GymEquipment Chapter 1-3

Westmead International School
College of Engineering
CHAPTER I: PROJECT BACKGROUND
1.1 The Project
New technologies are being invented and energy demand is increasing. Growth of
population has always been and will remain one of the major causes of vast increase in energy
demand. Science is therefore looking for new major and minor energy resources to keep world in
progress. Most of the growth in global electricity consumption occurred in Asia (almost 80%, with
China accounting for nearly 60%). Electricity demand in China accelerated against steady
economic growth and industrial demand. Demand also increased in India, South Korea, Japan and
Indonesia. Electricity consumption in the United States, which dipped by 1% in 2017, recovered in
2018 (+2.2%). Most of this increase came from the residential sector (+6.2%), mainly due to an
increased electricity consumption for appliances. A theoretical research is introduced in this paper
which will contribute its reasonable share in the field of renewable and green energy sector.
There are lots potential energy sources in our world that can be used for everyday lives.
One of these is the renewable energy, the energy that can be found almost everywhere. This type
of energy is being worked for the reduction of carbon emission produced by conventional energy
production using fossil fuels. Under this type of energy, waste kinetic energy also has potential
maybe not to replace the conventional energy production but can reduce it by widely using this
type of energy conversion.
Waste kinetic energy is the energy we lost in mechanical systems like automotive. This
energy is overlooked but has capability to cover some of the electricity consumption of the facility.
The designers pursued the utilization of kinetic energy that is produced by humans in
fitness gym. There are basically two types of equipment in the fitness center. They are free weights
and machines. Free weights are the most basic form of body building equipment. The reason they
are called “free weights” is because there are no attached pulleys, cables, pins, or weight stacks.
They consist of barbells, dumbbells and weight plates. The wide variety of exercises are performed
in the machines. Some machines are designed to work individual muscles, while other machines
consist of a multi-station that works the whole body. Most of the gyms have different machines for
each muscle group. Machines are generally easier to use and safer than free weights.
In this project the proponents designed the modifications of the machines that will make it
produce electrical energy. Specifically, the Lat Pulldown, Butter Fly, Stationary Bike, and Tread
Mill. The kinetic energy is converted to electrical energy and used as alternative source for
electricity consumption of the facility. Design modifications and improvements for better energy
Design of Electric Generating Lat Pull-down Machine
1
utilization and conversion are included. The functional life of the system is also designed to meet
the purpose and economic factor of using the technology.
1.2 Project Objectives
The intention of this project is to design and produce a renewable energy source from
exercise equipment. Also, people who have a heart in keeping down environmental impacts and
those who want to preserve the environment will use this type of electrical energy generation
thereby reducing the emission of CO2 to the atmosphere. Specifically, this aims to:
1. Design a mechanical system that will utilize the waste kinetic energy on gym
equipment
2. Identify all the required materials.
3. Determine the most economical sizes.
4. Determine the detailed estimate of the modifications of the machines; labor and
material cost.
1.3 The Client
The perspective clients of this project are the fitness gym owners. With this power
producing equipment, wasted kinetic energy will help to lessen the energy consumption of the
building.
1.4 Project Scope and Delimitations
The study focuses mainly on the design modification of gym equipment that can produce
electricity for facility lighting. The design necessities including the material specifications and
dimensions were methodically considered prior to final design of modification. The system
components, cost and availability of the materials were also considered.
The project is limited to the mechanical and electrical factors of the project from
mechanical energy exerted by human unto to the power conversion.
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1.5 Project Development
Conceptual framework sets the stage for the presentation of the research question that
drives the investigation being reported based on the problem statement according to McGaghie et
al. (2001),. The problem statement of a thesis presents the context and the issues that caused the
researcher to conduct the study. In other words, the conceptual framework is the researcher’s
understanding of how the particular variables in his study connect with each other. Thus, it
identifies the variables required in the research investigation. It is the researcher’s map in pursuing
the investigation. Common gym equipment energy harvesting technology fall into the cardio type
wherein, there is already rotational motion that can be converted to electricity. On the other hand,
there are different types of gym equipment that can be the basis of the energy harvesting
technology.
The proponents focus on harvesting energy from gym equipment that can be found to gym
facilities. Specifically, Lat pull down machine, Butter fly, Stationary bike and Tread mill, knowing the
challenge of converting the linear motion to rotational before converting to useful energy. Mainly,
the energy that will be produced will be the alternative for facility lighting.
In this design project, the input is made of mechanical engineering learning and practice,
and hardware essentials. The principles and related studies are also very crucial to the design.
Many subjects that will be used for the projects were reviewed for the calculation and decisions.
Hardware components include materials. It is necessary to determine the appropriate and
operative parts to produce the final output. Inputs were attentively studied and analysed for the
design of Lat Pull down Machine for power generation.
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Figure 1-2: Research Paradigm
Figure 1-2 presents the input and necessary knowledge applied in the design of the
project. The process also describes the step by step action performed to come up with Design of
Electric Generating Lat-pulldown Machine.
4
Figure1-3: Process Flow Diagram
Figure 1-3 shows the process flow of the design project. The design begins with the idea
then next is the gathering of information needed. With the help collected related studies and
journals with, its feasibility is verified. Then, the document is prepared prior to the information
gathered.
After the accumulation of data, the conceptualization is subsequent step. Out of the
concepts produced, the finest is solution is then applied to the project enable to start the design
and calculation proper. Then, the design and calculation is performed. After, the document is
finalized.
CHAPTER 2: DESIGN INPUTS

