FABRICATION OF

WATER FUELLED VEHICLE

NAME OF THE GUIDE : Mr. P.SRINIVAS RAO, M.Tech
ASSOCIATE PROFESSOR, MECHANICAL DEPARTMENT
PROJECT BY : KARI JAGADISH
BACHELOR OF ENGINEERING (B.E)
MECHANICAL ENGINEERING(2011-2015)
RAGHU INSTITUTE OF TECHNOLOGY
VISAKHAPATNAM.
 ABSTRACT
 A Water fuelled Vehicle is an alternative fuel vehicle that uses “Oxyhrogen or HHO Gas” as its onboard fuel
for motive power. Combustion of hydrogen with air is receiving increasing attention in the future energy
scenario.
 The term may refer to a personal transportation vehicle, such as an automobile, or any other vehicle that
uses hydrogen in a similar fashion, such as an aircraft. The power plants of such vehicles convert the
chemical energy of hydrogen to mechanical energy either by burning hydrogen in an internal combustion
engine (spark ignition engine), Widespread use of hydrogen for fueling transportation is a key element of a
proposed hydrogen economy.
 Hydrogen fuel does not occur naturally on Earth and thus is not an energy source, but is an energy carrier.
Currently it is most frequently made from methane or other fossil fuels. However, it can be produced from a
wide range of sources (such as wind, solar, or nuclear) that are intermittent, too diffuse or too awkward to
directly propel vehicles. Integrated wind-to-hydrogen plants, using electrolysis of water, are exploring
technologies to deliver costs low enough, and quantities great enough, to compete with traditional energy
sources.
 INTRODUCTION
 A water-fuel generator that will convert the water into an extremely powerful, clean burning gas!

 An Hydrogen generator, like this one, uses electricity from your car battery to split water into
hydrogen and oxygen gasses. Together, these make a fuel that is much more powerful than
gasoline, and the only emission released is “water vapour”

 It does this by using some current from the cars battery and alternator to fracture water
into a mixture of hydrogen and oxygen gasses called HHO hydroxy gas which is then added to
the air which is being drawn into the engine.
 AIM OF THE PROJECT
 The Main Aim of the Project is to make a Non-Polluting Vehicle which is Eco-Friendly and
should fully function on “Water (H2O)” by using a HHO Generator.
 We will learn how to use HHO Gas to reduce fuel consumption and pollution and how to properly
tune the vehicle to work with those changes.
 HHO Generator could be easily created and installed on a car or truck, it improves the attributes
of both gasoline and diesel engines.
 This device produces a lot of hydrogen/oxygen gas on low amperage and even make you save
fuel when not connected to power supply!
 Only small amount of HHO Gas is required to improve the combustion so with the correct
electrolysis cell and proper fine tuning to the ignition system the additional load on the alternator
is be minimal.
 DESCRIPTION OF THE WORK
 The HHO Generator is a piece of equipment which increases the mpg performance of a car or
motorcycle, and reduces the harmful emissions dramatically. It does this by using some current from
the vehicle’s battery to break water into a mixture of hydrogen and oxygen gases called “hydroxy” gas
which is then added to the air which is being drawn into the engine.
 The hydroxy gas improves the quality of the fuel burn inside the engine, increases the engine power,
cleans old carbon deposits off the inside of an old engine, reduces the unwanted exhaust emissions
and improves the mpg figures under all driving conditions, provided that the fuel computer does not
try to pump excess fuel into the engine when it detects the much improved quality of the exhaust.
 This HHO Generator is easy to make and the components don’t cost much. The technical performance
of the unit is very good as it produces 1.7 to 2.0 litres of hydroxy gas per minute at a managable amp
current load and one litre of water could be split into a mix of 1800 litres of Hydrogen-Oxygen
gas at a very reasonable current draw.
 SCOPE
HYDROGEN IS THE KEY TO A CLEAN ENERGY FUTURE:
 It has the highest energy content per unit of weight of any
known fuel.
 When burned in an engine, hydrogen produces effectively
zero emissions; when powering a fuel cell, its only waste is
water.
 Hydrogen can be produced from abundant domestic
resources including natural gas, coal, biomass, and even
water.
 Combined with other technologies such as carbon capture
and storage,
renewable energy and fusion energy, fuel cells could make
an emissions-free
energy future possible.
 PLANNING AND SCHEDULING
CUTTING OF STEEL PLATES BY STEEL CUTTING MACHINE

DRILLING THE STEEL PLATES

ASEEMBLY OF THE STEEL PLATES

ELECTRIC CONNECTION

INSULATING THE PLATE ASSEMBLY

DRILLING THE CUP

CUP ASEMBLY
 PLANNING AND SCHEDULING
BUBBLER CONSTRUCTION

ASSEMBLY OF THE BUBBLER TO THE MAIN GENERATOR BODY

ADJUSTING THE ELECTROLYTE

FINAL ASSEMBLY

POWERING THE GENERATOR WITH ELECTRICAL CONNECTION

PLACING AND CONNECTING THE GENERATOR

FINAL TEST ON VEHICLE

 LITERATURE SURVEY
 We need to stop burning fossil fuels. If we do so, it leaves us with two problems, namely, a way to generate
power to run our electrical equipment and heat or cool our homes, and a way to power our vehicles. In this document,
we will consider the question of powering vehicles.

