POWER GENERATION BY EXERCISE BICYCLE

MAJOR PROJECT REPORT

Submitted in partial fulfillment of the requirements for the award of

DIPLOMA

In

MECHANICAL ENGINEERING

Submitted to

UNIVERSITY POLYTECHNIC

RAJIV GANDHI PROUDYOGIKI VISHVAVIDYALAYA

BHOPAL (M.P.)

Submitted By

ANOOP KUSHWAHA (0006ME121002) ARUN AHIRWAR (0006ME1210 3)

JITENDRA NIKUM (0006ME121017) ROHIT RAIMALE (0006ME121045)

GAURAV MISHRA (0006ME121014)

JUNE 2015
 UNIVERSITY POLYTECHNIC
RAJIV GANDHI PROUDYOGIKI VISHWAVIDYALAYA BHOPAL (M.P.)
DEPARTMENT OF MECHANICAL ENGINEERING

CERTIFICATE

We hereby declare that the work which is being presented in this Major Project Report entitled ”
POWER GENERATION BY EXERCISE BICYCLE” has been satisfactorily completed by
ANOOP KUSHWAHA (0006ME121002), ARUN AHIRWAR
(0006ME121003),JITENDRA NIKUM (0006ME121017), ROHIT RAIMALE
(0006ME121045), GAURAV MISHRA (0006ME121014). It is a bonafide piece of work,
carried out under our/ my guidance in the Department of Mechanical Engineering, University
Polytechnic RGPV Bhopal for partial fulfillment of the Diploma in Mechanical Engineering
during the academic year 2015.

Project Coordinator Project Guide

Ranjeet Joshi Mr. Rajendra Ahirwar

Approved and Forwarded by

Dr. R.K Shrivastava

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 UNIVERSITY POLYTECHNIC
RAJIV GANDHI PROUDYOGIKI VISHWAVIDYALAYA
BHOPAL (M.P.)
DEPARTMENT OF MECHANICAL ENGINEERING

DECLARATION

We ANOOP KUSHWAHA (0006ME121002), ARUN AHIRWAR (0006ME121003),

JITENDRA NIKUM (0006ME121017), ROHIT RAIMALE (0006ME121045), GAURAV
MISHRA (0006ME121014) students of Diploma in Mechanical Engineering, University
Polytechnic RGPV Bhopal hereby declare that the work presented in this major project report is
an outcome of my own work and it is bonafied correct to the best of my knowledge. Also, this
work has been carried out taking utmost care for engineering ethics. The work presented
herewith does not infringe any patented work and it has not been submitted to other universities
for the award of any professional diploma.

ANOOP KUSHWAHA (0006ME121002)

ARUN AHIRWAR (0006ME121003)

JITENDRA NIKUM (0006ME121017)

ROHIT RAIMALE (0006ME121045)

GAURAV MISHRA (0006ME121014)

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 UNIVERSITY POLYTECHNIC
RAJIV GANDHI PROUDYOGIKI VISHWAVIDYALAYA
BHOPAL (M.P.)
DEPARTMENT OF MECHANICAL ENGINEERING

ACKNOWLEDGEMENT

Every accomplishment requires effort of many with coordination in same direction and this work
is no different.

This is a small gesture and gratitude that we express for help rendered to us by our Project
Coordinator Ranjeet Joshi and our Project Guide Mr. Rajendra Ahirwar of Department of
Mechanical Engineering, University Polytechnic RGPV, Bhopal for suggesting and exhibiting
keen interest in project work.

We are also thankful to Dr. R K Shrivastava, Principal University Polytechnic RGPV, Bhopal for
his continuous encouragement and efforts in securing the required accessories of our project.

We are also thankful to all the members of Mechanical Deprment University Polytechnic RGPV,
Bhopal.