2.1 Literature Review
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The word “Lat” is short form for Latissimus Dorsi which is the name of the muscle. Lat pull
down machine is designed for the development of latissimus dorsi muscle. Pull down machine
simply comprises of pulleys and metallic cable rolled over pulleys. One end of cable is attached
with adjustable weight and on the other end force is applied by the user in lifting the weight. Cable
may be pulled up or down depending on the nature of exercise.
According to Bidwai, Jaykar, and Shinde (2017), a person can get calories from food and
can avoid by performing daily life activities, however the excess calories, unbalanced diet and extra
fats make him unhealthy. Gymnasiums are the place where different types of equipments are
available to perform exercises like running, weight lifting, and muscles building in order to burn the
excess of calories and fats. There are specified machines to perform exercise of a particular
portion of human body e.g., cable preacher curl, close grip bar curl, barbell curl, and dumbbells
lifting are some exercises for biceps. Chest exercises include barbell bench press, flat bench
dumbbell press, low inclined barbell bench press, seated machine bench press, etc. As the
demand of energy is increasing day by day, it is necessary to develop new methods and
techniques to produce energy within a small area which may be a gymnasium or home. Most of
cardiovascular machines in gymnasiums are made of cables and pulleys and these machines are
the main focus of this research, because these machines can contribute in harvesting energy.
During exercise, persons apply force on machines and exert energy to do work. This expenditure
of energy may be converted in other form of energy e.g., in the form of electrical energy. It is
possible to construct gymnasium machines that can convert and store energy exerted by the users
into electrical energy throughout the exercise.
As stated by Herman (2016), Adenosine Triphosphate (ATP) is a source of energy which is

stored in human muscles and available for muscles movements. Hence any movement that is last
longer than a few seconds, more ATP is produced in human body. This research study will lead to
the belief that ATP possessed by human body is a source of renewable energy and may be
converted into electrical energy.
According to Yildiz and Fahmy (2009), a human being with an average athletic ability has
been seen to be able to produce 100-1500 watts of energy, which can charge a battery of 50mA
current and power a small electronic device, like an Iphone.
According to Kumar and Mundada (2017), the stronger the human power, the more
electrical power which can be generated and stored. The power output of the generator unit was
directly proportional to the effort placed into it, but the output power of energy harvesting circuit
was a fixed voltage to avoid damaging the storage device.
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Agogino (2010) mentioned that a treadmill is not a self-powered machine, therefore it