There are two main options.

The first is to achieve a reduction in the amount of fossil fuel burnt. The second is to eliminate the use of fossil
fuel altogether. Both have been achieved. As an example of the first option, consider a car powered by a petrol (gasoline)
engine. In the average car, only 35% or so of the fuel is burnt in the cylinders of the engine, the remaining 65% burns in the
catalytic converter or is pushed, unburnt, out of the exhaust pipe as major pollution.

Reducing the fuel used:
It is possible to reduce the amount of fuel used, by utilising any or all of the following:
1. Improving the quality of the burn.
2. Reducing the amount of fuel in the cylinder.
3. Introducing water vapour into the cylinder.
4. Improving the quality of the spark.
5. Improving the streamlining of the vehicle
 HHO GENERATOR PARTS
Part
4-inch diameter Acrylic pipe 12-inches long
4-inch diameter PVC pipe end-cap
4-inch diameter PVC pipe screw cap
90-degree Quick Connect Outlet fitting
Level indicator Nylon barbed tube fitting
Quarter-inch I.D. Poly sight tube
Stainless steel switch covers
Stainless steel straps 12-inches long
3/4" Inside Diameter Clear poly tube
5/16” stainless steel bolts 1.25” long
5/16” stainless steel nuts & washers
5/16” diameter nylon threaded rod
5/16” inch nylon washers 1.6 mm thick
5/16”-18 s/s jam nuts (7/32" thick)
90 degree Bubbler Fittings
Check valve
PVC glue
5/16" Neoprene sealing washer
Tool dip – 14.5 oz
Optional: Light Emitting Diode
Quantity Comment
1 Forms the body of the booster
1 Closes the bottom of the booster
1 The top of the booster
1 3/8" O.D. Tube x 1/4" NPT from Hardware store
2 1/4" Tube x 1/8" NPT Part Number 2974K153 or from your local hardware store
8” Water-level indicator tubing - Hardware store
16 The plate array components
2 The electrical connections to the plates
12-inch From your local hardware store
2 Electrical strap connection to the top cap
6 each To fit the steel bolts in the cap
8” min. Nylon Threaded Rod 5/16"-18 Thread.
1-pack Nylon 6/6 Flat Washer 5/16", Pack of 100 McMaster Carr Part No 90295a160
20 McMaster Carr Part No 91841A030
2 1/4" Barbed Tube 1/2" NPT. McMaster Carr Part No 2974K156
1 1/4" tube, McMaster Carr Part No 47245K27 or from your local Hardware store
1 tube Same color as the PVC pipe if possible
2 McMaster Carr Part No 94709A318 or from your local Hardware store
1 McMaster Carr Part No 9560t71
1 10 mm diameter, red, with panel-mounting clip
ACRYLIC PIPES WITH END CAPS : STAINLESS STEEL PLATES AND STRAPS :

Nylon Pipe : SWIVEL ELBOWS :

DIFFERENT PARTS OF GENERATOR :
 CONSTRUCTION OF HYDROGEN GENERATOR

PREPARATION OF STEEL PLATES :

 We use 20 gauge stainless steel, and with the help

of the drilling machine we make holes at top and
bottoms of the plates.
 When finished, I had 12 plates measuring 3" x 6", 4
plates at 1-1/2" x 6", and three 1" connector bands
that were 6", 4-1/2", and 3 1/4".
 A Grinding machine was used for smoothing down
the jagged edges around the hole and edges of the
plates.
 Next I used 100 grit sandpaper to sand each of the
plates diagonally.You can see the "X" pattern I
sanded into both sides of the plates. This increases
the surface area of the plate, and will assist in
producing more gas.

