knob. It can be
divided into (a) Carbon composition (b) Wire wound (c) Special type. The most
common type of resistors used in our projects is carbon type. The resistance value is
normally indicated by colour bands. Each resistance has four colours, one of the band
on either side will be gold or silver, this is called fourth band and indicates the
tolerance, others three band will give the value of resistance (see table). For example
if a resistor has the following marking on it say red, violet, gold. Comparing these
coloured rings with the colour code, its value is 27000 ohms or 27 kilo ohms and its
tolerance is ±5%. Resistor comes in various sizes (Power rating). The bigger, the size,
the more power rating of 1/4 watts. The four colour rings on its body tells us the value
of resistor value as given below.

COLOURS CODE

Black------------------------------------------------------ 0

Brown ---------------------------------------------------- 1

Red -------------------------------------------------------- 2

Orange ---------------------------------------------------- 3

Yellow ---------------------------------------------------- 4

Green ----------------------------------------------------- 5

Blue ------------------------------------------------------- 6

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Violet ----------------------------------------------------- 7

Grey------------------------------------------------------- 8

White ----------------------------------------------------- 9

Table 2 : Colour Rings of Resistance Value

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 Fig 19 : Resistance
The first rings give the first digit. The second ring gives the second digit. The
third ring indicates the number of zeroes to be placed after the digits. The fourth ring
gives tolerance (gold ±5%, silver ± 10%, No colour ± 20%).

In variable resistors, we have the dial type of resistance boxes. There is a knob
with a metal pointer. This presses over brass pieces placed along a circle with some
space b/w each of them.

Resistance coils of different values are connected b/w the gaps. When the knob is
rotated, the pointer also moves over the brass pieces. If a gap is skipped over, its
resistance is included in the circuit. If two gaps are skipped over, the resistances of
both together are included in the circuit and so on.

A dial type of resistance box contains many dials depending upon the range,
which it has to cover. If a resistance box has to read upto 10,000 , it will have three
dials each having ten gaps i.e. ten resistance coils each of resistance 10 . The third
dial will have ten resistances each of 100 .

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 The dial type of resistance boxes is better because the contact resistance in this
case is small & constant.

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How Gear Ratios Work

Fig 20 : Gear Ratio

You see gears in just about everything that has spinning parts. Car engines and
transmissions contain lots of gears. If you ever open up a VCR and look inside, you
will see it is full of gears. Wind-up, grandfather and pendulum clocks contain plenty
of gears, especially if they have bells or chimes. You probably have a power meter on
the side of your house, and if it has a see-through cover you can see that it contains 10
or 15 gears. Gears are everywhere where there are engines and motors producing
rotational motion.

Putting Gears to Work

Gears are generally used for one of four different reasons:
1. To reverse the direction of rotation
2. To increase or decrease the speed of rotation
3. To move rotational motion to a different axis
4. To keep the rotation of two axes synchronized

You can see effects 1, 2 and 3 in the figure above. In this figure, you can see that
the two gears are rotating in opposite directions, that the smaller gear is spinning
twice as fast as the larger gear, and that the axis of rotation of the smaller gear is to
the right of the axis of rotation of the larger gear.

The fact that one gear is spinning twice as fast as the other is because of the ratio
between the gears -- the gear ratio. In this figure, the diameter of the gear on the left
is twice that of the gear on the right. The gear ratio is therefore 2:1 (pronounced "two
to one"). If you watch the figure, you can see the ratio: Every time the larger gear
goes around once, the smaller gear goes around twice. If both gears had the same
diameter, they would rotate at the same speed but in opposite directions.

Understanding the Concept of Gear Ratio

Understanding the concept of the gear ratio is easy if you understand the concept
of the circumference of a circle. Keep in mind that the circumference of a circle is
equal to the diameter of the circle multiplied by Pi (Pi is equal to 3.14159...).
Therefore, if you have a circle or a gear with a diameter of 1 inch, the circumference
of that circle is 3.14159 inches.

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 The following figure shows how the circumference of a circle with a diameter of
1.27 inches is equal to a linear distance of 4 inches:

Fig 21 : Concept of Gear Ratio

Let's say that you have another circle whose diameter is 0.635 inches (1.27 inches
/ 2), and you roll it in the same way as in this figure. You'll find that, because its
diameter is half of the circle's in the figure, it has to complete two full rotations to
cover the same 4-inch line. This explains why two gears, one half as big as the other,
have a gear ratio of 2:1. The smaller gear has to spin twice to cover the same distance
covered when the larger gear spins once.

Most gears that you see in real life have teeth. The teeth have three advantages:

 They prevent slippage between the gears. Therefore, axles connected by gears are
always synchronized exactly with one another.
 They make it possible to determine exact gear ratios. You just count the number of
teeth in the two gears and divide. So if one gear has 60 teeth and another has 20, the
gear ratio when these two gears are connected together is 3:1.
 They make it so that slight imperfections in the actual diameter and circumference
of two gears don't matter. The gear ratio is controlled by the number of teeth even if
the diameters are a bit off.

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 DC MOTOR DRIVE

Fig 22 : Dc Moteor Drive

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ADVANTAGES

 Power is also generated by running or exercising on the step.

 No need of fuel input
 This is a Non-conventional system.
 Battery is used to store the generated power
 Efficient Generation
 Smart Power Generation Mechanism
 Dual Purpose Machine

APPLICATIONS

Power generation using gym pulling can be used most of places such as

 Colleges
 Schools
 Gym centre
 Power generation is simply walking on the step.

CONCLUSION

The project ‘power generation by gym pulley’ has been successfully designed and
tested. It has been developed by integrating features of all the hardware components
used. Presence of every module has been reasoned out and placed carefully thus
contributing to the best working of the unit.

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 REFERENCES

 www.google.com

 www.wikipedia.org

 www.studymafiya.org

 www.pptplenet.com

 www.mitsubishi-motors.co.jp

 www.auto.howstuffswork.com

 www.boschusa.com

 www.delphi.com

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