needs to be plugged in all the time even if no one is using it. This indicates that treadmill was
considered to have large electric consumption compared to other gym equipment. Treadmill was
the third in terms of the overall energy consumption. Out of all the powered exercising equipment in
the Gym, treadmills consume most power.
In addition, Mankodi (2012) stated that the power consumption for a treadmill with a speed
of 5 mph is 480W and by increasing the speed to 9W increases the consumption to 1083W.
However, during standby, it consumes around 3 Watts.
According to World Energy Council (2016), Fossil oil remained the world’s leading fuel,
accounting for 32.9% of global energy consumption and roughly 63% of oil consumption comes
from the transport sector. Natural gas is the second largest energy source in power generation,
representing 22% of generated power globally. Coal still provides around 40% of the world’s
electricity and Asia presents the biggest market for coal and currently accounts for 66% of global
coal consumption. Therefore, new techniques are being employed for energy harvesting.
The basic concept of the project is to convert mechanical energy into electrical energy.
The mechanical energy is produced by the Lat Pull Down machine when operated by user. The
exercise equipment, Lat pull down will be attached to a generator. This creates a dc voltage which
will be fed into a circuit and then sent to a battery where it can be stored for future use. The form of
ambient energy source was the waste kinetic energy from fitness exercise equipment which was
converted to electrical energy. An appropriate energy harvesting and storage system was built and
demonstrated to investigate reliability of the fitness equipment as an ambient energy source.
Lat pull down machine may be connected with a generator by 2 methods, according to
Musharraf (2018).
Method 1: The shaft of generator will be attached with the axle of pulley. This combination
will give result of transformation of torque from pulley to the armature of the generator. Rotation of
armature will produce electrical energy. The electrical voltage and current will be the alternating as
the direction of rotation of pulley will change in clock wise and anti-clock wise direction. A rectifier
will be necessary in order to charge the D.C batteries.
Method 2: The second way of installing the generator will be, the generator will be placed
in the basement of machine. When the cable is pulled downward the armature of generator will
rotate and electrical power will be produced through the generator.
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Based on Mohurle, Deshmukh and Patil (2016) design of Lat Pull Down machine, pulley is
directly connected to mechanical arrangement which consist of chain and sprocket, freewheel,
flywheel. This mechanical arrangement is directly connected to shaft which is connected to the
rotor of the generator. This rotor contains a magnet which when turned produce rotating magnetic
field (emf) which in turn produces electromotive force. The rotor is surrounded by stator which is
nothing only a stationary case, which contains the wound copper coils or windings. When the
moving magnetic field passes through these wound copper coil or windings, they generate
electricity.
In Muthu Subash and Pathiban (2016) design of lat pull down machine, they analyze the
machine structure for the applied load. For the stability of the structure they chose to used A36 mild
steel. It is used to support all the part of the machine and to stabilize the overall weight of the
machine. ASTM A36 is the most commonly used mild and hot-rolled steel. It has excellent welding
properties and is suitable for grinding, punching, tapping, drilling and machining processes. It has
the maximum deflection of 0.450893mm. For the hand rod, they used a solid bar made up of alloy
steel with the maximum deflection of 0.02355mm.
The time the light takes to turn on is dependent on the speed and stroke length of the hand
rod. If all the equipments in the fitness center are fabricated with power generating unit, we can
generate more power (Muthu Subash and Parthiban, 2016 et al)
The literature will help the proponents in designing the Electric Generating Lat Pull-down
Machine. Important data includes the feasibility of the project. The information gathered from these
articles and studies helped the researcher in understanding the direction of this study.
With the help of the related studies presented, the proponents decided to change the chain
and sprocket that was used from parallel studies with belt and pulley. Belt and pulley has the same
transmission efficiency also is more considerable with concern on safety.
Furthermore, the research literature presented some previous studies related to this
study. The knowledge gained from there literatures served as guide for the researchers to come up
with a good and functional design.
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2.2 Description of the System
The trend of exercising in gym is increasing among people. The researchers studied about
which machine is being used often. The Lat Pull Down Machine is used by many users and the
researchers decided to modify this machine mechanism.
Fitness is important factor in modern life and young generations are interested for the
exercises. Implementation of such provisions in gym machines will be surely a help in renewable
energy field. The alternate source of energy will reduce the overall energy cost of such particular
organization.
In this study the researchers look into options of improving a non energy consuming gym
equipment to an energy-producing one, thereby promoting the sustainability of the recreation and
health facilities. It was found that the energy-producing equipment in the gym not only benefit
environmentally but also economically in the long run.
The method of generating electricity, discussed in this paper was eco-friendly and causes
no pollution. They are easy to install and utilizes the human bio-energy in the most efficient way.
The concept has great scope in developing countries where youths are becoming more fitness
conscious.
The lat pull down machine could be used by anyone who could bear the weights applied to
the machine. The adjustable weight used in the machine is limited to 165 kg the average person
could carry. Energy generation will begin once the force is applied by user to lift the weight.
2.3 System Parameters Consideration
The system adapts the existing model of lat pull down and remodels its working principle.
The efficiency and the performance of the system are based on the different parameters which are
hypothesized to influence it. The consideration of different parameters from experiments will help
the proponents in designing a lat pull down machine that will give a better performance.
The following parameters will be considered to obtain an efficient model of a lat pull down
machine.s
2.3.1 Effect of force exerted to the handle
The higher the force applied to the handle or lat bar, the faster the rotation of the pulley,
the higher the power can be generated. A person with average athletic ability has been seen to be
9
able to produce 100-1500 watts of energy, which can charge a battery of 50mA current and power
a small electronic device (Yildiz and Fahmy, 2009).
Since the main component of the design project is a lat pull down machine, the expected
beneficiary were those who are fitness conscious.
2.5 Components of the System
Figure 2-1: Assembled