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 ABSTRACT

In 21st century the world is going towards a new era of invention. Every rising day comes with
new invention or discovery. But all this is for what? Just to enhance the life of human being and
to improve the living standard of human. The basic thought behind all this is that everyone is
working for getting more and more comfort in this life. Now a day, our country and human life is
mostly affected by load shedding. This is all from the shortage of electricity due to break down
of power plant several times. So the production of electricity is affected. Therefore it is not
possible to supply electricity as per requirement. It has badly affected the daily human life. Thus
taking this point of view a human power generator should be designed that can work according
to the human comfort requirement. Different type of generator is available in market, but they
are not economical for common people. By keeping this point, the human power generator is
useful for production or generation of electricity to fulfill our preliminary requirement of
electricity in daily life by use of dynamo for its use in stationary condition.

So our project based on Power Generation By Exercise Bicycle which works on faraday’s law
of electromagnetic induction. And generated power is used to charge battery then use electricity
to light bulbs, computers, television etc.

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 Contents

1. Introduction 8

2. History Of Power Generation By Dynamo 10

2.1Why Pedal Power Need 11

2.2 First Prototype 11

2.3 Second Prototype 11

2.4 Third Model 11

2.5 History of Dynamo 12

3. Component of project 14

3.1 Mechanical Part of Project 15

3.1.1 Exercise Bicycle 15

3.1.2 Bicycle Wheel 16

3.1.3 Bicycle Chain Wheel Crank 17

3.1.4 Chain 17

3.1.5 Paddles 17

3.2 Electrical parts of project 19

3.2.1 Dynamo 19

3.2.1.1 Working Principle of Dynamo 19

3.2.1.2 Construction 22

3.2.1.3 Dynamo Parts 22

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4. Project model 26

4.1 Working of Project 27

4.2 Mathematical Calculation 28

4.3 Electrical Calculation 29

4.4 Electrical Characteristics of Bicycle Dynamos 30

4.4.1 Summary 30

4.4.2 Dynamo Power 30

4.4.3 Test Units 30

4.4.4 Graphical Measurements 33

5. Advantages & Cost of Project 36

6. Design Overview of Project 37

7. Conclusions 39

8. References 40

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INTRODUCTION

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 INTRODUCTION

Human invented most of the things for his comfort and convenience. Electricity is one of them.
Now days, the production of electricity more hydraulic power plant, thermal power plant, wind
power plant etc are constructed. In the hydraulic power plant the kinetic energy of water is used
to run turbine and convert into mechanical energy and again into electrical energy by connecting
generator. In the thermal power plant, the kinetic energy of pressurized steam is used to rotate
the turbine and generate electricity. In wind power plant, the kinetic energy of wind is converted
into electricity. In the human power generator, it works on the principle of convert muscular or
physical energy of human being into the electrical energy by means of applying gear wheel
arrangement. The gear wheel arrangement converts the efforts which are applied by human being
into the rotating motion which is used to generate electricity and this electricity will be used as a
preliminary requirement of electricity and also use in stationary condition and also use of AC
appliances by use of inverter. The dynamo in the bicycle uses rotating coils of wire and magnetic
fields to convert mechanical rotation into a pulsing direct electric current through Faraday's law
of induction. 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. The motion of the wire within the magnetic field causes the field to push on the
electrons in the metal, creating an electric current in the wire. 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. Thus by the above mechanism dynamo charges the battery.

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HISTORY OF POWER GENERATION BY DYNAMO

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Why Pedal Power Need
We explored a lot of different ways of lighting the schoolrooms. The requirements were quite
minimal. Only lighting was the basic need. We considered solar photovoltaic, pressure kerosene
lamps, liquid petroleum gas fired mantle lamps etc. Ideal would have been the photovoltaic
system but it is prohibitively expensive for a common school in India. Therefore we decided to
develop a pedal power generator for battery charging.

Pedal power by itself is not a new concept but is not widely used. The basic idea was to pedal at
a comfortable speed and still generate enough power to make it worthwhile. We felt a ratio of 1:3
to 1:5 of pedaling time to lighting time would be encouraging enough to use this way of lighting.
And we felt that this could be achieved by using compact fluorescent lamps.

First Prototype
The first prototype was developed using a car alternator. A used 40 Amp car alternator was used.
The speed needed to get an output of 6 amps was over 90 rpm (at pedals). It was felt after use for
about a month that this speed was pretty high and could not be maintained. A reclining chair was
used for sitting. Therefore other design changes were considered. Limitations were found to be
the design of generator and lighting system.