STEEL PLATES ASSEMBLY :

The plates are joined in this configuration, using
plastic rods, plastic washers, and stainless steel nuts
to make the proper electrical connections. Then a
4" ABS clean out plug was attached at the top with
some stainless steel bolts.
I attached a swivel elbow to the top of the cap, and
the main generator is finished.
MAIN GENERATOR BODY ASSEMBLY :

• The plate assembly which is fitted to the

end cap is get assembled with the 4 inch
Acrylic pipe and thus the assembly of
main generator body is finished.
• The Generator body consists of a Pressure
Guage and swivel elbow(to which nylon
tube is connected)
 MAKING OF THE ELECTROLYTE :

 The electrolyte is distilled water and about

2-4 teaspoons of KOH (potassium
hydroxide). Salt or baking soda could also
be used, but may dirty the plates over
time.
 The Electrolyte is get purified with the
filter paper such that all the dirt present
inside the electrolyte is get removed and
the electrolyte is poured inside the
Generator body.
COMPLETE ASSEMBLY OF HYDROGEN GENERATOR AND TESTING :

 The Generator is get connected

with the bubbler in which a Air
check valve is present in between
Generator and bubbler.
 The Power supply is given by
means of a 12 volts battery with
electrical wires connection.
 The current is measured by means
of Multimeter.
HYDROGEN GENARATOR INSTALLATION TO THE BIKE :

 The HHO gas which comes from the

bubbler is get connected to the Air
intake valve or carburretor of the
vehicle.
 Such that the Gas get ignited inside the
combustion chamber of the Engine
and then the vehicle runs.
 The exhaust pollutant will be the water
vapour.
 FEEDBACK AT EVERY STEP

 Thus we bulit a Hyrogen generator with the

help of guide and team work and the results
were quite satisfying.
 It’s a Green technology and eco-friendly
because it is pollution free.
 RESULT ANALYSIS
 HHO Generator uses electrolysis to split water (H2O) into it´s base molecules, 2 hydrogen and 1 oxygen molecule. This
is why it is often referred to as an HHO gas generator.The HHO in itself is not an alternative to gasoline but a additive to
boost the efficiency of the engine. Gasoline engines are unfortunately not burning gasoline to its full potential.
 The average gasoline engine in a car is about 18% to 20% efficient. That leaves a lot of room for improvement and Brown
gas is one good way of improving the efficiency. The reason for this is simple, the hydrogen is highly flammable much
more so than gasoline so when your engine ignites the hydrogen the explosion ignites the gasoline with much better
results (cleaner, less waste and fewer emissions) than it would otherwise have done.
 Some basics the burn speed of hydrogen is 0.098 to 0.197 ft/min (3 to 6 cm/min) compared gasoline´s 0.00656 to 0.0295
ft/min (0.2 to 0.9 cm/min).
 The hydrogen explosion is so fast that it fills the combustion cylinder at least 3 times faster then the gasoline explosion
and subsequent ignites the gasoline from all directions (it is like putting flue on a fire), instead of just a spark in one end
of the combustion cylinder, and we would like to do that because the gasoline only has a short time in the combustion
cylinder and if its not fully burnt in that short amount of time then it just goes out the exhaust and is lost.It is also
preferable to ignite all of the gasoline when it is under maximum compression in combustion cylinder to get the
maximum amount of energy out of it ,when once the piston starts going down the energy transfer from the explosion to
the engine becomes less efficient.
 The hydrogen´s higher burn temperature and explosive force is such that it cleans the soot that collects in the engine (it is
like having the engine consistent maintains) and with a cleaner engine you get better mileage and fewer oil changes
 CONCLUSION
 The new generation of hydrogen generators comes with extremely highpurity devices, that are safe and that present
no danger to the environment. They are the best alternative to gas cylinders, and they are simple to use anywhere. The
HHO Generator just needs to be plugged in the electrical supply and it is ready to go.
 The hydrogen generator need of course a source of distilled water, or justwater at some models, to produce hydrogen,
because it separates the hydrogen from the oxygen in the water, thus producing highly pure hydrogen for weeks.
These hydrogen generators can generate hydrogen that is 99.99..% pure, giving over 1000 cc/min, and they do not
require changing their cylinders.
 The safety of the hydrogen generators has been certified. How the hydrogen generator works may vary from
manufacturer to manufacturer, for example some models use a solid polymer electrolyte to from hydrogen, which
makes them more safe than other models that use acaustic liquid electrolyte. After the hydrogen is generated it passes
through a palladium membrane that lets only 99.99% pure hydrogen pass through, thus insuring the gas' purity.
 In conclusion, the latest generation of hydrogen generators brings some series of improvements that makes it extra
reliable, with almost no need of maintenance or downtime.The best way of increasing the safety and lowering the
costs in the laboratory is to acquire a hydrogen generator, and we can be sure that the investment is worth it, because
we will no longer have to buy hydrogen cylinders, so the hydrogen generator will pay for itself in a year or two.
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