Lat Pull Down Machine
Figure 2-1 shows the

3D view of the assembled
lat pull-down machine.
The lat pull down
machine will serve as the main component of the project. It is a human-powered machine that will
incorporate other minor components. The cable lat pulldown is done where the handle is moved via
a cable pulley, as opposed to doing pulldowns on a leverage machine.
10
Figure 2-2: Weight
Figure 2-2 shows a weight which will be use in the machine. It can be adjusted depending
on the desired weight of the operator.
Figure 2-3: Rack and Pinion
Figure 2-3 shows a rack and pinion which is a type of linear actuator that comprises a
circular gear (the pinion) engaging a linear gear (the rack), which operate to translate rotational
motion into linear motion. Driving the pinion into rotation causes the rack to be driven linearly.
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Figure 2-4: Belt and Pulley
Figure 2-4 shows a pulley which is a machine comprises of a wheel on a fixed axle, with a
groove along the edges to guide a rope or cable. The two fixed pulleys are used together to reduce
the amount of force needed to lift the weight. The belt shown is used to link two pulleys. It is used
in this prototype to transmit power efficiently and track relative movement.
Figure 2-5: Generator
Figure 2-5 shows an electric generator which is a mechanical device used to convert
mechanical energy into electrical energy.
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Figure 2-6: Shaft
Figure 2-6 shows a shaft which is a rotating machine used to transmit power from one part
to another.
2.6 Design Calculation
The following parameters are calculated to determine the mechanical characteristics of the
design:
a. Power
Power is a measure of how much energy can be transferred in a specific amount of time. It
is the indication of how efficient the fabricated lat pull down machine was.
b. Belt and Pulley
Belt runs smoothly with a little noise. It does not require a lubricating system and minimal
maintenance, but has the same output similar to a chain.
c. Stress of the Shaft
The term stress is used to express the loading in terms of force applied to a certain cross-sectional
area of an object. From the perspective of loading, stress is the applied force or system of forces
that tends to deform a body. From the perspective of what is happening within a material, stress is
the internal distribution of forces within a body that balance and react to the loads applied to it. The
stress distribution may or may not be uniform, depending on the nature of the loading condition.
For example, a bar loaded in pure tension will essentially have a uniform tensile stress distribution.
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However, a bar loaded in bending will have a stress distribution that changes with distance
perpendicular to the normal axis. (Non-destructive Testing, 2001)
d. Welding
Welding is the process by which two pieces of metal can be joined together. The process of
welding doesn't merely bond the two pieces together as in brazing and soldering, but through the
use of extreme heat and sometimes the addition of other metals or gases, causes the metallic
structures of the two pieces to join together and become one. (Bright Hub Engineering)
In designing the Lat pull down machine, the proponents considered the welding parameters to
compute minimum weld thickness that could hold the two metals as one.
CHAPTER III: DESIGN OF THE SYSTEM
3.1 Research Design
The main purpose of having an established research methodology is to gain knowledge

and arrive at an organized and cohesive plan associated with the design process in order to
produced outcomes
The proponents used the applied technique of research to be able to meet the
requirements needed to accomplish this study. Applied research, includes the practical application
of science. It accesses and uses some part of the research communities, accumulated theories,
knowledge, methods and techniques, for a specific purpose. It is contrasted with pure research
discussion about research ideals, methodologies, programs and projects (Nils, 2009)
3.2 Project Development
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Distinct stages are undertaken to attain the proponent’s objectives in foregoing design.
The procedures used are the following
3.2.1 Methods of Data Gathering
Data gathering and formulating hypothesis is the first step of the design and study. With
the help of different libraries from different schools, colleges and universities: city and provincial
libraries for related literature, and information on internet, the proponents gained enough
knowledge for the progress of the study. The dimensions of the machine structure are based on
the standard sizes available on market.
3.2.2 Pre-Design Stage
The second stage is the pre-design phase. The data gathered are analysed, compared,
and evaluated in this stage. The proponents have carefully analysed the mechanical parts and
develop the system parameters in this stage. The study’s feasibility must have been confirmed in
this part enable to proceed to the design proper.
3.2.3 Design Stage
The third stage is the design stage which is the main part. In designing, the proponents
used the engineering references for the forces and power that can be observed in the equipment.
All the inputs collected from the pre-stages are now applied into calculation. All of these data are
keys to determine the types and sizes of materials are suitable for the study.
The calculations will be the layout of the design, and shall be the ground for the design
improvement.
Mechanical materials were selected based on their properties, availability, and

specification. Also, different insights and advice from reliable instructors and personnel were
considered.
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Figure 3-1: Proposed design of Electric Generating Lat Pull-down Machine
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Figure 3-2: Proposed design of Electric Generating Lat Pull-down