Photo on the right shows the first model.

Second Prototype
The second prototype was developed using a reclining chair but a low rpm DC motor that was
originally developed for an electric bicycle. A 15-ampere diode was connected so that the battery
would not drive the motor when the pedaling stopped. Pedaling speed required to achieve 6 amps
output was brought down to 70 rpm. The frame was made of mild steel angles and square
channels. A 40 Amp-hour battery was used to store the electricity. Two 11-watt compact
fluorescent lamps were used for lighting. This model was installed in the Narmada valley and
used for a year and feedback obtained. The photo on the right shows the second prototype. • The
reclining chair was not found to be most appropriate because it did not permit totally free
movement of the legs. • Students also found the load on legs irregular during pedaling, which in
turn made people tired quicker. • An indicator for battery state of charge was also felt necessary.

• Another feedback was that if the pedaling speed was reduced further then people could pedal
longer.

Third Model
A Third model was made to include all the feedback received for the second prototype. The seat
was changed to a standard bicycle seat and basic frame of a bicycle was used to manufacture the

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machine. An LED bar indicator and an ampere meter were added for state of battery and rate of
charging indicator respectively. The ratios were changed so that pedaling speed was brought
down to 40-60 rpm. Various experiments were done with varying sizes of flywheels and finally a
flywheel was attached on the generator to balance the irregularity of pedaling force.

The above photo shows a close up of the generator and drive pulley assembly, flywheel was
removed for better clarity:

Stepping-up of input pedal speed is in two stages, as mentioned earlier. A toothed belt drives the
generator with 77:15 ratio pulleys. The chain stage has 16 and 44 teeth ratio, so that the overall
speed step-up would be 5.133 X 2.75 = 14.12. At the chain stage (pedaling), the two sprocket
wheels combination (in place of 16:44) can be varied as follows: 16:60 or 18:60 or 18:80 or
16:80 etc. These are readily available sizes in the open market in India. Other sizes would have
to be custom manufactured. The 80 tooth is custom manufactured.

List of Major Components and brief descriptions

Bicycle Frame Old Bicycle frames are recycled to make the basic frame of the
machine. Seating arrangement and rear wheel fork is kept as is, so are
the pedals, rest is cut away and a basic smithy shop is used to make
the machine.
Generator A 12 V DC, 10 Amp, four pole permanent magnet motor is used.
Drive Train • First step-up is by a normal bicycle chain and freewheel drive.
• Second step-up is achieved by toothed pulley and matching belt.
Battery Usually a 12 V, 40 Amp-hour tubular lead-acid battery is used.
Indicators • An LED bar level indicator with color coded LEDs is used to
indicate level of charge of battery.
• A centre zero ammeter (-8A-0-+8A) is used to display charging rate.
Protection • A 20 Amp diode is used to protect prevent current flowing to the
battery when pedaling is stopped
• A 20 Amp fuse is used to prevent shorting of the battery terminals.

History of Dynamo
The Faraday disk was the first electric generator. The horseshoe-shaped magnet created a magnetic field
through the disk . When the disk was turned, this induced an electric current radically outward from the
center toward the rim. The current flowed out through the sliding spring contact m, through the external
circuit, and back into the center of the disk through the axle.

The operating principle of electromagnetic generators was discovered in the years of 1831–1832
by Michael Faraday. The principle, later called Faraday's law, is that an electromotive force is
generated in an electrical conductor which encircles a varying magnetic flux.

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He also built the first electromagnetic generator, called the Faraday disk, a type of homopolar
generator, using a copper disc rotating between the poles of a horseshoe magnet. It produced a
small DC voltage. This was not a dynamo in the current sense, because it did not use a
commutator.

This design was inefficient, due to self-cancelling counter flows of current in regions that were
not under the influence of the magnetic field. While current was induced directly underneath the
magnet, the current would circulate backwards in regions that were outside the influence of the
magnetic field. This counter flow limited the power output to the pickup wires, and induced
waste heating of the copper disc. Later homopolar generators would solve this problem by using
an array of magnets arranged around the disc perimeter to maintain a steady field effect in one
current-flow direction.

Another disadvantage was that the output voltage was very low, due to the single current path
through the magnetic flux. Faraday and others found that higher, more useful voltages could be
produced by winding multiple turns of wire into a coil. Wire windings can conveniently produce
any voltage desired by changing the number of turns, so they have been a feature of all
subsequent generator designs, requiring the invention of the commutator to produce direct
current.

Independently of Faraday, the Hungarian Annoys Jellico started experimenting in 1827 with the
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.

About 1856 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 placed opposite to each other to induce
the magnetic field around the rotor.[1][2] It was also the discovery of the principle of dynamo self-
excitation.

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COMPONENT OF PROJECT

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 MECHANICAL PART OF PROJECT

1. Exercise Bicycle

A stationary bicycle (also known as exercise bicycle, exercise bike, or exercycle) is a device
with saddle, pedals, and some form of handlebars arranged as on a bicycle, but used as exercise
equipment rather than transportation.

An exercise bicycle is usually a special-purpose exercise machine resembling a bicycle without

true wheels, but it is also possible to adapt an ordinary bicycle for stationary exercise by placing
it on bicycle rollers or a trainer. Rollers and trainers are often used by racing cyclists to warm up
before racing, or to train on their own machines indoors.

A cycloergometer, cycle ergo meter or bicycle ergo meter is a stationary bicycle with an ergo
meter to measure the work done by the exerciser.

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General Uses of Exercise Bicycles

Exercise bikes are used for exercise, to increase general fitness, and for training for cycle events.
The exercise bike has long been used for physical therapy because of the low-impact, safe, and
effective cardiovascular exercise it provides. The low-impact movement involved in operating an
exercise bike does not put much stress on joints and does not involve sporadic motions that some
other fitness equipment may require. Stationary bikes are also used to exercise for weight loss.

Benefits

 See To Use
 Convenient
 Home Use
 Ideal For People Not Used To Exercising Or Very Overweight People
 Ideal If Bead Weather Doesn't Allow Outside Activities
 Watch TV During A Workout
 Low Injury Risk To Knees And Ankles
 Easy To Develop A Rhythmic Pace For Better Fat Burning
 Helps Develop A Little Leg Strength
 Air/Fan Assisted Bikes Help Cool Down Skin While Working Out

2. Bicycle Wheel
The first bicycle wheels followed the traditions of carriage building: a wooden hub, a fixed steel
axle (the bearings were located in the fork ends), wooden spokes and a shrink fitted iron tire. A
typical modern wheel has a metal hub, wire tension spokes and a metal or carbon fiber rim which
holds a pneumatic rubber tire.

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3. Bicycle Chain Wheel Crank
The crank set (in the US) or chain set (in the UK), is the component of a bicycle drive train that
converts the reciprocating motion of the rider's legs into rotational motion used to drive the chain
or belt, which in turn drives the rear wheel. It consists of one or more sprockets, also called chain
rings or chain wheels attached to the cranks, arms, or crank arms to which the pedals attach. It is
connected to the rider by the pedals, to the bicycle frame by the bottom bracket, and to the rear
sprocket, cassette or freewheel via the chain

4. Chain
A chain is a unit of length. It measures 66 feet, or 22 yards, or 100 links,[1] or 4 rods (20.1168
m). There are 10 chains in a furlong, and 80 chains in one statute mile. An acre is the area of 10
square chains (that is, an area of one chain by one furlong). The chain has been used for several
centuries in Britain and in some other countries influenced by British practice

5. Paddles
The bicycle pedal is the part of a bicycle that the rider pushes with their foot to propel the
bicycle. It provides the connection between the cyclist's foot or shoe and the crank allowing the
leg to turn the bottom bracket spindle and propel the bicycle's wheels. Pedals usually consist of a

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spindle that threads into the end of the crank and a body, on which the foot rests or is attached,
that is free to rotate on bearings with respect to the spindle.

a. A foot-operated lever used for actuating or controlling a mechanism, as in a loom, sewing

machine, piano, or organ.
b. A similar foot-operated part attached to a crank and used for powering various devices, such
as a bicycle.