Machine (Different Views)
3.3 Project
Materials
MATERIALS AND
UNIT QUANTITY PRICE AMOUNT
COMPONENTS
3”x3” Tubular Steel meter 15 10 000
17
3”x1” Tubular Steel meter 4 1 500
Low RPM DC Generator piece 1 2 000 2 000
Belt piece 3 200 600
Pulley
50mm 2 150 300

90mm piece 2 200 400
150mm 3 500 1 500
5 cm dia. Steel Tube meter 2.5 700
Rack and Pinion set 2 5 000 10 000
Pillow Block Bearing piece 4 1 000 4 000
Wire Rope meter 2 250 500
Gym bench piece 1 500 500
Leg lock piece 1 500 500
Labor person 2 5 000 10 000
TOTAL COST P 42 500
BIBLIOGRAPHY
http://ijesc.org/upload/55461d0acdbe900b15b35bcf97f64adf.Design%20and%20Development%20
of%20Lat%20Pull%20Down%20Machine%20for%20Power%22Generation.pdf
https://www.irjet.net/archives/V5/i12/IRJET-V5I1229.pdf
18
https://www.researchgate.net/publication/329929709_Theoretical_Design_of_Energy_Generating_
Gymnasium_Pull-down_Machine_for_Green_Renewable_and_Sustainable_Energy_Production
https://www.researchgate.net/publication/283523880_Recovery_of_Useful_EnerEn_from_Lost_Hu
man_Power_in_Gymnasium
http://citeseerx.ist.psu.edu/viewdoc/download?doi=10.1.1.742.611&rep=rep1&type=pdf
http://www.iosrjen.org/Papers/Conf.19050-2019/Volume-6/MECHANICAL/11. %2040-45.pdf
https://www.grainger.com/
19

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Westmead International School

CHAPTER I: PROJECT BACKGROUND

1.1 The Project

Design of Electric Generating Lat Pull-down Machine

1.2 Project Objectives

1.3 The Client

1.4 Project Scope and Delimitations

Design of Electric Generating Lat Pull-down Machine

1.5 Project Development

Design of Electric Generating Lat Pull-down Machine

Figure 1-2: Research Paradigm

Design of Electric Generating Lat Pull-down Machine

Figure1-3: Process Flow Diagram

CHAPTER 2: DESIGN INPUTS

Design of Electric Generating Lat Pull-down Machine

As stated by Herman (2016), Adenosine Triphosphate (ATP) is a source of energy which is

Design of Electric Generating Lat Pull-down Machine

Agogino (2010) mentioned that a treadmill is not a self-powered machine, therefore it

Design of Electric Generating Lat Pull-down Machine

Design of Electric Generating Lat Pull-down Machine

2.2 Description of the System

2.3 System Parameters Consideration

2.3.1 Effect of force exerted to the handle

Design of Electric Generating Lat Pull-down Machine

2.5 Components of the System

Figure 2-1: Assembled

Figure 2-1 shows the

Design of Electric Generating Lat Pull-down Machine

Figure 2-2: Weight

Figure 2-3: Rack and Pinion

Design of Electric Generating Lat Pull-down Machine

Figure 2-4: Belt and Pulley

Figure 2-5: Generator

Design of Electric Generating Lat Pull-down Machine

Figure 2-6: Shaft

2.6 Design Calculation

b. Belt and Pulley

c. Stress of the Shaft

Design of Electric Generating Lat Pull-down Machine

CHAPTER III: DESIGN OF THE SYSTEM

3.1 Research Design

The main purpose of having an established research methodology is to gain knowledge

3.2 Project Development

Design of Electric Generating Lat Pull-down Machine

3.2.1 Methods of Data Gathering

3.2.2 Pre-Design Stage

3.2.3 Design Stage

Mechanical materials were selected based on their properties, availability, and

Design of Electric Generating Lat Pull-down Machine

Figure 3-1: Proposed design of Electric Generating Lat Pull-down Machine

Design of Electric Generating Lat Pull-down Machine

Figure 3-2: Proposed design of Electric Generating Lat Pull-down

3”x3” Tubular Steel meter 15 10 000

Design of Electric Generating Lat Pull-down Machine

3”x1” Tubular Steel meter 4 1 500

Low RPM DC Generator piece 1 2 000 2 000

Belt piece 3 200 600

50mm 2 150 300

5 cm dia. Steel Tube meter 2.5 700

Rack and Pinion set 2 5 000 10 000

Pillow Block Bearing piece 4 1 000 4 000

Wire Rope meter 2 250 500

Gym bench piece 1 500 500

Leg lock piece 1 500 500