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 ELECTRICAL PARTS OF PROJECT

1. Dynamo

A dynamo is an electric generator made from coils of wires that are made to turn in a permanent magnetic field
by way of a commutator. Essentially any electric DC motor with a permanent magnet can become a dynamo.
Rather than applying current to the motor to cause it to spin, you can turn the shaft of the motor and generate a
current.

Working Principle of Dynamo

Basic principle on which dynamo works is “Faraday’s law of electromagnetic induction”
According to this law if an object or material that conducts electricity passes through a magnetic
field then an electric current will begin to flow through that material.

Faraday’s First Law

Whenever the magnetic flux linked with a circuit changes, an e.m.f. is always
induced in it.

OR

Whenever a conductor cuts magnetic flux, an e.m.f. is induced in that conductor.

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Second Law

The magnitude of the induced e.m.f. is equal to the rate of change of flux linkages.

Faradays Law of Electromagnetic Induction

A changing magnetic flux through a loop or loops of wire induces an electromotive force
(voltage) in each loop.

Lenz’s Law
“The induced currents in a conductor are in such a direction as to oppose the change in
magnetic field that produces them.”

OR
The direction of induced E.M.F in a coil (conductor) is such that it opposes the cause of
producing it.

Fleming's Right Hand Rule

• The Thumb represents the direction of Motion of the conductor.

• The First finger (four finger) represents Field.

• The Second finger (Middle finger) represents Current

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Construction
Single turn rectangular copper coil ABCD(assume) rotating about its own axis I magnetic field
provided by either permanent magnet or electromagnets. The two ends of coil are joined to two
slip ring “a” & “b” which are insulated from each other and from central Shaft. The two
collecting brushes (carbon or copper). Press against slip rings. Their function is to collect current
induced in coil and to convey it to external load resistance Rather rotating coil may be called
“armature” and the magnets are called as “field magnets”.

Dynamo Parts
 Magnetic frame or Yoke
 Pole core or pole shoes
 Pole coils or Field coils
 Armature core
 Commutator
 Brushes & Bearings

1 Yoke
The output frame or yoke serves double purpose. x It provides mechanical supports for the poles
and made up of cast iron. But for large machine casting or rolled steel is employed.

• Acts as frame of the machine

• Mechanical support
• Low reluctance for magnetic flux
• High Permeability
• For Small machines -- Cast iron—low cost

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2 Poles cores
The field magnets consist of cores & Pole shoes. The Poles shoes two purposes.

 They spread out the flux in the air gap and also being of larger cross-section; reduces the
reluctance of the magnetic path.
 They support the exciting coils or field coils.

The complete poles cores & shoes are built of thin laminations of annealed steel. The
thickness of lamination varies from 1mm to 0.25mm. Poles coils When current is passes
through these coils, they electromagnetic the poles which produces the necessary flux that is
cut by revolving armature conductors.

Field Magnets

a) Pole core (Pole body):-

• Carry the field coils

• Rectangle Cross sections
• Laminated to reduce heat losses
• Fitted to yoke through bolts

b) Pole shoe: - Acts as support to field poles And spreads out flux Pole core & Pole
shoe are laminated of annealed steel

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3 Armature core

It houses the armature conductors or coils and cases them to rotate and hence cut the magnetic
flux of the field magnets. In addition to this, its most important function is to provide a path of
very low reluctance to the flux through armature from a N-pole to a S-pole.

It is cylindrical or drum shaped and it is built up of usually circular sheet discs or laminations
approximately 0.5 mm thick. A compete circular laminations made up of 4 or 6 or 7.8 segmental
laminations. The purpose of using laminations is to reduce eddy current loss. Thinner the
lamination greater is the resistance offered to the endued emf, smaller the current and hence
lesser the I2 loss in the core.

4 Commutator
Hard drawn copper bars segments insulated from each other by mica

Segments (insulation) between armature & External circuit Split-Rings

(Acts like Rectifier AC to DC)

5 Brushes and brush gear:-

Carbon, Carbon graphite, copper used to collects current from commutation

(In case of Generator)

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6 Shaft and bearings:-
Shaft-- Mechanical link between prime over and armature Bearings– For free rotation

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PROJECT MODEL

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1. Working of Project
This project is based on the working of exercise cycle machine. The exercise cycle machines
have a wheel below the handle. When we will start exercise on this machine we gives the
rotatory motion with the help of paddle to primary gear(driver gear). When the primary gear
starts rotatory motion then it transmits the mechanical power to secondary gear (driven gear).
Our wheel is rigidly connected with driven gear & wheel will be rotate according to driven gear
speed.

The wheel start run and we used dynamo just top wheel’s external surface. Dynamos have a
friction surface geared wheel. And rotate on the wheel and dynamo start its working.

The basic concept behind a Power Generation from Exercise Bicycle is to use the motion of the
bicycle wheel to generate electricity. As the wheel rotates, it turns a dynamo of some kind, which
acts as a generator. The dynamo produces an electric current that is then delivered to the battery.
The faster the wheel moves, the more power is generated.

Dynamo Working In Project

When dynamo start its working and dynamo works according to the faraday second law in which
dynamo rotate and generate E.M.F. on conductor or electricity of 12V, 5A. Its electrical energy
is stored in batteries and inverters. And electricity is used by both DC & AC appliance with the
help of battery & inverter.

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2. Mathematical calculation:-

Velocity ratio
The reason bicycles are easier to cycle up a hill when the gears are changed is due to what is
called Velocity ratio (Gear Ratio). Velocity ratio can be worked out in the form of numbers
and examples are shown below. Basically, the ratio is determined by the number of teeth on
each gear wheel, the chain is ignored and does not enter the equation.

Data of mechanical parts

Diameter of driver gear wheel (d1) = 16cm

Diameter of driven gear wheel (d2) =8cm

Diameter of bicycle wheel (d3) =52cm

Diameter of dynamo wheel (d4) =1.5cm

Velocity ratio of driver gear wheel (d1) & driven gear wheel (d2).

Velocity ratio = dia. Of driver gear wheel (d1)\ Dia. of driven gear wheel (d2)

= 16/8 or 2/1 rpm.

Velocity ratio = 2/1

Means of that when the driver gear wheel rotate one (1) round , then the driven gear wheel
will rotate two(2) round.

Velocity ratio of bicycle wheel (d3) & dynamo wheel (d4)

Velocity ratio = dia. Of bicycle wheel (d3) \ Dia. of dynamo wheel (d4)

= 52/1.5 or 34.7/1

Means of that when the bicycle wheel rotate one (1) round , then the dynamo wheel will
rotate two(34.7) round.

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3. Electrical calculation

Specification of dynamo
Voltage (V) =12v

Power (P) =6w

Revolution per minute =200rpm

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4. Electrical Characteristics of Bicycle Dynamos
Summary
Bicycle Dynamos are alternators equipped with permanent magnets. They are typically claw-pole
generators and deliver energy at rather low rpm.
The sidewall-running bottle dynamo used to be the most popular type for many years, but today the hub
dynamo has taken over. There are a few other types (spoke dynamo, roller dynamo) but those gained
limited popularity.
This page focuses on the electrical characteristics of a typical bicycle dynamo and the maximum power
that can be extracted from it.

Dynamo Power
In Europe, most bicycle dynamos are rated 3W (that is 500mA at 6V). For sure, the power of a dynamo
light system depends somewhat on the speed. In a standard light system, the power is zero at standstill, at
moderate speed its 3W and at very high speed, it's just a little bit more than 3W. Some manufacturers
include limiting zener diodes or other forms of overvoltage protection, to make sure the voltage doesn't
rise to levels that kill the light bulb(s).

Test Units
I've tested 3 dynamos (from left to right): Busch + Müller Dymotec6, AXA HR and a cheap one from my
local supermarket.

1. The B&M Dymotec6 has the best mechanics. It runs very well on the side of the tire. This
dynamo is often found on high-quality touring bikes. I paid EUR 24.90 for this (yr 2004).
2. The AXA HR has the strongest magnets, it delivers the highest current. It contains 2 zener diodes
(BZX 85C 7V5) in series, to limit the output voltage. I had to open the glued plastic enclosure in

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 order to remove these diodes for the measurements. This dynamo is often found on branded
bikes. I paid EUR 16.99 for the AXA HR.
3. The cheaply from the local supermarket has a magnetic performance slightly inferior to the
Dymotec6. The mechanics are not designed for heavy use but it received all required approvals.
It's held together by two screws and can be completely disassembled. This dynamo is usually
stock on supermarket bikes. Riders who rarely ride in the dark may like this unit at a bargain
price of just EUR 3.45

Tools

For measuring the electrical characteristics of bicycle dynamos, I've created this instrument. It measures
the speed of a bike based on the rpm of the dynamo:

This equipment is built from a Panasonic flashlight and a Turlock FC 404 bicycle computer. It includes
additional circuitry (see below) to slice the AC voltage from the dynamo and divide it to a lower
frequency that the bicycle computer can handle.

Initially, I designed this with a cheap no-name bicycle computer. I soon found that this does
some terrible rounding at higher speeds. I switched to a branded item, the Turlock FC 404. It
displays the decimals of the speed and it does so correctly.

To properly set the wheel circumference in the bicycle computer, it's necessary to know the
diameter of the dynamo wheel as well as the number of magnet poles. Most sidewall dynamos
have 8 poles - you can feel 8 steps per rotation of the wheel (and measure 4 full sine waves per
rotation). Refer to the formula below.

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Other tools used for the measurements below are multimeters, oscilloscope, a lab power supply
and an adjustable current sink based on the LM317T linear regulator IC.

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Graphical Measurements
Maximum Power of different Dynamos
Setup: Dynamo, voltage doublers (Greinacher type using 2x 1N5818 & 2x 1000uF), current sink
(variable from 100 to 250 mA). Speedometer connected to dynamo.
Procedure: Run the dynamo at 15 km/h. Measure the voltage across the current sink for currents
100, 130, 160, 190, 220, 250 mA, Repeat at 40km/h. Do this for each of the 3 dynamos.
Calculate power from voltage and current. Plot power vs load current.

Observation: AXA HR delivers maximum power at 200 mA load current (note this is after
voltage doubling), B&M Dymotec6 at 180 mA, the cheaply at 160 mA. The absolute power
levels show the AXA HR on top and the cheaply on the bottom at any speed. Conclusion: The
maximum power is achieved at a specific load current. This depends little on the speed, but
mostly on the dynamo. In other words: A dynamo is a current source.

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Power vs. Speed of Dymotec6
I chose to do this measurement with the Busch & Muller Dymotec6. The nature of the curve is
similar for other dynamos, only they would meet a slightly higher or lower power.

Setup: Dymotec6, voltage doublers (Grenaches type using 2x 1N5818 & 2x 1000uf), 180 ma
current sink. Speedometer connected to dynamo.
Procedure: Run the dynamo at 4, 5, 7, 9, 12, 15, 19, 24, 31, 40, 50 km/h and measure the voltage
across the current sink. Plot for each speed the calculated power = measured voltage 180 ma
current.

Conclusion:

With perfect matching of the load, Dymotec6 delivers 2.7 W at moderate speed, 5 W at high
speed and 6 W at really high speed. This is what can be achieved without modification to the
dynamo.
Question: Why does a standard 3 W light system with the Dymotec6 not burn out the bulbs at 50
km/h? This is because at such high speed, the matching of the load is off (current is too high) so
that it can't drain maximum power.
Question: Where goes the lost energy when the load doesn't drain the maximum possible power?
It's not lost. The dynamo spins with less effort. Try and short-circuit the dynamo at full speed,
the current of the driving motor will drop a lot.

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Temperature Performance of Dymotec6

As the dynamo runs for extended periods of time, its temperature increases this test runs the B+M
Dymotec6 at 50 km/h and 23ºC ambient temperature. The Grenaches doublers circuit (2x 1N5818 & 2x
1000uF) and a 180 mA load is connected. The power into the load is being monitored. The experiment is
stationary on the workbench, so there's no draught to cool the dynamo. After around 20 minutes, the
dynamo output power has decreased from an initial 100% to 80%. For another 10 minutes, it doesn't drop
any further. The temperature on the casing of the dynamo measures 89ºC at the end of these 30 minutes.
It's considerably hotter inside.

Continuing this experiment, a standard 80mm computer fan is mounted to provide some cooling
as it would be on a moving bike. The power increases and eventually stabilizes at 89% of the
start value. The temperature stabilizes at around 40ºC.

The Dymotec6 was chosen for this experiment as it has the best mechanical design of all tested
dynamos. It doesn't suffer any noticeable deterioration after running at 50 km/h and delivering
well above 5 W for 2 hours. A lot of dynamos don't withstand this. Bearings and their lubrication
suffer from the high internal temperature, resulting in rapid wear. Once the rotating magnet
comes into contact with the stator, friction and internal temperature dramatically increase, the
dynamo body melts and eventually the rotor jams. In my setup, this just tears the coupling
between motor and dynamo while on a real bike; the dynamo wheel may pop off so that the rotor
shaft causes damage to tire, rim or spokes. Bottom line: Avoid using a cheap dynamo to assist
the brakes on long descents.

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ADVANTAGES & COST OF PROJECT

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Advantage of Project

 Easy To Use.
 Convenient.
 Home Use and save electricity.
 Best for rural area where electricity not available.
 Best electricity storage in batteries.
 We can use for low power used AC/DC electric appliance like television, computers,
laptop, CFL bulbs, fans etc.(according to capacity of dynamo & inverters.)
 Initial cost low.
 This project product is best for rural areas, medium & lower class people.
 Good idea to save energy for future generation.
 Ideal For People that Used To Exercising Or Very Overweight People
 Ideal If Bad Weather Doesn't Allow Outside Activities
 Watch TV During A Workout
 Easy To Develop A Rhythmic Pace For Better Fat Burning
 Air/Fan Assisted Bikes Help Cool Down Skin While Working Out

Result
 According to Faraday law of induction, the model works properly.
 The generation of voltage is varied with variation.
 We get constant supply of voltage by using battery and inverter section.
 We can use AC appliances by use of inverter.

Cost of Project
 Exercise bicycle body - 1300

 Dynamo - 350

 Chain drive mechanism - 450

 Electric circuit - 50

Total cost = Rs. 2150

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DESIGN OVERVIEW OF PROJECT

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 CONCLUSION

The purpose behind the our project to utilize unused energy of human effort which is spends
on exercise bicycle as calories through using dynamo to produce electricity and use some
kind of electric appliance.

Our project is the prototype and working model to show, how we can use waste energy of
human effort. Aspect future work about this project to produce more power using high power
dynamo with suitable design and fabrication of exercise bicycle.

We can use the muscular or physical energy of human being which is available at any time at
any place by converting it into electrical energy by means of gear wheel arrangement to
fulfill our preliminary requirement of electricity. The Human Power Generator is primarily
designed to charge a 12 volt, deep cycle battery or to contribute to a 12 volt system. It can
also provide direct DC power. The Human Power Generator will charge at a rate of between
3A to 10A when connected to a 12V battery. The average output is between 35 to 90 watts of
power. AC appliances can be used with the Human Power Generator by using a DC-AC
inverter connected to a battery. It is also possible to directly power certain DC powered
equipment such as a low power water pump without using a battery. Appliances such as a
DC television, light or radio may also be used. However, with this application, a voltage
regulator may be required. The amount of electrical power that can be generated by the
Human Power Generator is determined by the energy available to turn the crank. The
stronger the user, the more electrical power can be produced. Typical output in watts with the
Human Power Generator is about 90 Watts or 35 Watts with pedal cranks.

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 REFERENCES

• Images & material search from www.gooogle.com

• Dynamo materials from www.wikipedia.org/wiki & www.scribed.com
• PPT about project from www.seminarprojects.com
• PDF files from www.powergenerationproject
• Yearly Review, Central Electricity Authority, Ministry of Power, Government of India,
New Delhi, http://www.cea.nic.in/opt3_tbl67.htm
• Text book of machine design (R.S. Khurmi)

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